Diámetro[in] = [ ( Q[m3/h] ) ^0.

5 ] / 2
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CLIENT: SHEET:
COMPERJ 1 of 17
JOB:
RIO DE JANEIRO PETROCHEMICAL COMPLEX SEP
AREA:
DELAYED COKING UNIT U-2200
TITLE:
PROCESS DESIGN CRITERIA FOR SYSTEMS DESIGN
SOFTWARE: MICROSOFT OFFICE – WORD XP
FILE: I-ET-6000.67-2200-940-JCC-001=A.DOC

Nº. PROJECTUS: 4558-00999-01.P0.00118-ET Nº. CONTRACT:

0800.0039800.08-2
TÉC. RESPONSIBLE: ADILSON PIRES AFONSO CREA Nº.: 0601329712 SIGNATURE:

REVISION INDEX
REV DESCRIPTION AND/OR AFFECTED SHEETS

0 FOR COMMENTS
A VALID TO DETAIL

REV. 0 REV. A REV. B REV. C REV. D REV. E REV. F REV. G REV. H

DATE: 05/05/08 09/05/08
DESIGN: JCC JCC
EXECUTION: LIC1 LIC1
CHECK:: CDOM CDOM
APPROVAL: APA1 APA1
THE INFORMATION CONTAINED IN THIS DOCUMENT IS PROPERTY OF PETROBRAS AND SHALL NOT BE USED FOR PURPOSES OTHER THAN THOSE SPECIFICALLY INDICATED HEREIN.

THIS FORM IS PART OF PETROBRAS STANDARD N-381-REV.G. INCLOSURE A FIGURE A-1

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INDEX

1. OBJECTIVE.................................................................................................................. 3

2. CRITERIA AND PREMISES ......................................................................................... 3

2.1. General .................................................................................................................. 3

2.2. Sizing - liquid lines ............................................................................................... 4

2.3. Sizing - vapor lines ............................................................................................... 6

2.4. Total equivalent length estimate for pressure drop calculation....................... 8

2.5. Control valve sizing .............................................................................................. 8

2.6. Orifice meter and other flow elements sizing................................................... 10

2.7. Pressure and temperature design conditions for piping ................................ 10

2.8. Static equipments preliminary design .............................................................. 11

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1. OBJECTIVE
This document presents the criteria and technical considerations that will be used by
PROJECTUS in feed design services and in the preparation of Material Quantity Tables related
with the contract 0800.0039800.08-2. These services will be developed to Atmospheric and
Vacuum Unit (U-2100) and Delayed Coking Unit (U-2200) that belongs to RIO DE JANEIRO
PETROCHEMICAL COMPLEX – COMPERJ.
This will be done using the documents supplied by COMPERJ for the referred Units as indicated
in the document list: I-LD-6000.67-2100-940-PPC-001 and I-LD-6000.67-2200-940-PPC-001.
The following Standards will be adopted:

• MD-6000.67-2000-941-IPQ-001 Rev.0 – Memorial Descritivo,

• I-ET-6000.67-0000-941-PDY-009 Rev. B – Basic Data for Utilities
• Petrobras Standards:

¾ N-76 – Materiais de tubulação para instalações de refino e transporte – Rev.F A

2. CRITERIA AND PREMISES

2.1. GENERAL

The criteria to be followed are:

• Utility stations will have its consumption and simultaneous use estimated using PRJ own
criteria as follows:

TABLE 1. Utility Station criteria

A

Utility Station Simultaneous Flow

Fluid
Diam. (in) (1) (kg/h)
Industrial Water ¾ 2 1041.0
Plant Air ¾ 4 30.0
Medium Pressure Steam ¾ 1 55.0
Nitrogen ¾ 4 30.0
(1) For more detail see: I-MC-6000.67-2100-940-JCC-009 REV.A
I-MC-6000.67-2100-940-JCC-011 REV. 0
I-MC-6000.67-2100-940-JCC-012 REV. 0

The fluid conditions are indicated in the document: I-ET-6000.67-0000-941-PDY-009 Rev. B

– Basic Data for Utilities

• Machinery cooling water consumption will be estimated using as reference the

recommendations of Ludwig Book, volume 3, chapter 12 page 380 with delta T I-ET-
6000.67-0000-941-PDY-009 Rev. B – Basic Data for Utilities. The Ludwig recommendations
are shown in the following table.
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TABLE 2. Heat Rejected to Water A

Btu/Bhp (hr) Temperature

Small Cyl. Large Cyl. Difference
< 12in dia. > 20in dia. tC - tW
300 170 20
600 310 60
700 470 100

• All piping will be calculated taking into account a design flow of 15% plus the maximum
simultaneous normal flow;
• Pipe sizing will consider a roughness of 0.0018 in;
• For the design of all items (piping, instruments equipments, etc) it will be used the minimum
values of pressure / temperature in the Inlet side of the Battery Limit and the maximum
values for the Outlet side;
• The arrangement of block and measurements in the Battery Limit will follow the indications
supplied by COMPERJ in the document I-ET-6000.67-3000-200-PEI-001: DESIGN
CRITERIA – PIPING.

