Eni S.p.A.

Exploration & Production Division

DESIGN CRITERIA

PROCESS MINIMUM REQUIREMENTS

10009 HTP PRC PRG

Rev.0 September 2009

ENGINEERING COMPANY STANDARD

This document is property of Eni S.p.A. Exploration & Production Division.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
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INDEX

1 INTRODUCTION..................................................................................................................4

2 SCOPE.................................................................................................................................4

3 ACRONIMS..........................................................................................................................4

4 UNITS OF MEASUREMENTS.............................................................................................5

5 TERMINOLOGY ..................................................................................................................5

6 SPARING PHILOSOPHY ....................................................................................................6

7 OVERSIZING CRITERIA.....................................................................................................7

8 DESIGN TEMPERATURE AND DESIGN PRESSURE ......................................................8

8.1 DESIGN PRESSURE ..........................................................................................................8
8.1.1 Maximum operating pressure .........................................................................................8
8.1.2 Specific considerations ...................................................................................................8
8.1.3 Specific equipment requirements ...................................................................................9
8.1.3.1 Pressure Vessel ..........................................................................................................9
8.1.3.2 Tanks .........................................................................................................................10
8.1.3.3 Heat Exchangers & Aircoolers...................................................................................10
8.1.3.4 Pumps........................................................................................................................11
8.1.3.5 Compressors .............................................................................................................12
8.1.3.6 Piping.........................................................................................................................13
8.2 DESIGN TEMPERATURE .................................................................................................14
8.2.1 Maximum design temperature ......................................................................................14
8.2.2 Minimum design metal temperature .............................................................................14
8.2.3 Specific equipment requirements .................................................................................14
8.2.3.1 Heat Exchangers .......................................................................................................14
8.2.3.2 Compressors .............................................................................................................14
8.2.3.3 Piping.........................................................................................................................14

9 LINE SIZING CRITERIA....................................................................................................15

9.1 GENERAL ..........................................................................................................................15
9.2 GAS LINES ........................................................................................................................15
9.3 LIQUID LINES....................................................................................................................17
9.4 MIXED PHASE LINES .......................................................................................................19
9.5 FLARE & BLOWDOWN LINES..........................................................................................20
9.5.1 PSV Inlet Lines .............................................................................................................20
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9.5.2 BDV Inlet Lines .............................................................................................................21

9.5.3 PSV Outlet Lines...........................................................................................................21
9.5.4 BDV Outlet Lines ..........................................................................................................21
9.5.5 Flare Headers & Sub-Headers .....................................................................................22
9.5.6 Flare Stacks ..................................................................................................................22
9.6 NOZZLE SIZING CRITERIA SUMMARY ..........................................................................22
9.6.1 Feed inlet nozzle...........................................................................................................22
9.6.2 Gas outlet nozzle ..........................................................................................................23
9.6.3 Liquid outlet nozzle .......................................................................................................23
9.6.4 Flare k.o. drum nozzle ..................................................................................................23
9.6.5 Instrumentation connection...........................................................................................23
9.7 EQUIVALENT LENGTH.....................................................................................................23

10 PSV & BDV........................................................................................................................24

11 REFERENCES...................................................................................................................25
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1 INTRODUCTION

This document presents criteria to be used by Contractor as process minimum requirements in Oil & Gas
Plants.
However the Contractor is responsible of design hence of the deliverables issued to the Company and
shall agree with Company process specialists any variations, where it is deemed required, in respect with
the procedure described hereunder.
These process minimum requirements design criteria are only applicable to new Projects or where major
changes on existing plants are performed.

2 SCOPE
The minimum requirements reported in the paragraphs below should be used for Process sizing criteria
at either basic or detailed engineering phase.

This document is NOT applicable for pipelines.

3 ACRONIMS
BDV: Blowdown valves
C: Velocity of sound in medium
Cp: Specific heat at constant pressure
Cv: Specific heat at constant volume
D: Diameter
DCS: Distributed control system
DNV: Det Norske Veritas
DP: Design Pressure
DT: Design Temperature
ESD: Emergency Shut Down
Fr: Froude Number
G: Standard gravity
gu: Reduced gravity
HIPPS: High Integrity Pressure Protection System
HSE: Healthy Safety Environment
k: Specific heat ratio
KOD: Know-out Drum
Ma: Mach Number
MDT: Maximum Design Temperature
MDMT: Minimum Design Metal Temperature
MOP: Maximum Operating Pressure
NPSH: Net Positive Suction Head
OP: Operating Pressure
OT: Operating Temperature
PSV: Process Safety Valve
RAM: Reliability, Availability, & Maintainability
v: Velocity
ΔP : Pressure drop
ρ: Density
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4 UNITS OF MEASUREMENTS
The units of measurements shall be basically the SI System.
However, the following exceptions are preferred:
• Oil Volume, barrel
• Pressure, bar
• Temperature. °C
• Viscosity, cP
Prefix to be used:
• k – 10^3
• M – 10^6
• G – 10^9

