ChE 142 – Final Exam Reviewer LAYERS OF PROTECTION

01 Intro
HSE IN DESIGN
DEFINITION
-HSE in Design is the engineering of facilities in such a
way so they can be constructed, tested, commissioned,
operated, and decommissioned in ways that cause no
harm to the environment or to stakeholders, who
include:
-Owners, Employee, and the Community
-The key elements are:
-Health, Safety, Environment, and Sustainability
02 P&IDs
ELEMENTS OF HSE IN DESIGN WHAT IS A P&ID?
Health -The piping and instrumentation diagram (P&ID) is a
-Personal exposure to hazardous or toxic materials detailed graphic description of the process flow,
-Ergonomic design showing all piping, equipment, and instrument details.
-Industrial hygiene -The P&IDs are the bases for piping, mechanical, and
-Feed and product safety instrumentation design, among others.
-Noise control -Also the basis for process safety studies – consequence
Safety and risk assessments, process hazards analyses.
-Loss of containment
-Fire, explosion, and toxic clouds TYPICAL TYPES
-Evacuation, escape, and rescue -Lead Sheets
-Electricity -Process and Auxiliaries (Onsite)
-Radiation -Utilities – distribution, generation
Environment -Everything else (Offsite)
-Emissions to air
-Discharges to water MULTIDISCIPLINARY
-Waste management -Process Control
-Noise control -Instrumentation and analyzers
-Impact on habitat, flora, and fauna -Control valves
-Social and economic, impact on the community -Piping
Sustainability -Pipe specs and design
-Address siting and planning of project phases to reduce -Valves and drains
negative environmental and socioeconomic impacts, -Mechanical
now and for future generations -Vessels and columns
-Pumps, compressors
HAZARD MANAGEMENT -Electrical
-Motor details

SYSTEM OWNERSHIP
-Design execution is typically based on system
ownership.
The system engineer is responsible in the design of ALL
items present in his/her P&IDs.
Teamwork is strongly encouraged when designing
similar equipment, but the success (or failure) in the
design of an equipment can only be attributed to its
system engineer.
DETAILS TO INLCUDE MANAGEMENT OF CHANGE
-Instrumentation and designations -Interdisciplinary review on potential impacts to
-Mechanical equipment with names and numbers -Safety, Downstream design, Cost, and Schedule
-All valves and their identifications
-Process piping, sizes, and identification Note: For the rest of slide 02, see cheat sheet, and study
-Miscellaneous – vents, drains, special fittings, sampling for detail designs.
lines, reduces, increasers, and swaggers
-Permanent start-up and flush lines 03 Piping Specifications
-Flow directions LINE SIZING CRITERIA
-Interconnections references -General guidelines on size and schedule selection
-Interfaces for class changes -Piping smaller than ¾” is typically not used
-Computer control system input -Sizes that are not typically used:
-Vendor and contractor interfaces -1 ¼”, 2 ½”, 3 ½”, 5”, 9”
-Identification of components and subsystems delivered -Initial assumptions:
by others -Schedule 80 for sizes 1 ½” and smaller
-Intended physical sequence of the equipment -Schedule 40 for sizer 2” and larger
-Sizing considerations
DETAILS TO EXCLUDE -Pressure drop and velocity ranges
-Instrument root valves -Allowable pressure drop
-Control relays -Erosional velocity
-Manual switches -Critical velocity (sonic velocity, choke flow)
-Equipment rating or capacity -Economics (pipe cost vs pumping/compression
-Primary instrument tubing and valves cost)
-Pressure, temperature, and flow data -Typical design margins for frictional pressure drop
-Elbow, tees, and similar standard fittings -20% for single phase
-Extensive explanatory notes -30% for two phase

CONTENT ARRANGEMENT SIZING FOR SINGLE PHASE FLOW

-Each P&ID sheet contains 2 to 3 equipment. The -Given: mass flow rate, fluid velocity, and viscosity from
number of expected P&IDs can be estimated based o the HMB
PFDs. 1. Assume a nominal pipe size
-Arrange content and sheets according to the process 2. Solve for the Reynolds number
flow. Dvρ
ℜ=
μ
LEAD / LEGEND SHEETS 3. Determine the friction factor based in Re
-Index of drawings or P&ID list
-Symbology
-Abbreviations, service codes, tagging guides
-Equipment details
-Control valves
-Instruments
-General notes

