3210-8110-PD-0004 Rev A1

PARADIP REFINERY PROJECT PROJECT SPECIFIC PROCEDURES PROCESS ENGINEERING PROCESS ENGINEERING DESIGN GUIDELINES 3210-8110-PD-0004 PAGE 2 OF 24 REV A1
CONTENTS 1.0 INTRODUCTION.................................................................................................................... 3 2.0 VESSELS............................................................................................................................... 3 2.1 Drum Surge Capacity and Hold-up Volume ....................................................................... 3 2.2 Tower Bottoms Surge Capacity and Hold-up Volume ........................................................ 4 2.3 Knockout Drum Surge Capacity and Hold-up Volume ....................................................... 4 2.4 Minimum Auxiliary Nozzle Size .......................................................................................... 5 2.5 Towers and Columns.......................................................................................................... 5 3.0 HEAT EXCHANGERS ........................................................................................................... 7 3.1 Fouling Factors................................................................................................................... 7 3.2 Fluid Allocation ................................................................................................................... 7 3.3 Heat Exchanger Pressure Drops........................................................................................ 8 4.0 PUMPS ................................................................................................................................ 10 5.0 LINE SIZING ........................................................................................................................ 11 5.1 Liquid Flow ....................................................................................................................... 11 5.2 Vapour Flow ..................................................................................................................... 14 6.0 CONTROL VALVES............................................................................................................. 15 7.0 EQUIPMENT DESIGN LIVES.............................................................................................. 15 7.1 Design Life........................................................................................................................ 15 7.2 Corrosion Allowances....................................................................................................... 15 8.0 EQUIPMENT DESIGN TEMPERATURE AND PRESSURE................................................ 16 8.1 Design Temperature......................................................................................................... 16 8.2 Design Pressure ............................................................................................................... 17 8.3 Design Pressure and Temperature Example ................................................................... 19 9.0 EQUIPMENT DESIGN MARGINS ....................................................................................... 21 9.1 Columns ........................................................................................................................... 21 9.2 Pumps .............................................................................................................................. 21 9.3 Heat Exchangers .............................................................................................................. 22 10.0 EQUIPMENT SPARING ................................................................................................... 22 10.1 General ......................................................................................................................... 22 10.2 Heat Exchangers .......................................................................................................... 22 10.3 Pumps........................................................................................................................... 22 10.4 Compressors, Fans and Blowers.................................................................................. 22 11.0 VALVE LEAKAGE CLASSIFICATION.............................................................................. 23
W:\Project\IOCL\3210\DMGInbox\NAGA'S WORKING FOLDER\3210-8110-PD-0004 REV A1 .doc
DSN : 131
1.0
INTRODUCTION
The purpose of this document is to ensure consistency of approach to design of equipment across the Paradip Refinery Project. Where the process design has developed more than one heat and material balance (eg. multiple cases), all equipment and piping shall be specified for the most onerous case.
2.0 2.1
VESSELS Drum Surge Capacity and Hold-up Volume

For drums the surge capacity (hold-up) is defined as the volume between high and low liquid levels. If a uniform discharge rate is important, provide the general hold-up times recommended below: Service Feed to Tower or Furnace - drum diameter: < 1.2 m - drum diameter: 1.2 to 1.8 m incl. - drum diameter: > 1.8 m Reflux to Tower Product to Storage Flow to Heat Exchanger Flow to Sewer or Drain 20 15 10 5 2 2 1 Hold-up, minutes
In case hold-up must be provided for both product and reflux, the larger volume is used, not the sum of the two volumes. When the discharge rate is unimportant, a nominal hold-up time of approximately two (2) minutes is provided. The normal operating liquid level should be taken as the midpoint between the high and low levels. Level control should span between the high and low levels. Where high and low level trips are required, these should be located at a reasonable elevation above and below the high and low levels respectively, to allow operator intervention before a trip occurs. Low liquid level shall be at least 200 mm above the bottom (for horizontal vessels) or bottom tangent line (for vertical vessels).
DSN : 131
For water settling the above applies but this may need to be increased. Where there may be solids in the drum, which are not to be drawn off, the liquid outlet may be raised and the low liquid level shall be increased accordingly For horizontal vessels, the highest liquid level shall be at least either 300 mm or 20% of the drum diameter below the top, whichever is the greater. Note: if a crinkled wire mesh pad is present then highest liquid level shall be at least 300 mm below the bottom of the pad. For vertical vessels, if vapour flow is present the highest liquid level shall be at least 300mm below the bottom of the inlet arrangement. If little or no vapour is present, the highest liquid level shall be at least 300 mm or 15% of the drum diameter below the top tangent line, whichever is the greater. The minimum time between a HHLL alarm and trip and between a LLLL alarm and trip shall be no less than 2 minutes.
2.2
Tower Bottoms Surge Capacity and Hold-up Volume

