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Process Design Criteria
Process Design Criteria
INDEX
Design Conditions
Design temperature and pressure, in pairs, shall be specified according to the following
conditions:
− Normal operation.
− Other non-operating conditions (catalyst regeneration, star-up, short-term
conditions...etc.) (1)
− Steam-out (1)
− Minimum temperature (1)
− Vacuum conditions (1)
(1) If applicable and conditioning the material selection or material treatment.
Pressure
Design pressure shall be the greater of the following:
− 1.1 x Maximum Operating pressure.
− Maximum Operating pressure + 1.75 kg/cm2
− 3.5 kg/ cm2,
To define the design pressure it must be taking into account other conditions like block-
out, pumps shut-off, settling out, etc.
Vessels in vacuum conditions during normal operation, start-up, shutdown, catalyst
regeneration, etc. shall be designed for total vacuum.
It is also required total vacuum in the following cases:
− Those vessels which normally operates liquid full and can be blocked in and cooled
down (not apply to cooling water service)
− Those vessel which can undergo a vacuum condition when are blocked in and
cooled
− Vessels containing steam.
Vacuum design requirement does not apply due to blocking in after steaming out.
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Temperature
Design temperature shall be the greater of the following:
− Operating Temp. + 15ºC
− Other not normal temperature conditions (start-up, shutdown, catalyst regeneration,
etc.) + 15ºC
− 80ºC
The design temperature at vacuum conditions shall be the dew point temperature at
atmospheric pressure plus 15ºC. In case of steam consider 120ºC.
In the case of vessels with internal thermal insulation, it shall be specified different
design temperature for the refractory and the shell.
Pressure vessels shall be designed for a minimum temperature, which is the lower of the
following:
− Minimum ambient temperature.
− Minimum operating temperature minus 5ºC.
− Minimum temperature reachable by the effect of auto-refrigeration due to
depressurization (LPG systems for example)
When vessels zones operate at different temperatures and these can be clearly defined,
each zone shall be designed based on its respective design temperature.
Nozzles
All nozzles for piping connections should be flanged, except for particular services
determined by Basic Engineering. The use of other type of nozzle shall be subject to the
prior approval.
Inlet nozzles
If the product inlet speed would exceed 10 m/s, or if accelerated erosion is expected in
the area of incidence of the fluid vein a minimum 10mm thickness wear plate must be
installed, with same quality as the vessel shell to completely cover this area; otherwise a
protective system should be designed to mitigate this problem.
connection. In case of vessel operating liquid full or with more than one demister, the
connection will be agreed.
Instrumentation nozzles
See attachment 3.14 - Instrumentation.
Horizontal vessels with compartments shall be provided with separated drain nozzles in
each zone.
Steam-out connections shall be located in the bottom for horizontal vessels and close to
the lowest tangent line for vertical nozzles.
On horizontal vessels, blanked off ventilation nozzle will be provided on the top of the
vessel near the end opposite the manway. The vent nozzle will be provided near the end
opposite the steam-out connection.
Manhole
Vessel
size
Without internal elements 20”
With internal elements
Column
24”
In vessels where it may be necessary to use internal
scaffolding (for inspection and repair work)
On unlined horizontal vessels, a manhole will be provided on the side of the vessel at
horizontal centerline. If the bottom half of the horizontal vessel is lined, the manhole will
be located on the top of the vessel.
Horizontal vessels with compartments shall be provided with openings on the separation
walls.
Heads
2:1 semi-ellipsoidal or Korbogën head types shall be specified.
Other head types (hemispherical, conical ...) may be used if so required under process
conditions and always subjected to approval.
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Number of downcomers
As a general rule, trays shall be specified with 1-pass or 2-pass trays. The use of multiple
downcomer trays (4-pass or 3-pass trays) is subjected to the prior approval.
Jet Flooding
For new column design and for normal capacity use jet flooding values between 75 –
85%.
In case column revamp, the use of higher Jet flooding values is subjected to the prior
approval.
