3210-8110-PD-0004 - Rev A1 - Process Engineering Design Guideline

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

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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 VESSELS
2.1 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 Hold-up, minutes
Feed to Tower or Furnace

- drum diameter: < 1.2 m 20
- drum diameter: 1.2 to 1.8 m incl. 15
- drum diameter: > 1.8 m 10
Reflux to Tower 5
Product to Storage 2
Flow to Heat Exchanger 2
Flow to Sewer or Drain 1
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).

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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.

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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 Vent Drain Pumpout Steamout Blowdown

1.5 25 (1”) 25 (1”) 25 (1”) 25 (1”) 50 (2”)
1.5 – 5.6 25 (1”) 40 (1½ ”) 40 (1½”) 25 (1”) 80 (3”)
5.6 – 17 50 (2”) 50 (2”) 50 (2”) 25 (1”) 80 (3”)
17 – 70 50 (2”) 80 (3”) 80 (3”) 50 (2”) 100 (4”)
70 and over 50 (2”) 80 (3”) 80 (3”) 80 (3”) 100 (4”)
2.5 Towers and Columns
2.5.1 Minimum Tray Spacing
Tower ID Max No. of Tray Min Tray Spacing

mm Passes mm
750 to 1800 1 500
1800 to 2700 2 500
2700 to 3300 2 600
3300 to 4800 4 600
4800 to 6000 4 600
> 6000 4 750
For draw off trays, the spacing is set by the draw off tray design, including hold up.

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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 For: Pressure Service For: Vacuum Service

kg/cm2 per tray mm Hg per tray
Sieve 0.007 - 0.014 1.0 – 2.0
Valve 0.007 – 0.014 3.5 – 4.5
2.5.4 Preferred Internal Diameters (mm) of Columns/Vessels
300 1100 2000 (3400)

(350) (1200) (2100) 3600
400 (1300) 2200 (3800)
500 1400 (2300) 4000
600 (1500) 2400 4250
700 1600 2600 4500
800 (1700) 2800 4750
900 1800 3000 5000
1000 (1900) 3200
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.

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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 HEAT EXCHANGERS
3.1 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 m².hrºC/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.

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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/cm²) for Liquid Flow Through Exchangers in Series
Viscosity @ avg. One Shell Two Shells Three Shells

temperature Pressure Drop Pressure Drop Pressure Drop
cP kg/cm² kg/cm² kg/cm²
< 1.0 0.35 – 0.70 0.35 – 0.70 0.70 – 1.05
1.0 to 5.0 0.70 1.05 1.05 – 1.41
5.0 to 10.0 1.05 1.05 – 1.41 1.41
> 10.0 1.41 1.41 – 2.10 2.10
3.3.2 Gases
Pressure Drop (kg/cm²) for Vapour Flow
Operating Pressure (kg/cm²a) Pressure Drop (kg/cm²)

0 – 1.72 Approx. 0.03 - 0.07
> 1.72 0.14 – 0.35
3.3.3 Condensers and Reboilers

For partial condensers allow 0.14 to 0.35 kg/cm² 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/cm².

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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 Allowable Pressure Drop

Pressure kg/cm²
kg/cm²a
Liquid Cooling All 0.70 Not valid for viscous fluids
Gas Cooling 2.06 – 4.50 0.07
4.50 – 18.2 0.21
18.2 – 104 0.35
Total Atmospheric & 0.03 min For multi-pass air coolers, high-
Condensation above pressure drops assure proper
flow distribution. The higher
pressure drop will also assure
good flow distribution at lower
than design throughput
Partial Atmospheric & 0.14 - 0.35 Note as for total condensation
Condensation above
Condensation Vacuum 3 - 5 mm Hg Selection of an allowable
pressure drop should be from
the results of an economic
study
3.3.5 Viscous fluids

The following typical pressure drops shall be allowed for more viscous fluids.
Service Allowable pressure drop, kg/cm²
Light gas oil cooler (airfin) 1.05

Light gas oil cooler (shell and tube) 0.70
Pumparound cooler (airfin) 1.05
Light gas oil cooler (shell and tube) 0.70
Waxy distillate cooler (airfin) 1.41 – 1.75
*
Vacuum residue cooler (airfin) 1.75 – 3.52
*
Vacuum residue cooler (shell and tube) 1.75 – 5.27
Tempered water cooler (airfin) 2.81 – 3.52
*Must be estimated by specialist engineers.