2.2. SIZING - LIQUID LINES

SERVICE VELOCITY ΔP/L maximum

(kg/cm2)/
ITEM DESCRIPTION ft/s m/s psi/100 ft
100m
A
2.2.1 HYDROCARBONS
2.2.1.a General recommendations:

2.2.1.a.1 Specific gravity = 1.6 5 to 8 1.5 to 2.4

2.2.1.a.2 Specific gravity = 0.8 6 to 15 1.8 to 3.1 1.0 0.23

2.2.1.a.3 Specific gravity = 0.3 10 to 15 3.1 to 4.6
2.2.1.b Special services:
Pump suction. bottom of vessels and towers:
2.2.1.b.1
Saturated liquid or at bubble point 2 to 3 0.61 to 0.92 0.35 0.08
Sub cooled liquid 3 to 8 0.9 to 2.4 1.0 0.23
Pump discharge (except high pressure pumps) 5 to 12 1.5 to 3.6 1.5 to 2.0 0.35 to 0.46
2.2.1.b.2 2
High pressure pumps discharge (>50kgf/cm ) 1.0 0.3 3.0 to 4.0 0.69 to 0.92
2.2.1.b.3 Gravity flow 4 to 6 1.2 to 1.8
2.2.1.b.4 Liquid to chillers 3 to 6 0.9 to 1.8 0.5 0.115
2.2.1.b.5 Condenser outlet 1 to 4 0.3 to 1.2 0.15 0.035
Liquid to reboilers. feed of distillation columns and
2.2.1.b.6 3 to 6 0.9 to 1.8
refrigeration pipes
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SERVICE VELOCITY ΔP/L maximum

(kg/cm2)/
ITEM DESCRIPTION ft/s m/s psi/100 ft
100m
A
2.2.2 WATER (Including COOLING WATER)
2.2.2.a General recommendation (Note 1) 2 to 12 0.6 to 3.6 1.0 0.23
2.2.2.b Specific services:
2.2.2.b.1 Pump suction and drains 4 to 7 1.2 to 2.1 0.35 0.08
2.2.2.b.2 Pump discharge Note 1 Note 1 Note 1 Note 1
2
2.2.2.b.3 Boiler feed water: P < 50 kgf/cm 5 to 10 1.5 to 3.1 2.0 0.46

2.2.2.b.4 Boiler feed water: P > 50 kgf/cm2 6 to 12 1.8 to 3.6 1.0 0.23

2.2.3 SPECIAL LIQUIDS

2.2.3.a In carbon steel pipes :
2.2.3.a.1 Sulfuric acid - concentrated 4 1.2
2.2.3.a.2 Sour water 6 1.8
2.2.3.a.3 Caustic solutions 4 1.2
2.2.3.a.4 Lean Amine 5 to 7 1.5 to 2.1
2.2.3.a.5 Phenolic water 3 0.9
2.2.3.b In rubber or plastic lined pipes
2.2.3.b.1 General liquids 10 3.1

2.2.3.b.2 Liquids with suspended solids 3 (min.) 0.91 (min.)

2.2.3.c In stainless steel pipes

2.2.3.c.1 Amine solutions rich in H2S 5 to 7 1.5 to 2.1

NOTES:
(1) In the case of water in pump discharge lines use
¾ Diameters from 3/8” and bigger use the ΔP100 criteria as indicated in the
following table:
A

TABLE 3. Diameter of water pump discharge lines.

Pipe diameter (in) Velocity (m/s) ∆P maximum (kgf/cm²/100m)

3/8 - ½ - ¾ - 1 – 1 ¼ - 1 ½ - 2 0.5 to 1.0 0.23

3–4–6 1.0 to 2.0 0.23

8 – 10 – 12 2.0 to 3.0 0.23

14 – 16 – 18 – 20 3.0 to 3.6 0.23

> 20 3.6 -
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(2) For liquid effluents and drain pipes use PETROBRAS STANDARD N-38,
(3) For fire protection systems in hydrocarbon processing installations use
PETROBRAS STANDARD N-1203,
(4) For steam condensate pipes:
(4.1) Before traps and control valves keep the ΔP as low as possible to avoid flash
ΔP100 = 0.1kgf/cm²/100m. Take into account elevations between liquid
surface and control valve. ΔP by friction must be lower than the static pressure
increase,

(4.2) After traps and control valves pipe must be calculated considering that the
ΔPTOTAL = 0.33 a 0.5(PSTART – PFINAL), being PSTART the steam pressure at
the equipment and PFINAL the final condensate destiny pressure.