PROJECT DEVELOPMENT

4. Calculate ΔP (in bar) for a length of 100m

5. Change the NPS based on the maximum ΔP and
velocity criteria

TWO-PHASE FLOW
-Evaluate flow regimes considering:
-Normal Operation
 -Turndown Operation maintenance (insulation material)
-Abnormal Operation -Design of insulation material and thickness is typically
-Design around slug flow conditions done by piping engineers
-Line sizes may be reduced to increase velocity
above slug flow conditions but will lead to LINE LIST
additional pressure drop -Summarizes details on all pipes in the facility
SIZING FOR TWO-PHASE FLOW -Details that are typically included:
-Recommended pressure drop range = 0.22 – 0.90 -Line identification
bar/100m A-BBB-CCC-DDD-EEE-F
-Use the Dukler-Taitel Method for calculations with -Design and operating pressure and
two-phase flow Temperature
-Pipe end-points
INSULATION -Testing conditions (commissioning)
-For temperature maintenance and protection -Hydro test fluid pressure
-Heat conservation
-Cold conservation 04 Static Equipment
-Personnel protection WHAT ARE STATIC EQUIPMENT?
-Anti-sweat protection -Non-moving equipment
-Fire proofing -Tanks, Vessels, Columns, Reactors, Drums, and
-Explosion protection Separators
-Acoustic protection
Heat Conservation CODES AND STANDARDS
-Limit heat loss -ASME Boiler and Pressure Vessel Code
-Maintain temperature constant -Comprises 12 sections
-Maintain temperature higher than ambient -Section VIII Rules for the construction of
Cold Conservation pressure vessels
-Limit hear ingress -for most chemical plant and refinery
-Maintain temperature lower than ambient vessels
Personnel Protection -Has three divisions
-Prevents direct contact to hot or cold piping Div1 – General rules, low pressure
-Typical applied where: Vessels
-No other insulation is installed Div2 – Alternative rules, large high
-Temperature is > 50°C or < 0°C pressure vessels
Anti-sweat Div3 – Alternative rules, vessels with
-Prevents/minimizes condensation on cold pipe surfaces design pressure >10,000psig
-Reduce the likelihood of corrosion
NOZZLE SIZING
COMMON INSULATION MATERIALS -Inlets and outlets – based on line sizes
-Instrument connections – 2 inches (typical)

MANWAYS
-Size and number of manways will depend on
-The vessel/column diameter
-Tray spacing for columns
-Ergonomics requirements
-Maybe located on the side or at the top

DIMENSION GUIDELINES
-Minimum vessel/column diameter
INSULATION GUIDELINES -if entry is required for maintenance – at least
-There is an optimum thickness 30 inches (2 ½ feet)
-Too thin – high cost to operations (energy lost) -if entry is not required – less than 30 inches is
-Too thick – high cost to capital and allowed (could be fabricated from pipes)
 -Limited by shipping – 162 inches (13 ½ feet)
-Larger vessels
-Split the volume to two parallel vessels
-Site fabricated
-Inside diameter and tangent-to-tangent lengths =
specify in increments of 6 inches
Packing < 20 inches ID < trays
-Limit*:
-Packed bed height to 1.5 feet
-Column height to 175 feet
-Column height-to-diameter ratio to 30
-Modify the design if the above limits are
exceeded
-Equipment and piping operate at a range of pressure
and temperatures, and so they must be designed to
withstand the highest possible pressure and
temperature.
Design pressure and temperature must therefore be
designed.
-Design conditions are based on the maximum
operating conditions
-Some guides. Use whichever is greater.
DP = 1.1 x MOP DT = MOT + 50°F
DP = MOP + 25 psi DT = 300°F
DP = 50 psig
-Round the design pressure and temperature to the
nearest tens digit
-Hotter
-The following guidelines are observed in the selection
of tube dimensions and layout:
- ¾” 14 BWG tubes with 1” triangular pitch for
straight tubes
-1” 14 BWG tubes with 1 ¼” square pitch for U-
tubes
-The preferred straight tube lengths are 16 ft and 20 ft.
-Baffle designs
-Spacing between 20% and 100% of shell
diameter, but default is 20%
-Cut bet between 15% and 45% of shell
diameter, but default is 20%
NOTE: Study sample calculation in UVLe.
05 Plant Layout
PLOT PLAN
-Arrangement drawing showing the locations of
equipment and supporting infrastructures.
-Used by various engineering and construction
disciplines
BASIC PLOT PLAN

NOTE: Study Vessel Examples in slide 04.