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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 ºC. 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. ½ 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 ½ 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 Centre Line Elevation

m3/h m
Up to 45 0.76
45 - 225 0.91
225 - 2270 1.07
2270 - 4540 1.37

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5.0 LINE SIZING
5.1 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, Velocity (4, 5)

kg/cm² m/sec
Pump suction lines (1)
- bubble point liquids 0.10 1.8
- subcooled liquids (< DN 200) [< 8”] 0.45 2.4
- subcooled liquids (≥ DN 200) [≥ 8”] 0.45 3.7
Pump discharge lines
- CS 0.90 6.1
- alloy / SS 0.90 7.6
Reboilers
- trapout lines (3) 0.07 1.5
- return lines 0.07 -
Liquid transfer lines (2) 0.35 3.7
Cooling water lines 0.35 3.7
Steam condensate lines (liquid) - 0.6
Notes
(1 Pump suction line diameters should normally not be more than two (2) standard line
) sizes larger than the pump suction nozzle.
(2
Or as required by system pressure balance.
)
(3
For sizing of tower draw-offs, refer to section 5.1.2 below
)
(4 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.
(5
For velocity limits in amine systems, refer to section 5.1.3 below
)

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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 Carbon Steel Piping Alloy Piping

m³/hr ∆P, kg/cm² per 100 m ∆P, kg/cm² per 100 m
0 - 60 0.6 – 2.0 1.4 –3.5
60 - 160 0.3 – 1.6 0.9 – 2.5
160 + 0.2 – 0.9 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 – 1½ 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 Allowable Velocity Flowrate
mm m/s m³/hr (BPSD)
80 0.70 12.5 (1,890)
100 0.70 21.6 (3,260)
150 0.70 50.4 (7,610)
200 0.80 88.1 (13,300)
250 0.85 153 (23,100)
300 0.90 237 (35,800)
350 1.00 305 (46,100)
400 1.05 426 (64,300)
450 1.10 567 (85,600)
500 1.15 735 (111,000)
600 1.20 1,027 (155,000)

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Capacities Of Bottom-Pan Drawoff Nozzles

Nominal Line Size Allowable Velocity Flowrate
mm m/s m³/hr (BPSD)
80 0.70 12.5 (1,890)
100 0.70 21.6 (3,260)
150 0.80 52.5 (7,920)
200 0.85 97.4 (14,700)
250 0.90 172 (26,000)
300 1.00 256 (38,700)
350 1.10 344 (52,000)
400 1.15 476 (71,800)
450 1.20 643 (97,000)
500 1.30 838 (126,500)
600 1.40 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/cm² per 100 m.
3) Assumed drawoff fluid properties: hot SG = 0.8; viscosity ≤ 3 cSt.
Nominal Assumed Swaged Pressure drop Velocity in

line size Flowrate line size in swaged line swaged line
mm m³/hr mm kg/cm² per 100 m m/s
80 12.5 80 0.07 0.7
100 21.6 100 0.06 0.7
150 50.4 150 0.04 0.7
200 88.1 150 0.10 1.3
250 153 200 0.07 1.3
300 237 200 0.12 2.0
350 305 250 0.08 1.7
400 426 300 0.07 1.6
450 567 300 0.10 2.2
500 735 350 0.11 2.3
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.

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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 ‘Recommended’ High Limits
Operating Pressure Range ∆P per 100 m Velocity (1)

kg/cm² m/s
HYDROCARBON LINES (< 100 m in length)

Vacuum: 0.07 kg/cm²a or less 0.014 120 / ρ0.5
Vacuum: ~ 0.50 kg/cm²a 0.035 120 / ρ0.5
0.0 – 3.5 kg/cm²g 0.12 120 / ρ0.5
3.5 – 10.5 kg/cm²g 0.35 120 / ρ0.5
10.5 – 35 kg/cm²g - 0.69 120 / ρ0.5
> 35 kg/cm²g 1.15 120 / ρ0.5
STEAM LINES (< 100 m in length)

Vacuum: 0.07 kg/cm²a or less 0.014 -
Vacuum: ~ 0.50 kg/cm²a 0.046 -
0.0 – 3.5 kg/cm²g 0.12 -
3.5 – 10.5 kg/cm²g 0.35 -
10.5 – 35 kg/cm²g - 0.69 -
> 35 kg/cm²g 1.15 -
Notes
(1) Vapour density (ρ) measured in kg/m³

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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/cm² 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 EQUIPMENT DESIGN LIVES
7.1 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.

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Vessel/Equipment – shells
Carbon Steel and Low Alloys (incl. 0.5 Mo steel) 3 mm minimum
High Alloy steel 0.75 mm minimum
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
High Alloy steel No corrosion allowance
Vessel/Equipment – fixed internals*

Carbon Steel and Low Alloys (incl. 0.5 Mo steel) 6mm (total corrosion
allowance)
High Alloy steel No corrosion allowance
Cladding Thickness 3.0mm min
*Note: heat exchanger tubes shall not be provided with a corrosion allowance.
8.0 EQUIPMENT DESIGN TEMPERATURE AND PRESSURE
8.1 Design Temperature
8.1.1 Upper Design Temperature

Design temperature shall be set at 25ºC above the maximum operating temperature.
The minimum upper design temperature shall be 65ºC.
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 0ºC.
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For depressurisation of fluids which have an atmospheric boiling temperature below

0ºC 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 Design Pressure
8.2.1 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 = Maximum differential + Maximum suction
pressure pressure pressure
where:
Maximum suction = Suction vessel design + Vessel static head
pressure pressure taken @ HLL
(or RV set pressure)
Pressure drop across trays or vessel internals should be included if it is significant.