2.3. SIZING - VAPOR LINES

SERVICE VELOCITY ΔP/L maximum

ITEM DESCRIPTION ft/s m/s psi/100 ft (kg/cm2)/100m
A
2.3.1 HYDROCARBONS
2.3.1.a General recommendations:
2.3.1.a.1 P > 35kgf/cm²g 2.0 0.46
2.3.1.a.2 14 < P ≤ 35kgf/cm²g 1.5 0.35
2.3.1.a.3 10 < P ≤ 14kgf/cm²g 0.6 0.14
2.3.1.a.4 3.5 < P ≤ 10kgf/cm²g 0.3 0.07
2.3.1.a.5 0 < P ≤ 3.5kgf/cm²g 0.15 0.04
2.3.1.b Specific services
2.3.1.b.1 Atmospheric discharge 200 61
2.3.1.b.2 Compressor suction 0.1 to 0.3 0.023 to 0.069
2.3.1.b.3 Compressor suction headers 15 to 35 4.6 to 10.7
Reciprocating Compressor (suction and
discharge)
20 6.1
density = 10lb/ft³
2.3.1.b.4 42 12.8
density = 1.0lb/ft³
91 27.7
density = 0.1lb/ft³
200 61
density = 0.01lb/ft³
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SERVICE VELOCITY ΔP/L maximum

ITEM DESCRIPTION ft/s m/s psi/100 ft (kg/cm2)/100m
A
2.3.1.b.5 Compressor discharge lines 0.2 to 0.5 0.046 to 0.115
2.3.1.b.6 PSV discharge lines (note 2) 0.5 Vs
2.3.2 STEAM
2.3.2.a General recommendations: 100 30.2
2.3.2.a.1 Saturated 140 42.7
Superheated
2.3.2a.2 0 < P ≤ 3.5kgf/cm²g 0.25 0.057
10 < P ≤ 20kgf/cm²g 0.5 0.115
High & very high pressure superheated
2.3.2.b
(>50kgf/cm²):
2.3.2.b.1 125 38.1 1 0.23
Short pipes ( ≤ 180 m)
2.3.2.b.2 100 30.5 0.4 0.092
Long pipes ( > 180 m)
2.3.2.c Exhaust
2.3.2.c.1 P > atm pressure 0.5 0.115
2.3.2.c.2 Branch collectors 1.5 0.345

2.3.2.d To turbines and reciprocating machines 12.5 to 15 3.8 to 4.6

2.3.3 COMPRESSED AIR &NITROGEN

2.3.3.a Header 20 to 26 6 to 8 0.1 0.023

2.3.3.b Branches 26 to 33 8 to 10 0.35 0.080

NOTES:

(1) General: see standard API-521 to flare systems

(2) PSV discharge lines: if the allowable pressure drop is high enough use all of it
limiting the velocity to:

T
k
Vs = C M

Where: C = 91.2
k = Cp/Cv
T = Temperature, (ºK)
M = molecular weight
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2.4. TOTAL EQUIVALENT LENGTH ESTIMATE FOR PRESSURE DROP CALCULATION

During this phase of the job when it will be necessary to estimate the equivalent length of a pipe
use the Complexity Factor as defined as follows:

2.4.1. Equivalent length:

The following equation was obtained by PROJECTUS during previously contracts: A

Leq = 1 + (0.347 D½ + 0.216) x Fc

L

Where:
Leq = Total equivalent length
L = Straight length of pipe (from lay-out)
D = Pipe internal diameter (in)
Fc = Complexity factor
NOTE:

For hot pipes (temperature higher than 250ºC), it must be added a safety factor of 50% to take
into account the expansion loops.