5 TERMINOLOGY

• Design Pressure: The maximum internal or external pressure to be used in determining the minimum
permissible wall thickness of equipment and piping
• Maximum Design Temperature: The material temperature representing the most severe condition of
coincident pressure and temperature. The maximum design temperature shall encompass the
maximum operating temperature
• Maximum Operating Pressure: The maximum pressure predicted including deviations from normal
operations, like start-up/shutdown, process flexibility, control requirements and process upsets
• Minimum Design Temperature: The minimum temperature which serves as a base for specifying the
low temperature characteristics of the material. The design temperature shall encompass the
minimum operating temperature
• Maximum Operating Temperature: The maximum temperature in the equipment including plant
operation at unstable conditions, like start-up/shutdown, control requirements, process flexibility and
process upsets
• Operating Pressure: The pressure in the equipment when the plant operates at steady state
condition, subject to normal variation in operating parameters
• Operating Temperature: The temperature in the equipment when the plant operates at steady state
condition, subject to normal variation in operating parameters
• Shut-Off Pressure: The shut off pressure for pumps is determined by the curves for a “no flow”
situation, i.e. blocked outlet
• Settle Out Pressure: The pressure equilibrium after a compressor shutdown (pressure trapped
between the upstream and downstream check valve)
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6 SPARING PHILOSOPHY
The general sparing philosophy, to be applied as reference for the main process and utility equipment is
as follows:
• vessels: no spare
• columns: no spare
• heat exchangers: n+1
• pumps: n+1
• compressors and blowers: n+1 (UNLESS WHERE OTHERWISE INDICATED)
• fans (for air coolers): no spare
• filters: n+1 (*)
• PSV: n+1

(*) No spare can be considered in case the filter can be put off-line and bypassed for the time necessary
for any maintenance operation (i.e. replacement of the filtering elements), without any appreciable
problem which could occur on regular plant operation.
A RAM analysis should be performed at the beginning of the next detailed design phase, considering
also the planned shutdown for overall maintenance, to confirm the proposed spare configuration.
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7 OVERSIZING CRITERIA
The following table summarizes the over-design factors to be included in the design capacity for piping
and equipment

Description Over-Design Note

Equipment
Separators (5) 10% on flowrate
Storage tanks 10% on volume
Surge vessels/drums 10% on hold-up
Columns (2) 10% on flowrate
Shell & tube, frame & plate and hairpin 15% on surface area
heat exchangers (general service) (1) 10% on duty & flowrate
Shell & tube and hairpin heat exchangers 15% on surface area
(reboilers and condensers) (1) 15% on duty & flowrate
Air-coolers (general service) (1) 15% on surface area
10% on duty & flowrate
Air-coolers (condensers) (1) 15% on surface area
15% on duty & flowrate
Pumps (3) 10% on flowrate
Compressors 10% on flowrate
5% on polytropic head
Compressors KOD 15% on compressor design
flowrate
Compressor Intercooler 10% on duty based on design
compressor flowrate
Gas Turbine 10 % on power output
Filters 10% on flowrate
Furnaces 10% on duty & flowrate

Piping (4) 0% on flowrate

Table 7.1: over design factors

Notes:
(1) When overdesign on both surface and duty+ flowrate is required, each overdesign factor must
not be considered at the same time: the worst conditions in each of the two overdesign cases
have to be assumed.
(2) For columns, no other overdesign factor shall be added to the above detailed, apart from any
possible system factor required by engineering practice of the specific treatment or by specific
requirements of the Company.
(3) For pumps, the indicated overdesign is applicable only in case of continuous service. For
intermittent service no overdesign factor shall be applied.
(4) Piping shall meet process design criteria as defined under section “Piping process design
criteria”.
(5) Excluded compressors KOD.
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8 DESIGN TEMPERATURE AND DESIGN PRESSURE

The described minimum requirement shall be a reference those that have to calculate the design
temperature and pressure of equipment for process and utility systems.
However, the contractor remains responsible of the calculation and of deliverables issued to the
COMPANY and shall agree any variations concerning the procedure described hereunder.

8.1 DESIGN PRESSURE

8.1.1 Maximum operating pressure

The design pressure shall be based on the Maximum Operating Conditions plus a specified safety
margin.
During the definition of the Maximum Operating Pressure (MOP), the following has to be taken in
account:
• Maximum Operating Pressure is defined as the maximum pressure predicted including
deviations from normal operations, like start-up/shutdown, process flexibility, regeneration, control
requirements and process upsets;
• The maximum operating pressure for an equipment item or series of connected equipment items
protected by a common pressure relief device should be taken from the equipment item having the
highest normal operating pressure in a series of items, and should take into account all modes of
operation;
• The maximum operating pressure shall take into account the set points and accuracy of all
related pressure instrumentation. Pressure alarms and trips must be able to function reliably
before the PSV.
If the operating pressure can be reasonably expected to be subject to fluctuation or pulsation, wider
margins should be considered between normal operating pressure, alarm points, trip points and design
pressure;
• MOP shall be at least 105% of the normal operating pressure for:
¾ Maximum operating wellhead pressure defined as Well-head shut-in pressure or Maximum
Static Pressure.
¾ Equipment specific items such as shut-off of centrifugal pumps where the design pressure
will be established in function of the characteristics of the rotating machine.
¾ Case for which only one operating case is known, due to the early phase of the project.