Heat Exchangers
SELECTION
-Spiral heat exchanger if area is less than 2m 2
-Double-pipe heat exchanger if area is between 2 and
50m2
-Shell-and-tube heat exchanger if area is greater than
50m2 TYPICAL FACILITIES
-Process areas
PRICE COMPARISON -Utilities areas
Removable tube - Costlier for the same heat transfer -Plant Buildings
area, but can clean shell side -Control Bldg
Non-removable tube – Cheaper for the same heat -Electrical Sustations/Field Auxialiary Rooms
transfer area, but cannot clean shell side -Workshop and Warehouse
-Administrative Facilities
HEAT EXCHANGER SIZING -Safety and Security Facilities
-Place the fluid on the tube side if it is (arranged in -Roads and access ways
order of priority) -Shipping and receiving areas
-Corrosive
-Cooling water LOCATION AND SPACING
-More fouling -Physical flow follows process flow
-Less viscous -Locations in relation to other facilities
-More pressurized -Utility source (power, air, water, etc.)
 -Buildings -Sized to contain:
-Roadways and access ways -110% of the maximum capacity of the largest
tank/vessel
ACCESSIBILITY -Worst case rain fall
-Roadways -Firewater runoff
-Avoid dead end roads Gas Dispersion
-Size road widths and clearances to handle large -Locate vents to atmosphere Insafe locations away
moving equipment and emergency vehicles or from:
to a minimum of 28 ft, whichever is greater -Areas where personnel may be present
-Maintain sufficient overhead and lateral -Fixed ignition sources (flammable)
clearances for trucks and cranes to avoid hitting -Areas of congestion
piping racks, pipe ways, tanks, or hydrants. -HVAC inlets
-Do not expose roads to fire from drainage Thermal Radiation
ditches and pipe ways -May impair plant facilities due to excessive heat
-Slightly elevate roads in areas subject to local -Structural failure
flooding. -Personnel exposure
-Locate hydrants and monitors along roads to Firewalls and Blast Walls
allow easy hook-up of firefighting trucks -Used as passive protection to segregate plant areas
-Provide at least two entrances to the plant for -Reduces the likelihood of escalation
emergency vehicles to prevent possibility of -Designed based on fire and explosion studies
vehicles being blocked during an incident.
-Access wats and egress routes BUILDINGS
-Provide personnel access to equipment -Non-process buildings are typically located away from
-At least 1.5m on at least one side but process areas
will depend on equipment to be -Located beside roads for accessibility
accessed. -Structure is design to withstand fire and explosion
-Escape and evacuation routes.
Equipment Considerations
SPECIAL ZONES VESSELS
-Fire zones
-Physically separate areas of a facility such that
a fire event in one area will not escalate to
another area
-15 m apart
-Separated by a fire resistant barrier
-Hazardous Area Classification
-“any place in which an explosive atmosphere
may occur in quantities such as to require special -Default distance: 5 ft if below 600°F
precautions to protect the safety of workers” 15 ft if above 600°F
-Saddles are used to support horizontal vessels
SAFETY
-Segregate fixed ignition sources from flammable
materials
-Ensure hazardous materials do not reach critical areas
-Provide secondary containment for liquids
-Locate vents at safe locations
-Provide proper storage for bulk solids
Secondary Containment
-Double-walled vessels
-Impoundment basins -Same equipment distance rules apply
-Bunds and sumps Legs are used if the diameter is 5 ft or less
Skirts are used if the diameter is more than 5 ft
HEAT EXCHANGERS -Individual hardware components of the control loop
-Default distance: 5 ft if below 600°F
15 ft if above 600°F
-Similar to horizontal vessels, saddles are used to Shared Devices
support heat exchangers -Represents graphics on a computer screen or panel
-Software components that can be accessed by
PUMPS operators for adjustments
-Default distance: 10 ft if below 600°F -Might be used to show process measurements or
15 ft if above 600°F represent hand switches, among others
-Pumps are usually installed at the edge of the access
way for ease in monitoring

COMPRESSORS
-Default distance: 25 ft
-Where there are several large compressors in a unit, it Computer Function and Logic
is usually economical for operation and maintenance to -Complex processes carried out via computers
locate them in one area. -Software instructions for automated actions

06 Rotating Equipment -No horizontal line – in the field

STARTING DATA -Single horizontal line – in the main control panel or
-From the HMB some computer screen
-Pressure source and destination -Double horizontal line – in some secondary local panel
-Stream properties in the field
-Mass flowrate, Density, Viscosity, -Single dashed horizontal line – inaccessible or
Vapor Pressure somewhere not easily accessed; hidden/password
protected areas of the control system
VESSEL ELEVATIONS
-Determine the minimum vessel elevation Note: Study Instrument Identification
NPSHA = hP – hVP – hS – hF
-For this course, Developing a Control Scheme
-Set NPSHA at 25 ft. NPSHA seldom exceeds this DO I NEED TO INSTALL AN INSTRUMENT?
value per Exxon Mobil Design Practices -Ask the following questions:
-Set hF at zero -What data do I need from the process?
-Round up hS by increments of 6 in. -Flow, Pressure, Temperature, Level
-With the existing instruments, can I determine:
LINE SIZES AND LENGTHS -the temperature of or within
-Lengths can be estimated from the plot plan equipment?
-Multiply the x- and y-axis distances by a factor of three. -the temperature, pressure, or flow rate
of a process stream?
EQUIPMENT AND CV PRESSURE DROPS
-Set the pressure drops of control valves on pumped Alarms and Interlocks
circuits at 10 psi. LAYERS OF PROTECTION