The liquid residence time (from the low to high levels) for the design of the bottom section of a column is as follows: 1. Bottoms as feed to a subsequent tower on level control is five (5) minutes. In general, level control will frequently prove satisfactory to the second of a series of towers. 2. Bottoms as feed to a subsequent tower on flow control is ten (10) to twenty (20) minutes, when the column is acting as a feed surge drum to another unit. This surge capacity may be obtained by swaging to a larger diameter for the hold up section of the column, in some cases. 3. Bottoms to a heat exchanger and/or tankage is two (2) minutes. This may be reduced in the case of a crude or vacuum tower in order to prevent coking. 4. Feed to a fired coil reboiler is the sum of five (5) minutes on the vaporised portion and two (2) minutes on the bottoms product. It is normally desirable that the five (5) minutes on the vaporised portion be employed to establish the normal low level, with the subsequent two (2) minutes on bottoms product used to establish the high liquid level (normally 300 mm is the minimum allowed distance between these levels). 5. For vacuum towers, a space corresponding to 30 seconds surge on total vacuum bottoms plus quench rate is set between low and high liquid level at tower bottoms.
2.3
Knockout Drum Surge Capacity and Hold-up Volume

For normal accumulation the following liquid hold up applies: a) At low normal accumulation rate Liquid drawoff is usually manually controlled. Enough volume should be provided to ensure the frequency of emptying is less than once per shift (i.e. eight (8) hours) or preferably twenty four (24) hours. Generally a nominal height above the lower tangent line (say 200 mm) will be adequate.
DSN : 131
b) At higher normal accumulation rate Liquid drawoff is usually under level control. The distance between high and low level is usually made to suit a standard controller range, say 350 mm, (corresponding to controller connections and generally providing hold up time far in excess of the normal requirement of approximately two (2) minutes). For a spill the following liquid hold up applies: c) Frequently capacity is required for spill from preceding unit. Provide a volume equal to the entire production of the unit for ten (10) minutes between the alarm level (see Note * below) and a point 300 mm above the normal high level. Sometimes spill requirements govern the drum design. That is, an L/D ratio of approximately 3:1 results in a large drum diameter relative to the vapour load. Use of a critical wire mesh screen would then be uneconomic. (Note: * level alarm provided if level rises 300 mm above normal high level)
2.4
Minimum Auxiliary Nozzle Size

The following list is a guide to the minimum auxiliary nozzle sizes to be used for process design sizing of nozzles (minimum mechanical nozzle size of 50 mm (2) to be specified during vessel design). Vessel Volume, m3 1.5 1.5 5.6 5.6 17 17 70 70 and over Vent 25 (1) 25 (1) 50 (2) 50 (2) 50 (2) Drain 25 (1) 40 (1 ) 50 (2) 80 (3) 80 (3) Pumpout 25 (1) 40 (1) 50 (2) 80 (3) 80 (3) Steamout 25 (1) 25 (1) 25 (1) 50 (2) 80 (3) Blowdown 50 (2) 80 (3) 80 (3) 100 (4) 100 (4)
2.5
2.5.1
Towers and Columns

Minimum Tray Spacing Tower ID mm 750 to 1800 1800 to 2700 2700 to 3300 3300 to 4800 4800 to 6000 Max No. of Tray Passes 1 2 2 4 4 Min Tray Spacing mm 500 500 600 600 600
> 6000 4 750 For draw off trays, the spacing is set by the draw off tray design, including hold up.
DSN : 131
2.5.2
L/D Ratio Towers with L/D greater than 25 shall be avoided, if possible, due to support problems.
2.5.3
Allowable Pressure Drop Guidelines for Trays
Tray Type Sieve Valve 2.5.4
For: Pressure Service kg/cm2 per tray 0.007 - 0.014 0.007 0.014
For: Vacuum Service mm Hg per tray 1.0 2.0 3.5 4.5
Preferred Internal Diameters (mm) of Columns/Vessels 300 (350) 400 500 600 700 800 900 1000 1100 (1200) (1300) 1400 (1500) 1600 (1700) 1800 (1900) 2000 (2100) 2200 (2300) 2400 2600 2800 3000 3200 (3400) 3600 (3800) 4000 4250 4500 4750 5000
NOTE: second preference shown in brackets. 2.5.5 Manholes in Columns and Vessels: ID 900 mm Use flanged end/top cover if access is required
ID > 900 mm Preferred size: 600 mm (24); Min size: 250 mm (20) Columns: manholes are to be provided above the top tray and below the bottom tray. The spacing of manholes in trayed columns shall be every 6 m (approx). The minimum number of manholes for columns is three. Vessels: minimum number of manholes is one. For vessels more than 6 m in length the minimum number is two. In case of small vessels, hand holes of 150 mm (6) are to be provided.
DSN : 131
2.5.6
Tower Internals Where trays are specified, the preferred type is valve trays (stainless steel)
2.5.7
Minimum Corrosion Allowances Refer to Section 7.0 below
3.0 3.1
HEAT EXCHANGERS Fouling Factors