8.1.2 Specific considerations

During the definition of the design pressure the following need to be consider:
• Care should be taken when using rupture discs as protective devices. The difference between
Maximum Operating Pressure (MOP) and Design Pressure may need to be greater than that
stated in the section below;
• Hydraulic pressure due to relative elevation of the PSV’s and the equipment to be protected shall
be taken into consideration. Relief device set pressures shall be lowered to account for this in
liquid systems;
• The selection of the design pressure shall be made taken in account any impacts on material
selection and rating. In “borderline” cases, the system pressure could be reduced to allow less
onerous rating. This choice shall be made in according to good engineering judgement;
• Unless otherwise indicated, the design pressure, specified by Process engineer, is referred to
the vapour phase at the top of the vessel. The liquid density and the maximum liquid height shall
be specified on the Data Sheet to allow the vessel designer to calculate the bottom thickness;
• For reactors, pressure conditions during the regeneration of the catalyst shall be also taken into
account;
• For molecular sieves, pressure conditions during any operating phase shall be also taken into
account.
• For any equipment subject to operating cycles, pressure conditions during any operating phase
shall be also taken into account.
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8.1.3 Specific equipment requirements

8.1.3.1 Pressure Vessel

This section reports the minimum requirements to set the design pressure for Pressure Vessels are
shown in Table 8.1:

Maximum Operating Pressure (bar g) Design Pressure (bar g) (Note 1, 3)

Vacuum 1.0 / Full Vacuum
0–2 3. 5
2 – 15 MOP + 1.5
>15 1.1 * MOP (Note 2)

Table8.1: Design Pressure Criteria for Vessel

Note 1: Equipment in circuits that can be evacuated by an ejector and suction drums on reciprocating
compressors are to be designed for full vacuum conditions in addition to the operating
conditions.
Equipment that could face vacuum under abnormal conditions, such as:
• Vacuum conditions during start-up, shutdown and/or regeneration purges;
• Normally operated full of liquid but can be blocked in and cooled down;
• Containing condensable vapour, but can be blocked in and cooled down;
• Could undergo a vacuum condition through the loss of heat input
will be treated case by case, and they will be designed for full vacuum, unless appropriate
protective devices are provided.
Note 2: Proper protection for this equipment shall be foreseen such as the use of pilot-operated relief
valves shall be advised rather than conventional spring-loaded relief valves due to more
accurate settings.
Note 3: Equipment where the only contingency to experience vacuum is the steam-out shall not be
designed for Vacuum conditions.

For column:

• Equipment associated with the top of a column, such as, overhead condenser, reflux drum,
interconnecting piping and side drums, shall have the same design pressure as the column;
• For reboilers, the design conditions of the shell side should be the same as the design conditions
of the column, and no valves should exist between them. Column PSV’s will provide overpressure
protection covering reboiler tube rupture.

For filters and molecular sieves, same criteria of pressure vessel can be applied. Proper considerations
will be made for filters on pump discharge circuit regarding shut-off conditions (See section 8.1.3.4).
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8.1.3.2 Tanks
This section reports the minimum requirements to set the design pressure for Tanks as shown in Table
8.2:

Maximum Operating Pressure (bar g) Design Pressure (bar g) (Note 1)

Atmospheric Tank (Typically Cone Roof Type) [1]

Tank NOT blanketed and vent to atmosphere Atmospheric (Note 2)

Tank blanketed and vent to atmosphere 200 mm H2O & -60 200 mm H2O Vacuum
Tank blanketed and vent to flare 500 mm H2O & -60 200 mm H2O Vacuum
Low Pressure Tank [2]
Dome Roof From 0.05 to 1.0 barg

Table 8.2: Design Pressure Criteria for Tank

Note 1: Design pressure is for the top of the tank, liquid head to be added for the bottom of the tank. A
vacuum breaker shall be provided.
Note 2: Vendor should be left to cope with overpressure and underpressure experience as the tank
breathes.

8.1.3.3 Heat Exchangers & Aircoolers

This section reports the minimum requirements to set the design pressure for Heat Exchanger, these are
shown in Table 8.3:

Maximum Operating Pressure (bar g) Design Pressure (bar g) (Note 1, 2, 3)

Vacuum 1.0 / Full Vac

0–2 3. 5
2 – 15 MOP + 1.5
>15 1.1 x MOP

Table 8.3: Design Pressure Criteria for Heat Exchanger

Note 1: Heat Exchanger in circuits that can be evacuated by an ejector, using steam, and exchanger
with steam-out connections are to be designed for full vacuum conditions in addition to the
operating conditions.
Note 2: Proper considerations will be made for exchangers on pump discharge circuit regarding shut-
off conditions (See section 8.1.3.4);
Note 3: Complete tube rupture, in which a large quantity of high-pressure fluid flows to the lower-
pressure exchanger side is a possible contingency.

Air Coolers design pressure shall be set as per Table 8.3. Generally Air Coolers design pressure will be
equal to the associated equipment (e.g. overhead condenser with relevant column). Attention shall be
paid to air coolers on pump discharge circuit regarding shut-off conditions (See section 8.1.3.4).
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8.1.3.4 Pumps
This section reports the minimum requirements to set the design pressure for Pumps.