Openings
Product inlet and outlet nozzles:
Unless otherwise indicated, the minimum size for product inlet and outlet nozzles shall
be:
Tank Diameter Minimum Diameter
(m) (inches)
Up to 10 4
From 10 to 25 6
From 25 to 40 8
More than 40 10
Manholes:
All tanks shall have 24” manholes according to the following table:
Instrumentation
Temperature indicators:
− Local indicators: All tanks shall have at least one thermometer gauge type
temperature indicator.
For the readings to be as representative as possible the thermometer gauges shall be
placed in the tanks areas where fluid movement is relatively high, such as mixers, suction
nozzles, etc; in any case, thermometers shall be readily accessible to the operators
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Instrumentation
Temperature indicators:
− Local indicators: All tanks shall have at least one thermometer gauge type
temperature indicator.
For the readings to be as representative as possible the thermometer gauges shall be
placed in the tanks areas where fluid movement is relatively high, such as mixers, suction
nozzles, etc.; in any case, thermometers shall be readily accessible to the operators
Level instruments
The following transmitters shall be used:
− Servo-operated electronic level transmitters.
− Radar transmitters
Mixers.
Mixing systems can be propeller type with vertical or lateral shaft -always installed in
24” manholes- or high speed injection nozzles.
Heating systems.
For tanks larger than 20m diameter, the heating system shall have two independent heater
circuits, each one with a heating capacity of at least 60% of total required heating.
Pipes and accessories shall be schedule 80 minimum.
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The straight tube length shall be 6,096 m (20 feet). Exceptions will be made (depending
on plot area available, vertical reboilers) and the use of standard length tubes of 4,887m
(16 feet), 3,658m (12 feet), 3.048m (10 feet) and 2,438 (8 feet), shall also be acceptable
following prior approval.
In general, when the shell-side fluid side is not clean, specify the heat exchanger with
removable tube bundle and the tube layout shall be square (90º) or square rotated (45º)
¼” pitch (5,35mm).
Thermosiphon reboilers and condensers with the process fluid on shell-side shall
preferably have square pitch tube layout (90º)
Fixed tubesheet exchangers shall have triangular pitch.
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For water coolers exchangers the maximum inlet temperature for process fluid shall not
exceed 150 ºC
Typical configurations.
Typical configuration for cooling water exchanger will be:
TI TI
TW
Tubes
Maximum decoking temperature shall be:
− Carbon Steel 680 ºC
− Alloy Steel (P11 – P9) 735 ºC
− Stainless Steel 815 ºC
Burners
Unless otherwise stated, it shall be considered Low NOx burners dealing with FG and FO
(dual burners).
Soot blowers
Soot blowers shall be installed in the convection section of those fire heaters burning FO.
Stack
Except otherwise indicated, each fire heater shall have its own self-supporting stack
− Pressure gauge for draft measuring, with pressure connections in the burner level,
outlet of the radiant chamber, outlets of each section of the convection section and
air preheater, if any, and upstream and downstream from the flue gas damper.
− It shall be installed a high pressure switch at the plenum chamber
− Thermocouples for measuring the process fluid temperature shall be located at the
fire heater inlet and at the outlet of the radiant coils in each one of the passes.
− Thermocouples for measuring coil wall temperature (skin point)
− Flue gas temperature measurements at radiant floor and roof, convection section exit,
inlet and outlet of air-preheater and outlet air from air-preheater (if any)
− Oxygen analyzer at radiant section exit.
− Equipped with Burner Management System permissive start-up sequences and
automated safety shutdown system.
− Adjustable flame detector and flame scanner that continuously watching the pilot
and main flame.
− Igniter transformer to ignite pilot flame during initial firing.
− Equipped with Human Machine Interface (HMI) display panel at local and Control
Room, which provide simple information of step-by-step firing procedure.
− Equipped with Engineering Workstation to access logic and graphic builder and
Sequence of Event (SoE) application server.
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I.7 PUMPS
Design Codes.
Pumps shall be designed according to:
− ASME B73.1 or ISO 5199. Pumps in hydrocarbon and non-hydrocarbon services,
which do not exceed any of the following limits:
٠ Maximum discharge pressure: 16,32 kg/cm2g (16 barg)
٠ Maximum suction pressure: 6,12 kg/cm2g (6 barg)
٠ Maximum pumping temperature: 175ºC
٠ Maximum rated total head: 125 m
٠ Maximum rotative speed: 3600 rpm
− API 610. For the rest of services using centrifugal pumps not included in ASME
B73.1
− API 674. Reciprocating pumps
− API 675. Metering or proportioning pumps.