Site specific fouling factors will be set as shown below. However, where Licensor has requirements, which are more stringent than this, then Licensor values shall be applied. i) Cooling water: 0.0005 m.hrC/kcal ii) For other services, as per TEMA and Licensor standard
3.2
Fluid Allocation
To allocate fluids to shell or tube side of an exchanger, the following general principles of fluid allocation shall apply: a) cooling water on tubeside b) high pressure fluid on tubeside c) most corrosive fluid on tubeside d) higher fouling fluid on tubeside e) most viscous fluid on tubeside f) large volume of condensing vapours on shellside g) single phase fluids both sides put smaller flow on shellside The above principles may conflict in some instances and alternative designs shall be investigated. In these cases the most economical design shall be selected.
DSN : 131
3.3
Heat Exchanger Pressure Drops

The pressure drop available shall be specified as below and all hydraulic calculations shall allow for this specified pressure drop.
3.3.1
Liquids Total Pressure Drop (kg/cm) for Liquid Flow Through Exchangers in Series Viscosity @ avg. temperature cP < 1.0 1.0 to 5.0 5.0 to 10.0 > 10.0 One Shell Pressure Drop kg/cm 0.35 0.70 0.70 1.05 1.41 Two Shells Pressure Drop kg/cm 0.35 0.70 1.05 1.05 1.41 1.41 2.10 Three Shells Pressure Drop kg/cm 0.70 1.05 1.05 1.41 1.41 2.10
3.3.2
Gases Pressure Drop (kg/cm) for Vapour Flow Operating Pressure (kg/cma) 0 1.72 > 1.72 Pressure Drop (kg/cm) Approx. 0.03 - 0.07 0.14 0.35
3.3.3
Condensers and Reboilers For partial condensers allow 0.14 to 0.35 kg/cm pressure drop. For condensers where total isothermal condensation takes place, the pressure drop is usually low or negligible. For surface condensers allow 3 - 5 mm Hg for operating pressures about 30 mm Hg. For kettle type reboilers the shell side pressure drop is generally termed negligible. For thermosyphon type reboilers the exchanger pressure drop must be low and is normally in the region of 0.017 to 0.035 kg/cm.
DSN : 131
3.3.4
Airfin Cooler Pressure Drops The pressure drop available for airfin coolers shall be specified as below and all hydraulic calculations shall allow for this specified pressure drop. Service Operating Pressure kg/cma All 2.06 4.50 4.50 18.2 18.2 104 Total Condensation Atmospheric & above 0.70 0.07 0.21 0.35 0.03 min For multi-pass air coolers, highpressure drops assure proper flow distribution. The higher pressure drop will also assure good flow distribution at lower than design throughput Note as for total condensation Selection of an allowable pressure drop should be from the results of an economic study Allowable Pressure Drop kg/cm Not valid for viscous fluids
Liquid Cooling Gas Cooling
Partial Condensation Condensation
Atmospheric & above Vacuum
0.14 - 0.35 3 - 5 mm Hg
3.3.5
Viscous fluids The following typical pressure drops shall be allowed for more viscous fluids. Service Light gas oil cooler (airfin) Light gas oil cooler (shell and tube) Pumparound cooler (airfin) Light gas oil cooler (shell and tube) Waxy distillate cooler (airfin) Vacuum residue cooler (airfin) Vacuum residue cooler (shell and tube) Tempered water cooler (airfin) *Must be estimated by specialist engineers. Allowable pressure drop, kg/cm 1.05 0.70 1.05 0.70 1.41 1.75 1.75 3.52 1.75 5.27
* *
2.81 3.52
DSN : 131
3.3.6
Air Cooling versus Water Cooling Air-cooling shall be maximised for which the cut-off temperature of process streams shall be 55 C. Further trim-cooling will be by water as necessary. The dry bulb temperature specified in the BEDD shall be considered for cooler sizing. However, these guidelines can be relaxed to avoid small trim cooler or air cooler.
3.3.7
Preferred tube sizes Preferred size for Carbon Steel and low alloy (up to and including 5 Cr. Mo) tubes is 20 x 2 and 25 x 2.5 mm. Preferred sizes for brass tubes and admiralty tubes are 20 x 2 mm and 25 x 2.5 mm respectively. Standard TEMA tube sizes are an acceptable alternative. Preferred size for high alloy (above 5 Cr Mo and Austenitic) tube is 20 & 25 x t to suit design. Preferred tube pitch is square pitch in fouling services.
4.0
PUMPS
The available NPSH shall exceed the required NPSH by at least 0.6 m up to design (rated) capacity for boiling liquids, dissolved gases, foaming liquids and other fluids. For Boiler Feed Water Pumps the available NPSH shall exceed the required NPSH by a minimum 2.0 m margin up to design capacity at the initial calculation stage. When accurate pump suction layouts are known this margin may be reduced to 1.5 m following review of the calculation. Process engineers shall identify on the process specification turndown flows below 50% of the design capacity, when such flows are possible during long-term operating conditions covered by guarantees of plant performance. The reference levels for setting NPSHA shall be the bottom tangent line for vertical vessels, the bottom of the vessel for horizontal vessels, the low-low level for tanks, and the pump impeller centre line for pumps. The following elevations for pump impeller centreline shall be assumed if no pump vendor details are available:
Pump Capacity m3/h Up to 45 45 - 225 225 - 2270 2270 - 4540
Centre Line Elevation m 0.76 0.91 1.07 1.37
DSN : 131
5.0 5.1
LINE SIZING Liquid Flow