Centrifugal Pumps

Equipment in a pump discharge circuit with a downstream block valve and no relief valve shall have a
design pressure at least as high as the pump shut-off pressure. Suction piping of pumps from/and
including suction valve shall be designed for discharge conditions as well. This is to allow for backflow
through the pump during shutdown, without overpressuring the suction side.
If vendor curves are not available (thereby the head of the pumps at no flow is not available), pump shut-
off pressure for motor-driven centrifugal pumps will be estimated as follows:

Pump Shut-off Pressure [barg] = Vessel Design Pressure [barg] + (static head at HHLL [m] + 1.2 x head
[m] at operating point) x ρmax [kg/m3] / 10.2;

The following shall be also taken into account:

• It has to be carefully taken into account that vertical pumps could have a differential head at no
flow much higher than the operating one;
• Turbine driven centrifugal pumps could have a differential head at no flow higher than motor
driven centrifugal pumps.
• When pump curves are known, this design pressure has to be checked with actual head of the
pump at no flow condition with the maximum suction pressure and the maximum specific gravity.

Volumetric Pumps

These pumps can normally produce substantially higher pressures than the normal discharge pressure.
The design pressure on the discharge side should be specified with a margin compatible with the
downstream system, and a full flow pressure relief valve must be provided to protect downstream
equipment.
The Design Pressure of the discharge side of the Volumetric Pumps is shown in Table 8.4.

Maximum Operating Pressure (bar g) Design Pressure on discharge side(bar g)

Operating Pressure < 10 barg Operating Pressure + 2 bar
Operating Pressure ≥ 10 barg 1.2 * Operating Pressure

Table 8.4: Design Pressure Criteria for Volumetric Pump

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8.1.3.5 Compressors
This section reports the minimum requirements to set the design pressure for compressor.
Compressor discharges shall be provided with full flow relief valve(s). The PSV should be sized, also,
taken into consideration that the flow could instantly increase at the PSV opening due to the change of
the compressor downstream circuit due to decrease of the pressure at the compressor outlet.
The design pressure shall be specified with a suitable margin to ensure reliable operation without
spurious shutdown or PSV opening, considering that the PSV set is equal to the design pressure
As far as the compressor suction side, consideration to be given to compressor arrangement to
determine the “settling pressure” of the isolated system. The settling pressure is the equilibrium pressure
reached between the suction and discharge isolating valves of the compressor system when the
compressor is stopped or shutdown. The design pressure of the equipment and piping at compressor
suction shall be above this settling pressure as a general rule in order to prevent unnecessary PSV’s
lifting. In determining the highest settle-out pressure (the pressure equilibrium after a compressor
shutdown, it is define also as the pressure between the upstream and downstream check valve) of multi-
stage compression plant, consideration shall also be given to the potential failures of the interstage
check valves and recycle valves where this may cause increased settle-out pressure of the lower
pressure stage(s). In general, the settling out pressure should be considered during the evaluation af the
MOP.

Centrifugal Compressors

The minimum requirement for the Design Pressure of the discharge side of the Centrifugal Compressor
is shown in Table 8.5.

Maximum Operating Pressure (bar g) Design Pressure on discharge side(bar g)

Operating Pressure < 10 barg Operating Pressure + 1 bar
Operating Pressure ≥ 10 barg 1.1 *Operating Pressure

Table 8.5: Centrifugal Compressor Design Pressure Criteria

For centrifugal compressor driven by a variable speed driver, the design pressure may be increased
when the compressor operating curves are known in order that the compressor can operate in its full
operating range. When the compressor operating curves are not know, assumptions should be made on
this matter.

Reciprocating Compressors

The minimum requirement for the Design Pressure of the discharge side of the Reciprocating
Compressor is shown in Table 8.6.

Maximum Operating Pressure (bar g) Design Pressure on discharge side(bar g)

Operating Pressure < 10 barg Operating Pressure + 2 bar
Operating Pressure ≥ 10 barg 1.2 * Operating Pressure

Table 8.6: Reciprocating Compressor Design Pressure Criteria

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8.1.3.6 Piping
Piping [3] design conditions shall provide for the most severe condition both in normal operation and
during transient conditions such as start-up, shutdown.
The Piping Design Pressure shall be the highest pressure, as determined from the following:
− The maximum continuous operating pressure, as defined by process requirements, but not less
than 3.5 bar g;
− Vapour pressure of the fluid in the pipe at maximum design temperature, unless protected by a
pressure-relieving device;
− The set pressure of the relieving device that protects the pipe;
− The maximum pump shut-off or blocked-in discharge pressure.
Suction piping of pumps from/and including suction valve shall be designed for discharge conditions.
This is to allow for backflow through the pump during shutdown, without overpressuring the suction side.
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8.2 DESIGN TEMPERATURE

8.2.1 Maximum design temperature

The Maximum Design Temperature (i.e. MDT) shall be specified at least of the highest of the following:
• Maximum Operating Temperature (MOT) + 30°C;
• Maximum Ambient Temperature;
• Boiling Water Service: saturation temperature at design pressure;
• Sun bare metal temperature for above ground piping not buried or insulated, and consequently
exposed to solar radiation;
• Proper consideration shall be made for transient operation such as End of Run, Catalyst/Bed
Regeneration.
Equipment subject to steam-out shall include additional design conditions of 1 bar g @ 120°C.
Exception shall be made for systems downstream of heat exchangers as per section 7.2.2
The exceptional temperature generated by fire will not be considered to specify the design temperature
selection.

8.2.2 Minimum design metal temperature

The Minimum Design Metal Temperature (i.e. MDMT) shall be specified at least of the lowest of the
following:
• Minimum Operating Temperature (MOT);
• Minimum Ambient Temperature;
• Minimum metal temperature calculated as a result of blowdown.
The Minimum Design Temperature shall be indicated together with the coincidental pressure.