POWER CONSUMPTION
q∆ P
Power=
η

07 Process Control and Safety

INSTRUMENTATION SYMBOLS

Discrete Devices
-Physical instrument or device in the field or on a panel
ALARMS
-An alarm is an instrument that provides a visible
and/or audible indication when the value of the
measured variable deviates from normal operating
limits.
-The purpose of the alarm is to alert operators to ac t
08 Relief Systems
upon the cause of deviation
TERMINOLOGY
-Set pressure – pressure at which the relief valve will
INTERLOCKS
open
-Interlocks serve the protection and safety of operators,
-Burst pressure – pressure at which a rupture disk will
equipment, and the environment
“fail”
Failure interlocks – serve to initiate equipment
-Overpressure – pressure increase over the set pressure
shutdown (or trip)
where the relief valve is fully open; expressed as a
Permissive interlocks – evaluate conditions to allow the
percentage of set pressure
starting or the continuation of action
-Accumulation – pressure increase over MAWP of the
vessel during relief, expressed as a percentage of
Safety Instrumented Systems
MAWP or in pressure units
WHAT IS AN SIS?
-Simmer – audible or visual release of fluid across a
-A system composed of sensors, logic solvers, and final
relief valve just before opening at set pressure
elements designed for:
-Excessive simmering can damage valve seat
-Automatically taking an industrial process to a
surfaces
safe state when specified conditions are
-Chattering – rapid opening and closing of a relief valve
violated.
-Can be detrimental to valve seats and may lead
-Permit a process to move forward in a safe
to leaks in normal operation
manner when specified conditions allow
-Caused by
(permissive); or
-Oversizing
-Taking action to mitigate the consequences of
-Inlet losses exceed 3% of set pressure
an industrial hazard.
-Excessive back pressure
-Broken or leaking balance bellows
BPCS VS SIS
-Back pressure – pressure at the outlet side of the relief
-BPCS – maintain that processed within normal
valve
operating conditions
-Superimposed back pressure – pressure at the outlet
-SIS – in case conditions continue to go beyond normal
before the relief valve opens
operating conditions, the SIS is triggered.
-Constant – does not change appreciably under
any condition
SAFETY INSTRUMENTED FUNCTIONS
-Variable – discharge system pressure that may
-Individual functions implemented by the SIS to achieve
fluctuate
a safe state
-Built-up back pressure – pressure that builds up in the
-For example:
discharge header when the relief valve opens
-High pressure will open a vent valve
-Total back pressure = superimposed + built-up
-Low temperature will close a drain valve
-High flow will shut down a pump or a
WHY DO WE NEED PRESSURE RELIEF SYSTEMS?
compressor
Prevent losses or damage to:
-High level will close the inlet valve
-Personnel
-Environment
SAFETY INTEGRITY LEVEL
-Asset
-A measure of the reliability and availability of the SIF
-Reputation
-For “Demand Mode” operation
-Profit

INDUSTRY GUIDELINES
-Mandated by national, state, and local requirements
-Industry codes and standards
-Project, corporate requirements -Noise

RELIEF DEVICES Note: Study causes of overpressure and utility failure.

-Pressure and vacuum valves
-Pressure relief valves
-Rupture disks
-Emergency vents

PRESSURE/VACUUM VALVES
-Reclosing devices for low pressure tanks
-Used for pressure less than 15 psig
-Pressure scenarios occurring due to liquid movement
to or from tanks

PRESSURE RELIEF VALVES

-Reclosing devices for pressure vessels, boilers, etc
-Used for 15 psig or higher pressure

RUPTURE DISKS
-Non-reclosing devices for pressure vessels, etc
-Used for 15 psig or higher pressure

EMERGENCY VENTS
-Used for low pressure tanks
-Used for pressure less than 15 psig
-For infrequent overpressure emergencies

DISCHARGE POINTS
-Open Discharge
-Used for non-combustible and non-toxic
materials
-Relief to atmosphere
-Closed Discharge
-Used for process fluids – hazardous materials
-Relief to flare or the process

Relief Scenario Analysis

SCENARIO IDENTIFICATION
 Start with P&IDs and PFDs
 Analyse by equipment
 Start from the beginning
 Identify sources of feed and its max pressure
 Identify all sources of heat, including external
fire
DESIGNING THE RELIEF
 Calculate the relief flow rate
 Calculate the relief device size
 Develop specifications for the relief device
-No credit taken for favorable instrument or operator
response
-Piping considerations
-Pressure drop
-Reaction force, stress