The guidelines shown in the following table should be used to size process piping for liquids. The guidelines cover most normal situations for systems within unit battery limits, but they may not be applicable for all cases. For critical services and long headers, the total pressure drop in the system must be checked to ensure the system meets the design pressure balance, whether or not individual process lines meet the pressure drop and velocity criteria given here. This standard may not apply to critical services, such as slurry lines or high pressure piping, for which reference should be made to additional standards.
SIZING LIQUID LINES Recommended High Limits P per 100 m, kg/cm Pump suction lines (1) - bubble point liquids - subcooled liquids (< DN 200) [< 8] - subcooled liquids ( DN 200) [ 8] Pump discharge lines - CS - alloy / SS Reboilers - trapout lines (3) - return lines Liquid transfer lines (2) Cooling water lines Steam condensate lines (liquid) Notes (1 ) (2 ) (3 ) (4 ) Pump suction line diameters should normally not be more than two (2) standard line sizes larger than the pump suction nozzle. Or as required by system pressure balance. For sizing of tower draw-offs, refer to section 5.1.2 below If the liquid velocity is too high, swaged up orifice meter runs may be required, hence it is recommended to restrict velocities in lines containing orifice meters within the following upper limits: - Line sizes 300 mm (12) : 3.4 m/s max. - Lines sizes 350 mm (14) : 3.1 m/s max. For velocity limits in amine systems, refer to section 5.1.3 below 0.07 0.07 0.35 0.35 1.5 3.7 3.7 0.6 0.90 0.90 6.1 7.6 0.10 0.45 0.45 1.8 2.4 3.7 Velocity (4, 5) m/sec
(5 )
DSN : 131
5.1.1
Pump Discharge Lines Line sizing is a trade-off between piping installation costs and operating costs. Typical values for allowable pressure drops in pump discharge lines are given below for both carbon steel and alloy piping. Pump Discharge Line Typical Pressure Drops
Flowrate m/hr 0 - 60 60 - 160 160 + Carbon Steel Piping P, kg/cm per 100 m 0.6 2.0 0.3 1.6 0.2 0.9 Alloy Piping P, kg/cm per 100 m 1.4 3.5 0.9 2.5 0.5 1.6
5.1.2
Tower Draw-Off Line Sizing Liquid from a tower tray is aerated to some extent depending on the foaminess of the gas-liquid mixture. The recommended method for sizing drawoffs employs the following criteria: i) The depth of the drawoff pan to be 1 1 times the nozzle diameter. The minimum allowable depth is 200 mm. ii) Allowable velocity may vary from 0.7 m/s to 1.2 m/s depending on the nozzle size (see following tables Capacities of Side-Pan Drawoff Nozzles and Capacities of Bottom-Pan Drawoff Nozzles). iii) The nozzle is to be swaged down to a line size which will not exceed 0.1 kg/cm2 /100m pressure drop. The swage is to occur at a point in elevation 1.2 m below the nozzle drawoff. Only lines 0.2 m and larger are to be swaged down, small lines will be maintained at nozzle size to the pump or first exchanger (see Table Typical Swaged Lines After Side-pan Drawoff Nozzle). Capacities Of Side-Pan Drawoff Nozzles
Nominal Line Size mm 80 100 150 200 250 300 350 400 450 500 600 Allowable Velocity m/s 0.70 0.70 0.70 0.80 0.85 0.90 1.00 1.05 1.10 1.15 1.20 Flowrate m/hr (BPSD) 12.5 (1,890) 21.6 (3,260) 50.4 (7,610) 88.1 (13,300) 153 (23,100) 237 (35,800) 305 (46,100) 426 (64,300) 567 (85,600) 735 (111,000) 1,027 (155,000) DSN : 131
Capacities Of Bottom-Pan Drawoff Nozzles