8.2.3 Specific equipment requirements

8.2.3.1 Heat Exchangers

The Maximum Design Temperatures of an air cooler, shell & tube or plate & frame exchanger shall be
set according to section 8.2.1.
The Maximum Design Temperatures of systems downstream of an air cooler, shell & tube or plate &
frame exchangers should be set at the greater of:

• The maximum inlet temperature to the exchanger (i.e. loss of cooling);

• The maximum outlet temperature plus 30°C.
The Design Temperature of equipment downstream of an air cooler shall be based on the loss of cooling
fans but credit should still be taken for cooling due to natural convection equal to 20% of the normal
operating cooling duty.
This is not applicable in case the air flow is shut off by louvers, in that case the design as per
Shell&TubeHeatExchanger.

8.2.3.2 Compressors
The Maximum Operating Temperature is the temperature at compressor discharge which will be
preliminary calculated by Process Engineer. This temperature shall be confirmed / corrected by Vendor.

8.2.3.3 Piping
The Design Temperature for Piping [3] shall be the maximum continuous operating temperature, as
defined by process requirements.
For system downstream of an air cooler, shell & tube or plate & frame exchangers, reference shall be
made to section 8.2.3.1.
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9 LINE SIZING CRITERIA

This chapter reports the sizing minimum requirements for the following services:
• Gas Lines (Vapour & Steam);
• Liquid Lines;
• Mixed Phase Lines;
• Flare & Blowdown Lines.
The sizing criteria reported in the next section shall be based on high limits for the following main
parameters:
• Pressure Drop [bar/100m];
• Velocity [m/s];
• ρv2 [Pa].

9.1 GENERAL
The following minimum requirements should be taken in account during the design phase:
A) Sizing shall be carried out in according to maximum nominal flowrate reported in the heat material
balance plus a 10% design margin. As far as discontinuous operation (i.e. start-up, shut-down, etc)
sizing shall be carried out according the normal flowrate;
B) The user shall calculate the required inner diameter selecting the proper line size in according to the
piping class in order to ensure that the calculated values matches with the available sizes.
C) The user shall also verify the overall system pressure balance where required and limit the analysis to
check if the single process lines meet the required criteria.
D) Except for instrument piping, the minimum piping size shall be limited as follows:
• 2” equipment nozzles;
• 1” for pipe when located above ground;
• 2” for process line on pipe rack;
• 2” for utility line on main pipe rack;
• 2” for underground steel pipe;
E) The non-standard line size (e.g. 1¼”, 2½”, 5”, 7”, 9”) shall not be used.

9.2 GAS LINES

Lines in which fluid is mainly in gas/vapour phase (>95 % volumetric) are indicated as “gas line”.
It must be noticed that pressure drop for gas lines has to be evaluated considering that gas/vapour are
compressible fluids so the density is strictly affected by pressure.
• For short lines it is necessary to perform the calculations considering the arrival pressure.
• For long lines, such as headers, the user shall perform a detail calculation, where the lines are split in
a reasonable number of segments. Thereby the user shall determine the overall pressure drop, as the
sum of the pressure drop of each segment where the pressure of each segment is calculated, the
pressure of upstream segment minus the pressure drop of the upstream segment (if the calculation
has been performed starting for the upstream section).
• For gas lines, where film forming corrosion inhibitor is used, the velocity shall limited to 20 m/s (max.).
However during detail design, when Vendor of the inhibitor is selected, a check shall be performed to
verify if the velocity is compatible with inhibitor film wall shear stress.
High limits for sizing parameters are show in Table 9.1 for Vapour Lines whereas for Steam Lines
reference shall be made to Table 9.2
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ρv2 (Note 1) Velocity

Service ΔP [bar] / 100 m [Pa] [m/s]
Continuous Operation

0 ÷ 3.5 [barg] 0.10 - 112/√ρ

3.5 ÷ 20 [barg] 0.15 6500 -

20 ÷ 50 [barg] 8000 -

Pressure drop shall

50 ÷ 100 [barg] 10000 -
match the required
process condition
100 ÷ 140 [barg] 15000 -

>140 [barg] 20000 -

Compressor Suction Lines
0.20 %Operating
Pressure
Reciprocating (max. 0.03 bar / 100m) As per above -
0.50 %Operating
Pressure
Centrifugal (max. 0.07 bar / 100m) -
Column
Inlet to Overhead Condenser 0.10 1500 -

Table 9.1: Vapour Line Sizing Criteria (High Limits)

Note 1: ρv2 is calculated at operating conditions but the selection criteria is based on design pressure
(e.g. if line operates at 60 barg but the design pressure is above 140 barg, ρv2 limit shall be 20000 Pa).

