G3ir 1000 25 SP 9001 - R1

Client Name : BASF India Limited Project Name : Project GIR Project Number : G3IR
Document No. : G3IR-1000-25-SP-9001 Date 17-Apr-12 Page 1 of 72
PROCESS DESIGN CRITERIA
Document No
G3IR-1000-25-SP-9001
Business Unit Discipline Document Type
: : :
General Process Specification
Document Title
ISSUED FOR DESIGN

17 Apr 2012
1 Revision
17-Apr-12 Date
Issued for Design Purpose
VQ Prepared By
TD Checked By
TD
VP
Approved By
PROCESS DESIGN CRITERIA Records of Revision This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No. Date 1 17-Apr-12 Description This specification number G3IR-1000-25-SP-9001 is based on FEED phase specification number G2IR-0000-25-SP-9001 and no changes have been made to the FEED Document.
TABLE OF CONTENTS 1.0 GENERAL ...................................................................................................................................... 7 1.1 1.2 Engineering Practices................................................................................................... 7 Engineering Units..........................................................................................................7 1.2.1 Metric System ....................................................................................................... 7 1.2.2 Standard Conditions ............................................................................................ 8 1.2.3 Pressure................................................................................................................ 8 1.2.4 Nozzles and Tubes ............................................................................................... 8 1.2.5 Calculation / Specification Precision .................................................................. 8 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 2.0 Site Conditions .............................................................................................................. 9 Codes and Standards ................................................................................................... 9 Physical Properties ..................................................................................................... 10 Noise Level Limitations .............................................................................................. 10 Flexibility and Expansion ........................................................................................... 10 Utility Design Criteria.................................................................................................. 11 Basis for Material Balance.......................................................................................... 13 Economics ................................................................................................................... 13 Electric Power ............................................................................................................. 13
PROCESS FLOW DIAGRAMS..................................................................................................... 14 2.1 2.2 PFD Preparation .......................................................................................................... 14 Piping and Instrumentation Diagrams (P&IDs) Preparation .................................... 14
3.0
EQUIPMENT................................................................................................................................. 15 3.1 Design Safety Factors................................................................................................. 15 3.1.1 Heat Exchangers ................................................................................................ 15 3.2 Pressure Vessels (including Reactors & Columns).................................................. 17 3.2.1 Design Pressure ................................................................................................. 17 3.2.2 Design Temperature........................................................................................... 18 3.2.3 Materials of Construction .................................................................................. 19 3.2.4 Corrosion Allowance.......................................................................................... 19 3.2.5 Shells and Heads................................................................................................ 19 3.2.6 Connections........................................................................................................ 19 3.2.7 Nozzle Sizes and Piping..................................................................................... 22 3.2.8 Instrument Nozzles ............................................................................................ 23 3.2.9 Vessel Supports ................................................................................................. 23 3.2.10 Special Provisions for Horizontal Vessels ..................................................... 23 3.2.11 Liquid Holdup ................................................................................................... 24 3.2.12 Level Controls and Gauge Glasses ................................................................ 26 3.2.13 Other Special Requirements............................................................................ 26 3.3 Storage Tanks ............................................................................................................. 27