− API 676. Rotatory pumps.
− API 685. Sealless pumps
− API 682. Shaft sealing systems for centrifugal and rotatory pumps.
Pumps installation
In all process services pumps shall be spared, except for:
− Intermittent services where maintenance can be done with the unit in operation. In
these cases, a warehouse spare pump shall be specified.
− No critical services with the possibility of common spare pump for two services,
always without creating incompatibilities between suction emergency block valves,
fluids for seal systems, shut-off pressures, etc.
If parallel operation is specified, the difference between the total differential heads at the
rated flow and at shut-off among the pumps test curves shall be less than 10%.
Pumps types
For certain low flow, high head services, the use of vertical, high speed, single stage
pumps (Sundyne) is acceptable.
Oversizing criteria
As a general rule, the rated capacity shall be equal to 110% of the normal capacity,
except for the following:
− Qrated = 1,2 x Qnormal on reflux and reboiler pumps.
− Qrated= 1,05 x Qnormal for big pumps (> 500 m3/h)
For pumps in services where a huge flowrate variability is expected, the overdesign shall
be jointly agreed.
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Available NPSH
The available NPSH shall be established without additional margin derived from the
rated capacity and considering that the static head is equal to the distance between the
vessel lower tangent line and the anticipated shaft center line.
For reciprocating pumps no acceleration head shall be included for NPSHA calculations.
This fact shall be stated in the datasheet.
Drivers
In general motor drivers shall be specified, unless the use of turbine drivers is required
for process reasons, safety (equipment, personnel or catalyst protection), or pump
availability for certain services (pump-out, etc.).
The use of sealless pumps (magnetic driver) is permitted in those services where it is
recommended for security conditions.
Mechanical seals
Unpressurized dual mechanical seals shall be specified in the following cases:
− When the vapor pressure at 38ºC is above 4,08 kg/cm2a (4 bara) or specific gravity is
below 0,55.
− When the pumping temperature above 260ºC.
− Pumps in light hydrocarbon services (C5- cuts).
− When the maximum pumping temperature is equal to or above the self-ignition
temperature of the liquid pumped.
Pressurized dual mechanical seal shall be specifies when:
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I.8 COMPRESSORS
Design Codes.
Compressors shall be designed according to:
− API 617. Axial and Centrifugal Compressors.
− API 618. Reciprocating Compressor.
− API 619. Rotary-Type Positive-Displacement Compressor.
As a particular case of centrifugal compressor, are those one stage centrifugal fans with a
total differential pressure between 0.020 – 0.250 bar, for use in heavy-duty petroleum,
chemical and gas industry services. The design of this equipment shall be according to
API 673.
If the specified driver is a steam turbine, it shall conform to:
− API 611. General-purpose Steam Turbine.
− API 612. Steam-Turbine Special-purpose applications.
Spare Capacity.
Centrifugal and axial compressor: Due to their high reliability, centrifugal and axial
compressors will not be spared, but spare rotors will be specified.
Reciprocating Compressors: Spare Capacity will be specified according to the service
criticism level. Usually, it will be two 100% spare capacity, but it must be consider three
50% spare capacity, in case 50% will be the operating capacity for long periods.
Drivers
Reciprocating Compressors: The driver shall be an electric motor. The driver nameplate
rating shall be the 110% of the greatest power absorbed for any of the specified operating
condition, or the power absorbed at the set point pressure of the discharge relief valves
(whichever is greater)
Axial, Centrifugal and Screw Compressors: driver selection will be evaluated for each
application based upon critical service, utilities availability, and capital and operating
costs. For critical services and in the event of electric failure, it shall be specify a steam
turbine driver for the spared service to ensure the compressor operation.
Shaft sealing.
Unless otherwise specify, dry gas seals shall be installed.
Lube oil and oil sealing system shall be independent for compressors handling H2S or
other hazardous, corrosive, toxic or lethal gases.
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Material Selection
Material selection for equipment as well as lines shall be based on design conditions.