Velocity
Service ΔP [bar] / 100 m [m/s]
3.3% Operating
0 ÷ 3.5 [barg] Pressure -
3.5 ÷ 10 [barg] 0.35 -
10 ÷ 30 [barg] 0.7 40
> 30 [barg] 1.0 30

Table 9.2: Steam Line Sizing Criteria (High Limits)

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9.3 LIQUID LINES

Lines in which fluid is mainly in liquid phase (>95 % volumetric) are indicated as “liquid line” .
In addition to minimum requirements shown in Table 9.3 where high limits for sizing parameters are
shown, the user shall take in account the following rules:
A) Lines upstream a pressure letdown valve shall be sized to prevent vapour flash ahead the control
valve;
B) Where the presence of sand or other solids might occur, the flow velocity should not be less than 1
m/s to minimize deposition;
C) For gravity flow, gas or vapour entrained in liquid flowing by gravity from a vessel can decrease the
capacity of the outlet pipe. This can be avoided by designing the line “Self Venting” where any
entrained vapour will be vented back into the vessel and will not be carried through with the liquid.
Sizing Base is Froude Number lower than 0.3, where

Fr= v/(gu*d)1/2

With:
- v is the fluid velocity in m/s;
- gu equal g*(ρl-ρg)/ ρl in m/s2;
- ρl is the density of liquid in kg/m3;
- ρg is the density of gas in kg/m3;
- P is absolute pressure in Pa;
- g equals 9.81 m/s2

D) Drainage Headers (open and closed) shall not be less than 3”. The minimum gradient for horizontal
piping shall be
• Onshore: 3” ≤ D ≤ 6” = 1.25%
• Onshore: 6” ≤ D ≤ 20” = 0.4%
• Onshore: D > 20” = 0.2%
• Offshore platforms: 1%
• FPSO: 1% (attention should be paid to drain system gradients because of vessel
movement)

E) For sizing suction lines for reciprocating pumps, acceleration head shall be considered.
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Maximum Velocity
SERVICE ΔP[bar]/100m [m/s]

Nomal Maximum
(Note2) (Note2)
Pump Suction (Note 3)
▪ Liquid @ bubble point or with dissolved gas ( ≤ 4") 0.05 0.8 1.0
▪ Liquid @ bubble point or with dissolved gas (4"÷ 8") 0.07 0.1 1.5
▪ Liquid @ bubble point or with dissolved gas ( ≥8") 0.07 0.11 1.8
▪Subcooled Liquid (<8") 0.25 0.35 2.0
▪Subcooled Liquid (≥8") 0.25 0.35 3.0
Pump Discharge
▪Lines < 8" 0.7 4.0
▪Lines ≥ 8" 0.7 5.0
Liquid Transfer Lines
▪ Liquid @ bubble point or with dissolved gas − 0.15 2.0
▪ Subcooled Liquid − 0.3 3.0
Or as
required
by system
balance
Liquid from Total Overhead Column Condensr 0.1 − 1.0÷2.0
0.035
Liquid to Reboiler (Natural Convection) (Note1) −
Gravity Flow 0.03 0.05 0.6
Drains
▪ Sanitary Drains − − 0.8/3 (Min/Max)
▪ Open Drain (Oil Contaminated Water) − − 0.8/3 (Min/Max)
▪ Open Drain (Oil Free Water) − − 0.8/3 (Min/Max)
Cooling Water Lines
▪ Headers 0.15 3.0
▪ Unit lines 0.35 3.0
As required
by Refers to
Seawater Lines
System Table 8.4
Balance
As required
by
Steam Condensate Return Lines 1.0
System
Balance

Table 9.3: Liquid Line Sizing Criteria (High Limits)

Note 1: ΔP of the feed line to a Natural Convection Reboiler shall take in account the overall circuit ΔP
(i.e. Thermosyphon effect).
Note 2: during engineering calculation, reference shall be made to normal value.
Note 3: when isometrics are not available, pump suction line sizing shall be made according the criteria
reported in Table 8.3 but a preliminary NPSH calculation shall be also performed assuming a minimum
equivalent length equal 80 meters.
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MATERIAL PIPE BORE[mm] VELOCITY [m/s]

10 0.7
Cast Iron 50 2.9
≥100 5.0
10 0.7
70/30 Copper/Nichel/Iron 50 2.3
≥100 4.0
10 0.7
90/10 Copper/Nichel/Iron 50 2.2
≥100 3.3
10 0.7
Steel, galvanized stell, aluminium brass 50 2.0
≥100 3.0

Table 9.4: Maximum Seawater Velocities in Pipes

9.4 MIXED PHASE LINES

The following minimum requirements shall be applied for mixed phase lines:

A) To calculate the erosional velocity and determine the pipe size to avoid erosion, reference will be
made to Table 9.5;
B) Check the flow pattern in order to avoid slug flow type. Annular flow is preferred.
In case annular flow can not be avoided, a note shall put on the relevant P&ID in order to highlight that
the line shall be properly supported.
C) Verify if the pressure drop shall match the required process condition;
D) Wellhead flowlines and manifold, where high pressure drops are available, shall be calculated
according to erosional velocity.

Erosional velocity shall be calculated as follows:

C ⎡m⎤
Ve = ,⎢ ⎥
ρ ⎣s⎦
where C in [kg1/2m-1/2s-1] is defined as following according API RP 14E. [4]

Consequently, fluid velocity inside the mixed line has to be lower than “Erosional Velocity”.
Erosional velocity is calculated using the following constant:
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Service (Note 1) C

[kg1/2m-1/2s-1]

Carbon Steel Lines WITHOUT solids but with corrosive

122
contaminants in CONTINUOUS service

Carbon Steel Lines WITHOUT solids but with corrosive

150
contaminants in INTERMITTENT service

Carbon Steel Lines WITHOUT solids and/or corrosive

200
contaminants (or inhibited fluid) in CONTINUOUS service

Duplex and Stainless Steel Lines in CONTINUOUS service 250

Duplex and Stainless Steel Lines in INTERMITTENT service 450

Table 9.5: “C” Constant for Erosional Velocity

Note 1: in presence of solids, different values of “C” may be used where specific application studies have
shown them to be appropriate.