2.4.2. Complexity Factor Table

FC Complexity Factor

Short pipes (≤ 30m) systems in congested areas. Typical example are

4
complex manifolds with too much valves, reductions, accessories, etc

Short pipes (near 30m) normally interconnect near equipments, do not pass
2
through pipe racks, lower than 3”

Normal length of pipe (30 a 100m), interconnects equipments; raw material,

1
intermediate products, final products inside battery limits,

Long pipe (about 150 m); pass trough units or interconnecting units, do not
0.5
pass trough pipe ways

0.25 Outside battery limits pipes, utility supply pipes

2.5. CONTROL VALVE SIZING

Control valve pressure loss must obey the following rules to give a reasonable control:
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¾ Rule 1
Select the HIGHER VALUE between:
• Valve ΔP equal to or bigger than 20%, of the friction loss in the system considering
the MAXIMUM FLOW RATE (consider all equipments and do not consider the valve ΔP),

ΔP CV. ≥ 0.2ΔP friction loss in Max. flow

• Valve ΔP equal to or bigger than 25% of the friction loss in the system considering
the NORMAL FLOW RATE (consider all equipments and do not consider the valve ΔP),

ΔP CV ≥ 0.25ΔP friction loss in NORMAL. flow

¾ Rule 2
Valve ΔP equal to or bigger than 10%, of the static pressure of the reservoir (located at the
suction or discharge).This rule is not applicable to systems where suction and discharge
pipes are connected with reflux recycles

ΔP CV. ≥ 0.10ΔP absolute pressure in the reservoir

¾ Rule 3
The control valve diameter cannot be bigger than pipe diameter.

¾ Rule 4
Maximum ΔP for compressible fluids shall not be bigger than 50% of the upstream pressure
(sonic flow).

¾ Rule 5
Minimum ΔP must be 1.05kgf/cm² (15psi) in normal flow rate or 0,70kgf/cm² (10psi) in the
maximum flow rate for reflux, recycle or raw material charge.

¾ Rule 6
ΔP in feed steam lines for turbine must be 5% of the absolute upstream pressure.

¾ Rule 7
ΔP in feed steam lines for reboilers must be between 5 and 10% of the absolute upstream
pressure. This ΔP cannot be lower than 0.35kgf/cm² (5psi).
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OBS.1: Rules 6 e 7 are specific and substitute rules 1 and 2 in the indicated services. Rule 5 is
limited to the indicated service and increases one limitation in rules 1 and 2. All other cases must
follow rules 1 and 2.

OBS.2: Rules 3 and 4 are predominant over the others and must be always followed.

2.6. ORIFICE METER AND OTHER FLOW ELEMENTS SIZING

Consider the following rules during this phase of the job:

ΔP orifice meter = 0.25kgf/cm² (250mmH2O)

A
ΔP other flow element= 0.14kgf/cm² (2psi)

Obs.: For CORIOLIS type use ΔP = 1.0 kgf/cm² Max. in maximum flow rate (If possible confirm
the value with a supplier).
A

2.7. PRESSURE AND TEMPERATURE DESIGN CONDITIONS FOR PIPING

2.7.1. Design temperature

A

The design temperature is defined as the operating temperature plus 30ºC.

All lines handling hydrocarbons are subject to steam-out cleaning, so such lines and the nozzles
and equipments to which they connect are subjected to steam temperature.
In this unit – U-2100 – medium pressure steam is used to steam-out procedures. Medium
pressure steam is furnished at battery limit at 16kg/cm²g and 228ºC.
In the document I-FD-6000.67-2100-200-JCC-001 – Line List – is indicated in which lines steam-
out is necessary.

2.7.2. Design pressure

2.7.2.1. Pump systems

¾ Maximum suction pressure

P suc max= P rs máxima + NLL x SGT

10

Where:
P suc max – maximum suction pressure in kgf/cm² man.;
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P rs máxima – maximum reservoir pressure in pump suction in kgf/cm² man;

NLL – liquid normal level for process vessels or maximum liquid level for storage
tanks in meters,
SG T – liquid specific gravity at pumping temperature,

¾ Maximum discharge pressure

P desc max = P suc max + AMT máxima

Where:
P desc max – maximum discharge pressure in kgf/cm² man,
AMT maxima – maximum AMT (shut off) in kgf/cm² (when there is no information
about this value use a factor of 1.2 over the normal AMT),
The maximum design pressure shall be compared against vendor data sheet previous purchase.
A

2.7.2.2. System without pump

Increase 2.0kgf/cm² to the maximum operating pressure of the equipment connected with the
line.

2.8. STATIC EQUIPMENTS PRELIMINARY DESIGN

2.8.1. General A

Vertical vapor-liquid separators are preferred for handling mixtures with high vapor/liquid mass
flow ratio and usually only one liquid phase. In certain cases, the vapor-liquid separation may
take place simultaneously with the settling separation of two liquid phases. In the cases where
only a small amount of heavy phase is present, vertical drums may still be used.
Horizontal vapor-liquid separators are preferred to handle mixtures with low vapor/liquid mass
flow ratio and only one liquid phase and to handle mixtures containing vapor and two immiscible
liquid phases. An attached pot may be used in certain cases to catch the heavy phase outside of
the drum, thus permitting better control of the operation and possibly reducing the drum size.
Another factor shall be considered before choose the vessel type:

- The space available in the plot-plan to the vessel and

- The support costs. In general is cheaper install a horizontal vessel than a vertical
vessel.