Nominal Line Size mm 80 100 150 200 250 300 350 400 450 500 600 Allowable Velocity m/s 0.70 0.70 0.80 0.85 0.90 1.00 1.10 1.15 1.20 1.30 1.40 Flowrate m/hr (BPSD) 12.5 (1,890) 21.6 (3,260) 52.5 (7,920) 97.4 (14,700) 172 (26,000) 256 (38,700) 344 (52,000) 476 (71,800) 643 (97,000) 838 (126,500) 1,272 (192,000)
Typical Swaged Lines after Side-Pan Drawoff Nozzle Assumptions are as follows: 1) Capacities of lines as per Capacities of Side-Pan Drawoff Nozzles table (above); 2) Allowable pressure drop limit is approx. 0.1 kg/cm per 100 m. 3) Assumed drawoff fluid properties: hot SG = 0.8; Nominal line size mm 80 100 150 200 250 300 350 400 450 500 Assumed Flowrate m/hr 12.5 21.6 50.4 88.1 153 237 305 426 567 735 Swaged line size mm 80 100 150 150 200 200 250 300 300 350 viscosity 3 cSt. Velocity in swaged line m/s 0.7 0.7 0.7 1.3 1.3 2.0 1.7 1.6 2.2 2.3
Pressure drop in swaged line kg/cm per 100 m 0.07 0.06 0.04 0.10 0.07 0.12 0.08 0.07 0.10 0.11
600 1,027 400 0.11 2.8 Notes: Swaged line size may be slightly different depending on physical properties of fluid, static head, physical layout and position of swage in relation to drawoff nozzle.
DSN : 131
5.1.3
Amine Lines Velocities in equipment and piping shall be limited as follows: Lean Amine: 2.0 m/s for carbon steel Rich Amine: 0.9 m/s for carbon steel 4.0 m/s for 300 series Stainless Steel and higher alloys.
5.2
Vapour Flow
The guidelines shown in the following table should be used to size vapour lines. The guidelines cover most normal situations for systems within unit battery limits, but they may not be applicable for all cases. For critical services and long headers, the total pressure drop in the system must be checked to ensure the system meets the design pressure balance, whether or not individual process lines meet the pressure drop and velocity criteria given here. For long vapour lines, such as flare headers or vacuum transfer lines, when the P > 10% P, the compressible flow calculation procedure should be adopted.
SIZING VAPOUR LINES Operating Pressure Range Recommended High Limits P per 100 m kg/cm Velocity (1) m/s
HYDROCARBON LINES (< 100 m in length) Vacuum: 0.07 kg/cma or less Vacuum: ~ 0.50 kg/cma 0.0 3.5 kg/cmg 3.5 10.5 kg/cmg 10.5 35 kg/cmg > 35 kg/cmg STEAM LINES (< 100 m in length) Vacuum: 0.07 kg/cma or less Vacuum: ~ 0.50 kg/cma 0.0 3.5 kg/cmg 3.5 10.5 kg/cmg 10.5 35 kg/cmg > 35 kg/cmg Notes (1) Vapour density () measured in kg/m 0.014 0.046 0.12 0.35 0.69 1.15 0.014 0.035 0.12 0.35 0.69 1.15 120 / 0.5 120 / 0.5 120 / 0.5 120 / 0.5 120 / 0.5 120 / 0.5
DSN : 131
6.0
CONTROL VALVES
Control valves shall be sized for a normal flow at no more than 70% of the capacity of the valve, with no less than 25% of the total system friction drop or 10% of the operating pressure to 70 kg/cm2, whichever is greater, allotted to the valve. Above 70 kg/cm2 a lower percentage of the operating pressure may be used for valve differential pressure depending on process and control considerations for non flashing services. (Note that a control valve having a pressure drop of 33% of the total frictional loss, excluding the valve, is approximately equivalent to a valve with a pressure drop of 25% of the total system friction drop) In all cases the minimum pressure drop allowed for a control valve is 0.7 kg/cm at design flow-rate. Exceptional cases (e.g. gravity flow) where lower pressure drops are required should be evaluated on a case by case basis. In summary: i) At normal flowrate, CV DP > 25% of Total Frictional Pressure Drop or CV DP > 33% of Frictional Pressure Drop, excluding CV DP. ii) At normal flowrate, CV DP > 10% of Discharge Vessel Pressure. iii) At design flowrate, CV DP > 0.7 kg/cm2 Control valves in continuous service shall generally be provided with isolation and bypass valves. Hand-wheels shall be provided wherever no bypass valves are envisaged. Bleeds shall be provided on the upstream side (or both upstream and downstream side) of the valve as appropriate.
7.0 7.1
EQUIPMENT DESIGN LIVES Design Life

The required minimum design life for equipment is defined in Basic Engineering Design Data, document no. 3210-8820-SP-0001, section 2.4.
7.2
Corrosion Allowances
If the corrosion allowance calculated to satisfy the required design life is less than the following minimum values, then the minimum values shall be used.
DSN : 131
Vessel/Equipment shells Carbon Steel and Low Alloys (incl. 0.5 Mo steel) High Alloy steel Vessel/Equipment removable internals Carbon Steel and Low Alloys (incl. 0.5 Mo steel) 50% of corrosion allowance for equipment (shell) i.e. 1.5 mm on each contact surface No corrosion allowance 3 mm minimum 0.75 mm minimum
High Alloy steel Vessel/Equipment fixed internals* Carbon Steel and Low Alloys (incl. 0.5 Mo steel) High Alloy steel Cladding Thickness
6mm (total corrosion allowance) No corrosion allowance 3.0mm min
*Note: heat exchanger tubes shall not be provided with a corrosion allowance.
8.0 8.1
8.1.1
EQUIPMENT DESIGN TEMPERATURE AND PRESSURE Design Temperature