A conservative approach is to halve the factor reported in Table 9.5. This might imply large line size. In
this case a detail analysis can be carried out according to “DNV RP O501” [5] in order to asses the
specific erosion per each component and to define the proper line size.

9.5 FLARE & BLOWDOWN LINES

Lines shall be calculated according to API 521 and API 520

9.5.1 PSV Inlet Lines

The following design rules shall be applied for PSV inlet lines:

A) The inlet line ΔP shall be less than 3% of the set pressure (gauge) calculated at rated flow based on
the installed PSV area. During FEED Phase when isometrics are not available an equivalent length of
60 meters for Onshore and 90 meters for Offshore could be assumed;
B) During FEED Phase when isometrics are not available to perform calculation reported at point A, the
following criteria shall be followed:
• Lines ≤ 2”: ρv2 ≤ 25,000 [Pa]
• Lines > 2”: ρv2 ≤ 30,000 [Pa] when relieving P is ≤ 60 barg
• Lines > 2”: ρv2 ≤ 45,000 [Pa] when relieving P is > 60 barg
C) The inlet line shall not be smaller than the inlet flange of the relieving device;
D) Manual Block Valve (for isolation) must be full bore;
E) The inlet system should be self-draining towards the protected equipment.
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9.5.2 BDV Inlet Lines

The following design rules shall be applied for BDV inlet lines:

A) The following criteria shall be followed:

• Lines ≤ 2”: ρv2 ≤ 25000 [Pa]
• Lines > 2”: ρv2 ≤ 30000 [Pa] when relieving P is ≤ 60 barg
• Lines > 2”: ρv2 ≤ 45000 [Pa] when relieving P is > 60 barg
B) The inlet system should be self-draining towards the protected equipment.

9.5.3 PSV Outlet Lines

The following design rules shall be applied for PSV outlet lines:
A) The discharge piping system should be designed so that the built-up back pressure caused by the
flow through the valve does not reduce the capacity of the relieving device. Limits are given as per
API 520 (Part 1) as follows:
• Conventional Valves: back-pressure at relief valve outlet < 10% of the set pressure (gauge);
• Bellows Valves: back-pressure at relief valve outlet < 30% of the set pressure (gauge);
• Pilot Operated Valves: back-pressure at relief valve outlet < 50% of the set pressure (gauge);
B) Mach number (Ma) shall be limited to 0.7 calculated at rated flow;

Ma=vs/u
With:
u= (k*P/ρ)1/2
where:
- k is the specific heat ratio (CP/CV);
- P is absolute pressure [Pa];
- ρ is gas density [kg/m3]

C) Minimum size 2” and however the outlet line shall not be smaller than the outlet flange of the relieving
device;
D) Outlet lines shall slope downwards to the relief header, without any low point (minimum slope 1:500);
E) The connections to headers/sub-headers shall be done with no low point and preferably top entry.
Connection will be preferably done at 45°C in the flow direction;
F) Manual Block Valve (for isolation) must be full bore.

9.5.4 BDV Outlet Lines

The following design rules shall be applied for BDV outlet lines:

A) The discharge piping system should be designed so that the built-up back pressure caused by
depressurization does not reduce the capacity of the relieving device (i.e. critical pressure ratio);
B) Mach number shall be limited to 0.7;
C) Minimum size 2”;
D) Outlet lines shall slope downwards to the relief header, without any low point (minimum. 1:500);
E) The connections to headers / sub-headers shall be done with no low point and preferably top entry.
Connection will be preferably done at 45°C, in the flow direction.
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9.5.5 Flare Headers & Sub-Headers

The following design rules shall be applied for Flare Headers & Sub-Headers

A) The discharge piping system should be designed so that the built-up back pressure does not reduce
the capacity of the relieving devices. Since this calculation might implies that different scenarios have
to be taken in account, the use of specific software might be necessary. The software recommended
to be used are listed hereunder:
• Flarenet (Aspentech)
• Flare Analizer (Honeywell)
• Visual Flow (Invensys)
The applicable version shall be specified and agreed with the Company .
B) Mach number shall be limited to 0.5;
C) Headers shall slope downwards to the flare K.O. Drum, without any low point (minimum 1:500);
D) Minimum size 2”;
E) The connections to headers shall be done with no low point and preferably top entry. Connection will
be preferably done at 45°C, in the flow direction.

9.5.6 Flare Stacks

Flare stacks shall be sized in order to limit Mach number to 0.7.

9.6 NOZZLE SIZING CRITERIA SUMMARY

The sizing of the nozzles shall be based on the maximum flow rates, including 10% design margin.