2.8.2. Vertical Vessel A

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2.8.2.1. Vessel diameter

A

The ratio H/D in general shall be between 1.5 and 5. The following table given the ratio H/D as
function of the vessel design pressure.

TABLE 4. H/D ratio.

Vessel Design Pressure H/D

P< 3.5kg/cm²g 2 to 3

3.5kg/cm²g < P < 42kg/cm²g 3 to 4

P > 42kg/cm²g 4 to 5

Calculate diameter using:

1. Va = K * [(rhol – rhov) / rhov] ** 0.5 where:

K = 0.2 vessels without demister,
K = 0.35 vessels with demister,
rhol = liquid density (lb/ft3),
rhoV = vapor density (lb/ft3).

2. D = 0.1457 * [(Wg / Va)] ** 0.5

Wg = flow (ft³/min)

2.8.2.2. Vessel height

2.8.2.2.1. Between Demister and upper vessel tangent line

Hd = 1.0 ft (or zero if there is not a demister)

2.8.2.2.2. Between Demister and liquid/vapor inlet nozzle (Center line)

Hv1 = 0.5 D (mini = 3.0 ft)

2.8.2.2.3. Between liquid/vapor inlet nozzle (Center line) and maximum liquid level (HLL)
Hv2 = 1.0 ft

2.8.2.2.4. Between HLL e lower liquid level (LLL)

HL1 = 10 minutes of HOLD UP or 15in (minimum)
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2.8.2.2.5. Between (LLL) and lower vessel tangent line

HL2 = 6.0 in

2.8.3. Horizontal Vessel

A

2.8.3.1. Horizontal vessel without demister A

For horizontal vessels without demister shall be considered:

- Design velocity factor f = 1.7

- Minimum diameter: 950mm
- Minimum distance between nozzles: 150mm

For more detail see Figure 1

Figure 1. Horizontal vessel without demister.

2.8.3.2. Horizontal vessel with demister

A

For horizontal vessels without demister shall be considered:

- Design velocity factor f = 0.8 – 2.2

- Minimum diameter: 1350mm
- Minimum distance between nozzles: 150mm
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For more detail see Figure 2

Figure 2. Horizontal vessel with demister.

The demister dimensions are designed in accordance with the design velocity as follow:

A = QV / VP
a = D x ((1-(2 x d)/D)2)1/2
l=A/a

where:

QV = vapor volumetric flow (m³/s)

VP = design velocity (m/s)
a = demister thickness
d = distance from vessel center line to demister’s bottom
l = demister’s length

2.8.3.3. Horizontal surge drum A

For horizontal surge drum shall be considered

- Minimum diameter: 950mm;

- Minimum distance between nozzles: 150mm
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Figure 3. Horizontal surge drum.

2.8.3.4. Liquid-liquid settler A

For horizontal liquid-liquid settler drum shall be considered:

- Design velocity factor f = 1.7

- Maximum settling velocity, vg = 0.00423m/s
- Minimum diameter: 1400mm
- Minimum distance between nozzles: 150mm

Figure 4. Liquid-liquid settler.

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2.8.3.5. Horizontal separator with a heavy liquid pot A

For horizontal separator with a heavy liquid pot drum shall be considered:

- Design velocity factor f = 1.7

- Maximum velocity – pot: vb = 0.152m/min.
- Maximum settling velocity, vg = 0.00423m/s
- Minimum diameter: 1350mm
- Minimum distance between nozzles: 150mm

Figure 5. Horizontal separator with a heavy liquid pot.

2.8.4. Vessels nozzles

2.8.4.1. Inlet of liquid/vapor

V < 60/(rhom)**0.5 for vessels with demister,

V < 45/(rhom)**0.5 for vessels without demister, where
rhom = Y * rhol + (1-Y) * rhov
Y = liquid volumetric fraction in the mixture
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2.8.4.2. Vapor outlet

V < 60/(rhov)**0.5

2.8.4.3. Drains and vents A

In general, venting and draining shall be accomplished through vessel and/or equipment
connections.
Drains shall also be provided on the low points of all process lines. Vents shall be provided on
high points of process lines.

Table 5. Drains and vents sizes.

Drum size Vent Drain

(m³) (in) (in)
< 1.4 1 1
1.4 – 5.7 1 1½
5.7 – 17 2 2
17 –177 2 3
177 – 220 2 3
220 – 420 4 4
> 420 6 4