Upper Design Temperature Design temperature shall be set at 25C above the maximum operating temperature. The minimum upper design temperature shall be 65C. The maximum operating temperature is defined as the highest material balance temperature. Consideration shall also be given to other conditions such as start-up, shut-down, catalyst regeneration, failure of upstream cooling and steam-out. Such temperatures should be considered on a case by case basis to establish if they should be taken as the maximum operating temperature. In the case of coolant failure for process units, the maximum operating temperature upstream of the cooler shall be taken as the downstream design temperature. This should apply to downstream pipework, only up to the next major item of equipment. For failure of rundown coolers, the higher design temperature shall only be taken to the battery limit. A high temperature alarm shall be installed downstream of all product rundown coolers.
8.1.2
Lower Design Temperature The minimum design temperature for which process equipment must be designed will normally be specified as the minimum operating temperature of the equipment. This minimum operating temperature could occur during an abnormal mode of operation such as start-up, shut-down or emergency depressuring, but only need be quoted for values less than 0C.
DSN : 131
For depressurisation of fluids which have an atmospheric boiling temperature below 0C the following should apply: a) Liquid Filled Systems Minimum temperature shall be for a near pure component at its atmospheric boiling point For multicomponent mixtures the minimum temperature shall be determined by flashing the fluid from operating to atmospheric pressure in a series of flashes, removing the vapour after each stage of flashing.
b) Gas Filled Systems Minimum temperature is to be taken as that resulting from a 40% efficient isentropic expansion from maximum operating pressure to atmospheric pressure.
8.1.3
Multiple Design Temperatures When different metal temperatures can be predicted to occur for different zones of a vessel during operation (as in the case of a large distillation column) then the different temperatures zones should be indicated on the vessel sketch in the vessel specification and these different temperatures should be taken into account for setting design temperatures for each zone.
8.2
8.2.1
Design Pressure
Pumped Systems Process piping and equipment which form part of a pumped hydraulic system, and which may operate liquid full, will normally be designed for the maximum pressure that can be developed by the pump. For centrifugal pumps for a single consistent case: Maximum discharge pressure where: Maximum suction pressure = Suction vessel design pressure (or RV set pressure) + Vessel static head taken @ HLL = Maximum differential pressure + Maximum suction pressure
Pressure drop across trays or vessel internals should be included if it is significant.
DSN : 131
and: Maximum differential pressure where F is: 1.25 for motor driven pumps 1.38 for turbine driven or variable speed pumps Note: calculation shall be based on maximum operating SG. For reciprocating pumps, these should be provided with discharge relief valves, the set pressure of which should be specified to avoid the pump over-pressuring any system into which it discharges. 8.2.2 Compressor Systems For centrifugal compressor systems, the design pressure of the suction system should be set considering the settle-out pressure at shut-down. Under these circumstances high pressure gas from the discharge side will pass to the suction side through the anti-surge recycle valve and through the compressor itself. The settle out pressure will be a function of the relative volumes of the suction and discharge systems. Reciprocating compressors shall be fitted with a discharge relief valve set to prevent the compressor over-pressuring any system into which it discharges. 8.2.3 Non-Pumped Systems The design pressure for equipment in non-pumped systems shall be set as follows: Max. Operating Pressure (MOP) kg/cmg 1.8 1.8 < MOP < 17 17 MOP <100 100 MOP <195 195 Design Pressure kg/cmg 3.5 MOP + 1.7 110% of MOP MOP + 10.0 105% of MOP = F x Net differential pressure @ rated capacity
For all process equipment (with the exception of storage tanks and certain offsites facilities) the minimum design pressure shall be 3.5 kg/cmg. 8.2.4 Shell and Tube Heat Exchangers For shell and tube heat exchangers where the design pressure of one side is considerably higher than the other, the design pressure of the lower-pressure side shall be set at a minimum of 77% of that of the higher-pressure side. This is sufficient to mitigate the need for provision of relief protection for the lower-pressure side of the
DSN : 131
exchanger in the event of a tube rupture. However, the potential for propagation of high pressure into the piping system and other equipment connected to the low pressure side must also be considered from a design pressure viewpoint. 8.2.5 Steam-Out Conditions Steam-out conditions are to be 3.0 kg/cmg @175C and Full Vacuum @ 175C. All process specifications for equipment that is to be steamed-out shall clearly state this requirement and define the steam-out conditions. 8.2.6 Vessels Subject to Vacuum Conditions Vessels which may operate under vacuum conditions during normal operation shall be designed for full vacuum.
8.3
Design Pressure and Temperature Example