9.6.1 Feed inlet nozzle

The internal nozzle diameter may be taken equal to that of the feed pipe:

EQUIPMENT FEED INLET NOZZLES

ρmv2 [Pa]
INLET DEVICE USED MAXIMUM
(Note 1)
Separator / Column with no Inlet Device ≤ 1300
Separator / Column with Half-Open Pipe ≤ 2000
Separator / Column with Schoepentoeter ≤ 7500
Heat Exchanger ( Shell & Tube Type ) - Tube Side ≤ 6000
≤ 2200
Heat Exchanger ( Shell & Tube Type ) - Shell Side (Note 2) (non corrosive, non abrasive,
single phase fluids)
All other Heat Exchangers Type ≤ 750 (for all other fluids)

Table 9.6: Equipment Inlet Nozzle Criteria (High Limits)

Note 1: ρm is the mean density of the mixture in the feed pipe

Note 2: During detail engineering could be necessary to decrease shell side inlet nozzle size in order to
optimize the mechanical design of the heat exchanger. In that case, if the maximum value of ρmv2
exceeds ones shown in the table 9.6, impingement plates on shell side inlet nozzles shall be foreseen to
protect the bundle against impingement by the incoming fluid. Anyhow, the inlet nozzle area should not
produce a value of ρmv2 greater than 6000 Pa.
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9.6.2 Gas outlet nozzle

The diameter of the gas outlet nozzle should normally be taken equal to that of the outlet pipe, but the
following criteria shall be satisfied:

ρgv2 ≤ 3800 Pa

In High Vacuum Units this criterion may result in a high outlet velocity, leading to a pressure drop which
is too high. In that case the gas outlet nozzle shall be sized such that the pressure drop requirements
between column and downstream system are met.

9.6.3 Liquid outlet nozzle

The diameter of the liquid outlet nozzle shall be chosen such that the liquid velocity does not exceed
1 m/s. The minimum diameter is 2”. The nozzle shall be equipped with a vortex breaker.

9.6.4 Flare KOD nozzle

For flare knock-out drums, less stringent criteria than the above may be used such as:

Feed nozzle
• No inlet device (Not Recommended): the ρmv2 limit can be relaxed from 1300 to 2000 Pa;
• Half-open pipe: the ρmv2 limit can be relaxed from 2000 to 5000 Pa;

Gas outlet Nozzle

The ρgv2 limit can be relaxed from 7500 to 10000 Pa.

9.6.5 Instrumentation connection

Provide rating 300# as minimum for the 1” connection of the level instrumentation of:
• Level gauges [6]
• Level switches with external float, 400m face to face [6]

9.7 EQUIVALENT LENGTH

For pressure drop calculation, it is not sufficient referring to the linear length. The pressure drop of fittings
should be considered, as well as the pressure drop to elbow, tee and so on. When it is possible, the
reference to isometrics should be considered. As during the different phase of the project it is not always
possible to know the isometrics (i.e. fittings, manual valves and elbows number), the total equivalent
length can be estimated by multiplying the pipe length determinate by plot plan by the following factors
reported in Table 9.7.

Pipe Size Intra Unit Line Pipe Rack Line

≤ 3” 2.0 1.5
4” – 6” 2.5 1.5
≥ 8” 3.5 2.0

Table 9.7: Multiplying Factors for Equivalent Length

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10 PSV & BDV

PSV and BDV shall be sized as per API 520/521. DNV shall be used only if strictly required by law or
local legislation or by HSE requirements [7]. API 2000 shall be followed in case of atmospheric tank.

Inlet lines shall have a slope towards the upstream equipments. No pockets are accepted.
Outlet lines shall have a slope towards the flare/vent KO-drum system/unit. No pockets are accepted.

All the plant shall be designed accordingly the following three levels of protection:

1) normal control (e.g. DCS)

2) emergency control (e.g. ESD)
3) mechanical protection (e.g. full rating or PSV).

HIPPS is acceptable as third element of protection instead of PSV to limit discharge to atmosphere. The
HIPPS system shall be independent, certified and subjected to dedicated and programmed maintenance.
SDV for level 2 (e.g. ESD) shall not be used for the HIPPS. The HIPPS valves shall not be used for
normal operations or for ESD.

The three levels shall be completely independent in all elements.

In case of spare PSV the inlet/outlet isolation manual valve shall be preferably mechanically
interconnected (key interlock system).

Inlet/outlet isolation manual valve on PSV shall be full bore and locked open or car seal open.
Outlet isolation manual valve on PSV shall be locked open also when PSV is used as spare.

Inlet/outlet isolation manual valve on BDV shall be locked open or car seal open.
Inlet isolation manual valve on BDV shall be full bore.

BDV shall be normally failed open. SDV shall be normally failed closed.
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11 REFERENCES
[1] “API 650 Welded Steel Tanks for Oil Storage”, Eleventh Edition 2007
[2] “API 620 Design and Construction of Large, Welded, Low-pressure Storage Tanks”, Eleventh Edition
2008
[3] “ANSI/ASME B31.3 Process Piping”
[4] “API 14E RP” Fifth Edition, 1991
[5] "Recommended Practice RP0501 – Erosive Wear in Piping System" Rev. 4.2
[6] Agip Standardization N°20041.ICO.STA.STD: “CONNECTION OF INSTRUMENTS TO THE
PROCESS”, 1994
[7] Eni Standard “HSE Minimum Requirements” N° 1.3.0.07 dated March 2009 or following revision.

This document refers to the criteria of:

• “API 520 RP (Part 1)” Seventh Edition, 2000
• “API 520 RP (Part 2)” Fifth Edition, 2003
• “API 521 RP” Fifth Edition, 2008
• “API 2000 Venting Atmospheric and Low-Pressure Storage Tanks", Fifth Edition, 1998