Column trays metallurgy should be 12%Cr or above. In some cases, lower quality
material can be specified according to design conditions.
C-Mo y C-Mn-Mo steels cannot be used unless prior approval.
Cr-Mo steels modified with V can be used.
Exchanger with seawater service shall use titanium.
Corrosion allowance
The over-thickness corrosion allowance shall be designed to warrant an operating life as
listed below:
− Heater tubes: Design live shall be 100.000 operating hours (According to API 530).
− Pressure Vessels with 50mm wall thickness, or greater, tanks and spheres: 20 years.
− Other pressure vessels (including shell and channels of heat exchangers): 10 years.
− Heat exchanger bundles and other piping: 5 years.
Heater tubes.
Corrosion
Material
allowance (mm)
Carbon steel and alloys up to 9%Cr – 1%Mo 3
Austenitic steels 1,5
Storage spheres.
Corrosion allowance shall be 1.5 mm.
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I.10 PIPING
Design Codes
Piping shall be designed according to ASME B31.3
Piping size
Lines of the following size shall not be used:
1¼”, 2 ½”, 3 ½”, 5” y 7”
Within the unit the minimum diameter shall be ¾”. Off-site the minimum size shall be 1
½”.
For XXS piping thickness the minimum diameter allowed is 1”.
Note 1 Note 1
Note 1: This valve may be available as part of a control valve assembly or provided for
other process reasons and would be used as part of the isolation system.
Drain Systems
Water and hydrocarbon drain system will be defined in agreement during the
development of the Basic Design.
The following sketch shows the typical lay out of this system:
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NOTES:
1.- This valve is connected to the
equipment and may be common
to different blow off lines.
2.- Minimum valve size 1”.
Notes:
1.- When was required by process piping
material specification, this valve shall be a
ball valve.
2.- If the line size is less than 2”, a flange
set shall be installed for mounting the
spectacle flange.
3.- The spectacle flange shall be
represented in the diagram according to
the position during normal operation of
the unit (open or close). When the disk
shall remain open in normal operation and
the pipe or equipment material
specification is more stringent, it shall
also cover the globe valve.
4.- In the case that the equipment or
piping requires jacketing, it shall be
jacketed up to the first block valve.
5.- Drainages shall have at least ¾” of
diameter
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Set Pressure
When more than one safety valve are installed to reach rated discharge capacity, the
selected Pset shall follow the API, ASME VIII or ASME I criteria, according to the
design code applied.
Accumulation
The accumulation depends on the design code of the protected system. Usually values
are:
Number of
Code Accumulation
valves
ASME I Any 6% (PG 67.2)
One 10% MAWP ó 3 psi (the greatest)
ASME VIII More than one 16% MAWP ó 4 psi (the greatest)
Any 21% MAWP (only for fire case)
MAWP: Maximum allowed working pressure: maximum gauge pressure permissible at the top of
a complete vessel in its normal operating position at the designated coincident temperature
specified for that pressure. The pressure is set by the materials, nominal thickness and design
codes.
Design overpressure
In relief valves that protect lines (and therefore that are not subject to the ASME codes)
the allowed overpressure shall be 25% of Pset as maximum.
In safety or relief valves that protect vessels subject to ASME I, the maximum admissible
overpressure shall not exceed 3% of the Pset. (Page 72.1 of referred code)
In safety or relief valves that protect vessels subject to ASME VIII, the maximum
admissible overpressure in each case can reach the difference between the permitted
accumulation and the Pset.
In the previous rule shall apply supposing that the maximum accumulation for a fire case
with an only one valve installed shall be 10% (an exception to API 520/521).
Discharge flow
To calculate the fire relief requirement, no reduced capacity shall be considered, even
when the vessel is insulated.
Process connections
The minimum rating of the inlet connection shall be 300#, and that of the outlet shall be
150# .
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Spare
In those cases where a safety valve must be often removable due to maintenance works
under normal process operation shall be install 100% capacity spare valve with inlet and
outlet block valves and adequate mechanical interlocks to avoid blocking by
miss-operation.
General.
Electronic instrumentation shall be used and the DCS shall be digital supplied by
Honeywell.