With reference to Fig 1 (below): 1. Vessel design pressure: Pd1 = Relief valve set pressure, Pr1, However, for liquid filled systems, Pr1 = Pd1 Ph3 2. Pump suction: PO2 = PO1 + Ph1 Frictional Losses (based on normal SG) Pd2 = Pd1 +Ph1 + Ph2 (based on maximum SG) For pumps in parallel, ie. one operating, one standby, the downstream design pressure is taken back to, and including, the suction block valve. 3. Pump discharge: PO3 is Net Discharge Pressure Pd3 is Maximum Discharge Pressure Pd3 = Maximum Pump Differential Pressure + Pd2 Pd3 should be checked against the design pressure of the downstream equipment. If, for example, a downstream column has a design pressure higher than expected, say to contain a runaway reaction, this pressure may be taken as the design pressure back to a suitable break point, say the pumps suction block valve. The method for setting the control valve pressure drop is given in Section 6 above. 4. Exchanger: In certain circumstances the low pressure side design pressure may be increased to 77% of the high pressure side design pressure to allow for the burst tube case as defined in API 520 & 521. Certain codes dictate the provision of relief protection on heat exchangers. Above matters must be agreed with FW and/or PMC Contractor prior to implementation.
DSN : 131
5. Column: Top: Bottom: Pd6 = Pr2 Pd7 = Pr2 + P across internals
Pd7 does not include the liquid static as this will be added by the vessel design group based on the high level. 6. Reboiler: Pd8 = Pd7 + Ph4 + Ph5
FIGURE 1 EXAMPLE PRESSURE PROFILE FOR A PUMPED SYSTEM
SET @ P r2
P P d3 d6 P o6 P d6
SET @ P r1 H 3 (P h3) P o1 P d1 H2 (Ph2) HLL NLL LLL
H1 (Ph1 )
BREAK POINT FOR PUMPS IN PARALLEL
H4 (Ph4) Po3 Pd3 H5 (Ph5) P o4 P o5
HLL
P o7 P d7
Pd2 Pd3
c L
P o2 P d2 Pd2 Pd3
FOR SINGLE PUMP
P o8 P d8
Po = OPERATING PRESSURE Pd = DESIGN PRESSURE Ph = PRESSURE DUE TO STATIC

STANDBY DPTDFIG1.DRW
DSN : 131
9.0
EQUIPMENT DESIGN MARGINS

The following values shall be incorporated into equipment design to allow for increased capacities.
9.1
Columns
Columns shall generally be sized according to vapour/liquid loads specified by the material balance. Over design on vapour and/or liquid loads must be agreed on a case to case basis, depending on the service and on whether foaming etc. may occur. The factors shall be specified on the equipment data sheets. The following design criteria shall apply. Trayed columns Columns with a diameter under 900 mm shall be designed to a maximum 70% of flooding rate All other columns shall be designed to a maximum 80% of flooding rate Packed columns Packed sections shall be designed to a maximum of 70% of flooding rate and shall be within the maximum pressure drop specified for the packing.
9.2
Pumps
Unless otherwise stated, the sizing of pumps shall be in accordance with the material balance and the following overcapacity rates on flow rate: Overcapacity, % Centrifugal Pumps - Reflux & pumparound pumps - Offsites product pumps - All other pumps - Intermittent services Reciprocating Pumps - All 10 20 Zero 10 Zero
DSN : 131
9.3
Heat Exchangers
Unless otherwise stated, heat exchangers shall be sized according to the heat and material balance and the following over capacity rates: 10% margin on flow, except for pumparound services where a flow margin of 20% shall be used 10% margin on duty 15% margin on reboilers and condensers (duty and flow)
10.0 10.1
EQUIPMENT SPARING General

Installation of standby spare equipment shall be included where justified for safety, reliability or economic reasons. All refinery units are scheduled for turnaround once every five years for planned maintenance. Running equipment requiring more frequent turnarounds shall justify a spare. Whilst aiming to minimise standby equipment care should however be taken to ensure that unit operations are not rendered vulnerable to failure of relatively inexpensive equipment (e.g. lube oil and seal oil pumps for large turbo-compressor units).
10.2
Heat Exchangers
Heat exchangers with a high fouling potential must always be arranged in parallel trains, such that one train can be taken out of service for cleaning while the train in operation meets the plants minimum capacity.
10.3
Pumps
All pumps with an immediate influence on the process must have a spare. However, consideration shall be given to the use of common installed stand-by pumps performing two duties. Sparing of pumps with a delayed influence on the process (e.g. inhibitor feeding pumps) will be evaluated on an individual basis. In general, both the main pump and the spare are to be motor driven. However, consideration is to be given to steam turbine drive for main and/or spare pumps where significant relief load reduction can be achieved. Consideration is also to be given to having steam turbine drives and motor drives in critical services, such as BFW. For critical services such as firewater, the use of diesel drives on pumps shall be considered.
10.4
Compressors, Fans and Blowers