PROCESS DESIGN CRITERIA 3.3.1 Tank Selection .................................................................................................... 27 3.3.2 Design Pressure ................................................................................................. 27 3.3.3 Design Temperature........................................................................................... 28 3.3.4 Storage Tank Breathing ..................................................................................... 28 3.3.5 Material of Construction & Corrosion Allowance ............................................ 28 3.3.6 Connections........................................................................................................ 28 3.3.7 Nozzle Projections ............................................................................................. 30 3.3.8 Appurtenance and Internal Details ................................................................... 30 3.4 3.5 Fired Heaters ............................................................................................................... 30 Heat Exchangers ......................................................................................................... 30 3.5.1 Codes and Standards......................................................................................... 30 3.5.2 Arrangement of Services ................................................................................... 30 3.5.3 Shell and Tube Heat Exchangers ...................................................................... 31 3.5.3.1 Design Pressure .................................................................................... 31 3.5.3.2 Design Temperature .............................................................................. 32 3.5.3.3 Exchanger Fouling Resistances........................................................... 32 3.5.3.4 Allowable Velocities and Pressure Drop.............................................. 35 3.5.3.5 Exchanger Approach Temperature ...................................................... 36 3.5.3.6 Material of Construction & Corrosion allowance ................................ 37 3.5.3.7Tubes ....................................................................................................... 37 3.5.3.8 PipingandConnections.......................................................................... 37 3.5.3.9 Construction .......................................................................................... 39 3.6 Pumps .......................................................................................................................... 39 3.6.1 Codesand Standards.......................................................................................... 39 3.6.2 Rated Capacity and Head .................................................................................. 39 3.6. Pump Sparing ....................................................................................................... 41 3.6.4 Net Positive Suction Head(NPSH)..................................................................... 41 3.6.5 Shut off Pressure ............................................................................................... 42 3.6.6 Minimum Flow .................................................................................................... 43 3.6.7 Pump Selection .................................................................................................. 44 3.6.8 Pump Piping ....................................................................................................... 44 3.6.9 Seal Flushing ...................................................................................................... 45 3.6.10 Cooling Water ................................................................................................... 46 3.6.11 Pump Strainers................................................................................................. 46 3.6.12 Motor Rating ..................................................................................................... 46 3.6.13 Reciprocating and Rotary Positive Displacement Pumps ............................ 47 3.7 Compressors & Fans .................................................................................................. 48 3.7.1 Codes and Standards......................................................................................... 48 3.7.2 Compressor Selection and Rating .................................................................... 48 3.7.2.1 General Selection Considerations........................................................ 48 3.7.2.2 Selection of Process Gas Compressors .............................................. 48 3.7.3 Design Pressure ................................................................................................. 48 3.7.4 Design Temperature........................................................................................... 48 3.7.5 Material of Construction and Corrosion Allowance ........................................ 48 3.7.6 Compressor Specifications ............................................................................... 48 3.7.7 Rated Capacity ................................................................................................... 49
PROCESS DESIGN CRITERIA 3.7.8 Rated Head ......................................................................................................... 49 3.7.9 Compressor Sparing .......................................................................................... 49 3.7.10 Compressor Knockout Drum........................................................................... 50 3.7.11 Compressor Piping .......................................................................................... 50 3.8 3.9 3.10 Filters ........................................................................................................................... 50 Packaged Units............................................................................................................ 51 Drivers.......................................................................................................................... 52 3.10.1Codes and Standards........................................................................................ 52 3.10.2 Driver Selection ................................................................................................ 52 3.11 4.0 Vacuum Equipment..................................................................................................... 52