Unit control system shall be located in a control room.
Process plants shall have independent control and emergency shutdown systems. The
instrumentation and their nozzles shall be independent for both systems.
Normal alarm functions shall be integrated into control system.
Critical and shutdown alarms are implemented in the emergency shutdown system.
All process unit charge and product streams shall be measured with flow recorders. If
accurate flow rate is needed for use in constructing material balances, it is recommended
the installation of pressure and temperature instruments in control board.
All inlet and outlet process streams needed to close material and heat balance in principal
equipment (fractionators, exchangers) shall be measured with flow recorders to control
board (If accurate flow rate is needed, it is recommended the installation of pressure and
temperature instruments in control board)
All inlet and outlet exchanger streams will be equipped with TI´s to control board.
Additional thermowells in every shell shall be installed. Not to apply to utilities (CW,
steam which will be equipped with local TI´s)
All utility flow rates shall be metered and recorded at unit battery limit. Additionally, is
required the readings of:
− Fuel gas to heaters.
− Steam to reboilers, steam turbines and ejectors.
− Utility to critical equipment.
Instrumentation
The measurement principle shall be indicated in each instrument.
Temperature Instruments.
ISA type K thermocouples shall be specified for general services when technically
feasible. If for a given service, the use of other type of thermocouple is recommended, it
shall be clearly stated.
Converters shall be field mounted.
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Level instruments
Differential pressure type level instruments are the preferred. External displacement type
level instruments shall be used in interface services or when the differential pressure type
are not technically viable.
All the level measures shall be indicated in the control system.
The minimum level instrument flange class shall be 300#
The level instrument connection size shall be:
− 2” for stand pipes.
− For external displacement type transmitters:
1 ½” if the equipment class is equal or less than 600#
2” if the equipment class is above 600#
− 1” for magnetic level transmitters.
Pressure Instruments
Pressure instruments shall be located in process lines or when feasible in stand pipes.
Analyzers
Continuous stream analyzers shall be specified where strictly required or those agreed for
process control and monitoring.
Surge Lightning Protector
All field devices that connected to the system shall be equipped with Surge Lightning
Protector, especially unit that located on high elevation or open area.
To each loop shall be installed two kinds of Surge Lightning Protector:
1. To Protect Control System, it will be installed serial on cabinet wiring before
introduce to FTA card or I/O module.
2. To Protect Field Transmitter, it will be mounted on transmitter conduit entry
(spare) and connected parallel with system wiring (power supply).
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I.14 INSULATION
Insulation selection
The service or purpose which motive the insulation requirements in lines and equipment
is classified and identified with the following symbols:
− Personnel protection (P): for lines and equipment which operating temperature is
above 65ºC.
− Heat conservation (H): when it is required a heat loss minimization.
− Cold conservation (C): when the operating temperature is below the ambient
temperature and it is required a heat gain reduction, prevent a surface condensation
or personnel protection caused by cold surfaces. It is included cold conservation (-
170ºC to 20ºC) and dual temperature services (-20ºC to 250ºC)
− Steam tracing (ST) or jacketed (SJ): to maintain the minimum fluidity of the process
streams
− Electric tracing (ET) and liquid jacketed (LJ): the use is under approval.
Steam supply and condensate return lines shall be specified with heat conservation for
their operating temperature, except for those discharging to the atmosphere.
When it is specified refractory insulation for lines or equipment, the use of external
insulation requires approval. If required guard personal protection (PG) shall be
specified.
Instruments
Instruments line up in normal operation shall be specified with the same insulation of
those lines or equipment which are connected to.
Jacketed lines
Jacket diameter depends on the line diameter to be jacketed. The jacket diameter
selection shall be according to the following table
LINE
1” 1 ½” 2” 3” 4” 6” 8” 10”
DIAMETER
JACKETING
2” 3” 3” 4” 6” 8” 10” 12”
DIAMETER
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The inventory shall be found out as 15% of the vessel volume for columns and 50% for
other vessels for a density corresponding to the average operating temperature.
Installation two out of three (2oo3) transmitters
All the transmitters as part of the interlock system and causing security risks or the
shutdown for the unit shall be installed two out of three.
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