Sparing of compressors will be as follows:DSN : 131
Centrifugal compressors shall have a spare rotor in the warehouse. Reciprocating compressors shall have a 100% spare ID fans shall have a 100% spare FD fans shall have a 100% spare
For fired heaters fans:
11.0
VALVE LEAKAGE CLASSIFICATION

All control valves and block & bleed valves connected to a flare system shall be of leakage Class V or better.
DSN : 131

3210-8110-PD-0004 Rev A1

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PARADIP REFINERY PROJECT PROJECT SPECIFIC PROCEDURES PROCESS ENGINEERING PROCESS ENGINEERING DESIGN GUIDELINES 3210-8110-PD-0004 PAGE 2 OF 24 REV A1

W:\Project\IOCL\3210\DMGInbox\NAGA'S WORKING FOLDER\3210-8110-PD-0004 REV A1 .doc

VESSELS Drum Surge Capacity and Hold-up Volume

W:\Project\IOCL\3210\DMGInbox\NAGA'S WORKING FOLDER\3210-8110-PD-0004 REV A1 .doc

Tower Bottoms Surge Capacity and Hold-up Volume

Knockout Drum Surge Capacity and Hold-up Volume

W:\Project\IOCL\3210\DMGInbox\NAGA'S WORKING FOLDER\3210-8110-PD-0004 REV A1 .doc

Minimum Auxiliary Nozzle Size

Towers and Columns

Allowable Pressure Drop Guidelines for Trays

Tray Type Sieve Valve 2.5.4

For: Vacuum Service mm Hg per tray 1.0 2.0 3.5 4.5

W:\Project\IOCL\3210\DMGInbox\NAGA'S WORKING FOLDER\3210-8110-PD-0004 REV A1 .doc

Minimum Corrosion Allowances Refer to Section 7.0 below

HEAT EXCHANGERS Fouling Factors

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Heat Exchanger Pressure Drops

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Liquid Cooling Gas Cooling

Partial Condensation Condensation

Atmospheric & above Vacuum

W:\Project\IOCL\3210\DMGInbox\NAGA'S WORKING FOLDER\3210-8110-PD-0004 REV A1 .doc

Pump Capacity m3/h Up to 45 45 - 225 225 - 2270 2270 - 4540

Centre Line Elevation m 0.76 0.91 1.07 1.37

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LINE SIZING Liquid Flow

W:\Project\IOCL\3210\DMGInbox\NAGA'S WORKING FOLDER\3210-8110-PD-0004 REV A1 .doc

W:\Project\IOCL\3210\DMGInbox\NAGA'S WORKING FOLDER\3210-8110-PD-0004 REV A1 .doc

Capacities Of Bottom-Pan Drawoff Nozzles

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W:\Project\IOCL\3210\DMGInbox\NAGA'S WORKING FOLDER\3210-8110-PD-0004 REV A1 .doc

EQUIPMENT DESIGN LIVES Design Life

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6mm (total corrosion allowance) No corrosion allowance 3.0mm min

EQUIPMENT DESIGN TEMPERATURE AND PRESSURE Design Temperature

W:\Project\IOCL\3210\DMGInbox\NAGA'S WORKING FOLDER\3210-8110-PD-0004 REV A1 .doc

Pressure drop across trays or vessel internals should be included if it is significant.

W:\Project\IOCL\3210\DMGInbox\NAGA'S WORKING FOLDER\3210-8110-PD-0004 REV A1 .doc

Design Pressure and Temperature Example

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5. Column: Top: Bottom: Pd6 = Pr2 Pd7 = Pr2 + P across internals

FIGURE 1 EXAMPLE PRESSURE PROFILE FOR A PUMPED SYSTEM

SET @ P r1 H 3 (P h3) P o1 P d1 H2 (Ph2) HLL NLL LLL

BREAK POINT FOR PUMPS IN PARALLEL

H4 (Ph4) Po3 Pd3 H5 (Ph5) P o4 P o5

Po = OPERATING PRESSURE Pd = DESIGN PRESSURE Ph = PRESSURE DUE TO STATIC

W:\Project\IOCL\3210\DMGInbox\NAGA'S WORKING FOLDER\3210-8110-PD-0004 REV A1 .doc

EQUIPMENT DESIGN MARGINS

W:\Project\IOCL\3210\DMGInbox\NAGA'S WORKING FOLDER\3210-8110-PD-0004 REV A1 .doc

EQUIPMENT SPARING General

Compressors, Fans and Blowers

W:\Project\IOCL\3210\DMGInbox\NAGA'S WORKING FOLDER\3210-8110-PD-0004 REV A1 .doc

For fired heaters fans:

VALVE LEAKAGE CLASSIFICATION

W:\Project\IOCL\3210\DMGInbox\NAGA'S WORKING FOLDER\3210-8110-PD-0004 REV A1 .doc

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