DSN : 131
PROCESS ENGINEERING
3210-8110-PD-0004
and:
Maximum differential = F x Net differential pressure @ rated capacity
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) Design Pressure

kg/cm²g kg/cm²g
≤ 1.8 3.5
1.8 < MOP < 17 MOP + 1.7
17 ≤ MOP <100 110% of MOP
100 ≤ MOP <195 MOP + 10.0
≥ 195 105% of MOP
For all process equipment (with the exception of storage tanks and certain offsites
facilities) the minimum design pressure shall be 3.5 kg/cm²g.
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
PROCESS ENGINEERING
3210-8110-PD-0004
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/cm²g @175ºC and Full Vacuum @ 175°C.
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 pump’s 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
PROCESS ENGINEERING
3210-8110-PD-0004
5. Column:
Top: Pd6 = Pr2
Bottom: 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
Pd3 Pd6
Po6
Pd6
SET @ P r1
H 3 (P h3)
Po1 HLL
Pd1
H2 NLL
(Ph2)
LLL
Po7
HLL Pd7
H4
H1 BREAK POINT
(Ph4)
(Ph1 ) FOR PUMPS IN
PARALLEL Po3
Pd3
Pd2 Pd3
H5
(Ph5)
cL Po4 Po5
Po2
Pd2 FOR SINGLE PUMP Po8
Pd8
Pd2 Pd3
Po = OPERATING PRESSURE
Pd = DESIGN PRESSURE
Ph = PRESSURE DUE TO STATIC
DPTDFIG1.DRW
STANDBY

DSN : 131
PROCESS ENGINEERING
3210-8110-PD-0004
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 20
- Offsites product pumps Zero
- All other pumps 10
- Intermittent services Zero
Reciprocating Pumps
- All 10

DSN : 131
PROCESS ENGINEERING
3210-8110-PD-0004
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 EQUIPMENT SPARING
10.1 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
PROCESS ENGINEERING
3210-8110-PD-0004
• Centrifugal compressors shall have a spare rotor in the warehouse.

• Reciprocating compressors shall have a 100% spare
For fired heaters fans:
• ID fans shall have a 100% spare
• FD fans shall have a 100% spare
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 - Process Engineering Design Guideline

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PARADIP REFINERY PROJECT

PROJECT SPECIFIC PROCEDURES

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

2.1 Drum Surge Capacity and Hold-up Volume

Service Hold-up, minutes

Feed to Tower or Furnace

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

2.2 Tower Bottoms Surge Capacity and Hold-up Volume

2.3 Knockout Drum Surge Capacity and Hold-up Volume

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

b) At higher normal accumulation rate

2.4 Minimum Auxiliary Nozzle Size

Vessel Volume, m3 Vent Drain Pumpout Steamout Blowdown

2.5 Towers and Columns

2.5.1 Minimum Tray Spacing

Tower ID Max No. of Tray Min Tray Spacing

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

2.5.2 L/D Ratio

2.5.3 Allowable Pressure Drop Guidelines for Trays

Tray Type For: Pressure Service For: Vacuum Service

2.5.4 Preferred Internal Diameters (mm) of Columns/Vessels

300 1100 2000 (3400)

2.5.5 Manholes in Columns and Vessels:

ID ≤ 900 mm Use flanged end/top cover if access is required

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2.5.6 Tower Internals

2.5.7 Minimum Corrosion Allowances

3.0 HEAT EXCHANGERS

3.1 Fouling Factors

3.2 Fluid Allocation

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3.3 Heat Exchanger Pressure Drops

Viscosity @ avg. One Shell Two Shells Three Shells

Pressure Drop (kg/cm²) for Vapour Flow

Operating Pressure (kg/cm²a) Pressure Drop (kg/cm²)

3.3.3 Condensers and Reboilers

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3.3.4 Airfin Cooler Pressure Drops

Service Operating Allowable Pressure Drop

3.3.5 Viscous fluids

Service Allowable pressure drop, kg/cm²

Light gas oil cooler (airfin) 1.05

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3.3.6 Air Cooling versus Water Cooling

3.3.7 Preferred tube sizes

Pump Capacity Centre Line Elevation

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5.0 LINE SIZING

5.1 Liquid Flow

SIZING LIQUID LINES ‘Recommended’ High Limits

∆P per 100 m, Velocity (4, 5)

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5.1.1 Pump Discharge Lines

Flowrate Carbon Steel Piping Alloy Piping

5.1.2 Tower Draw-Off Line Sizing

Capacities Of Side-Pan Drawoff Nozzles

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Capacities Of Bottom-Pan Drawoff Nozzles

Typical Swaged Lines after Side-Pan Drawoff Nozzle

Nominal Assumed Swaged Pressure drop Velocity in

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5.1.3 Amine Lines