PIPING SYSTEMS........................................................................................................................ 52 4.1 Pipe Line Sizing........................................................................................................... 52 4.1.1 Friction Losses and Velocities in Straight Pipe ............................................... 53 4.1.1.1 Process Fluids-Boiling Liquids ............................................................ 54 4.1.1.1.1 Pump Suction Lines............................................................... 54 4.1.1.1.2 Pressure Lines ....................................................................... 54 4.1.1.1.3 Liquids .................................................................................... 54 4.1.1.1.4 Special Limitations-Noise...................................................... 56 4.1.1.1.5 Gasesand Vapors................................................................... 56 4.1.1.1.6 Liquid-Vapor Mixtures / Slurries ........................................... 57 4.1.1.1.7 Gravity Flow ........................................................................... 58 4.1.1.1.8 Condensate Systems ............................................................. 58 4.1.2 Velocity Limits .................................................................................................... 59 4.1.2.1 Vortexing Velocity................................................................................. 59 4.1.2.2 Steam Trap Condensate........................................................................ 59 4.1.3 Special Considerations...................................................................................... 59 4.1.4 Vacuum Piping ................................................................................................... 60 4.1.5 High Viscosity Fluids ......................................................................................... 60 4.2 Pipe Line Design Conditions...................................................................................... 60 4.2.1 Design Pressure ................................................................................................. 60 4.2.2 Maximum Operating Temperature .................................................................... 62 4.3 4.4 Piping Details .............................................................................................................. 62 Piping Requirements for Sampling............................................................................ 63
5.0
INSTRUMENTATION ................................................................................................................... 64 5.1 Control Valves ............................................................................................................. 64
PROCESS DESIGN CRITERIA 5.1.1 Control Valve Sizing........................................................................................... 64 5.2 Pressure/Temperature Elements................................................................................ 64
6.0 7.0 8.0 9.0
RELIEF / VENTING SYSTEMS .................................................................................................... 64 MATERIALS OF CONSTRUCTION.............................................................................................. 65 WINTERIZATION.......................................................................................................................... 65 UTILITY CONDITIONS ................................................................................................................. 65
APPENDIX A: DESIGN PRESSURE FOR EQUIPMENT AND PIPING................................................... 66 APPENDIX B: DESIGN TEMPERATURE FOR EQUIPMENT AND PIPING ........................................... 71
PROCESS DESIGN CRITERIA 1.0 GENERAL This document is intended to provide a general but consistent basis for process design philosophy, process design work and process design documentation. It is also the intent of this document to set out the minimum requirements for process design. 1.1 Engineering Practices The contents of flow diagrams, criteria for designing and specifying major process equipment, and engineering guidelines are based on generally accepted sound engineering practices in the chemical processing industry and specific guidelines provided by BASF, where applicable. The plant and equipment shall be designed for a life of 20 years. 1.2 Engineering Units This project will use the Metric system of units. 1.2.1 Metric System
Measure Acceleration Area Area Area Concentration Density Duration Duration Duration Duration Electricity Electricity Electricity Electricity Electricity Electricity Flow Flow Flow Flow Flow Force Heat Heating Value Length / Distance
Metric m/s sq m sq mm sq m ppm kg/m3 sec min hr yr A Hz kV mA mV V m3/h m3/h cu m/h kg/h Nm3/h N kJ J/kg m
2
PROCESS DESIGN CRITERIA Length / Distance Length / Distance Length / Distance Load / Pressure Mass Mass Mass Mass Transfer Power Power Pressure Pressure Pressure Pressure Pressure Pressure Pressure Radiation Sound Speed Speed Temperature Temperature Torque Viscosity Volume Volume Volume 1.2.2 Standard Conditions
mm km m kg/sq m kg g ton kg/m2.h kW kW mBar mBar N/m2 Pa bar bar(a) bar(g) J/sq m dBA m/s km/h deg C deg K Nm cp cu m cu m cu m
Standard conditions (STP) are defined as 15.6 C and 1.01325 bara 1.2.3 Pressure Barg shall be used for vessel and equipment ratings except as required by local law or governmental regulations. 1.2.4 Nozzles and Tubes Heat exchangers nozzle sizes and tube diameters shall be specified in millimeters. Average tube thickness shall be specified in millimeters equivalent to BWG designation. All equipment nozzle sizes, pipe sizes, and nominal safety valves shall be specified in millimeters. 1.2.5 Calculation/Specification Precision The precision of calculated or specified numbers should be kept to no more than three (3) significant figures. Particularly sensitive or critical numbers may however require more precision.
1.3
Site Conditions Maximum wind velocity Design wind velocity Maximum Temp Design Maximum Ambient Temp Design Temp for Air Coolers, if different Design Temp For Storage of Volatile Liquids, if different Minimum Temp Relative Humidity Maximum Cooling Tower Design Information Design Wet Bulb Temperature Maximum Allowable Cooling Water Return Temperature Rainfall- Design storm based on 1 hour 24 hours Site Elevation Above Sea Level Barometric Pressure Seismic Data: Site Classification Importance Factor Height Above Sea Level (MSL) . 158.4 km/h 180 km/h 40 C 65 C 42.3 C 65 C 11 C 92% 28 C 40 C 70 mm 305 mm 6.6 m 1012 mbar Zone III 1.5 6.6 m
1.4
Codes and Standards 1.0 2.0 Pressure vessels Storage tanks Atmospheric tanks Low pressure tanks (< 1.03 barg) Floating roof tanks Refrigerated tanks Ethylene & Ethane Tanks FRP vessels Heat exchangers Air cooled exchangers Pumps Centrifugal pumps Reciprocating pumps PD pumps (Controlled volume) PD pumps (Rotary) Pump seal Piping Instrumentation Pressure safety valves Safety ASME Section 2,SMPV,IBR,IS VIII Div 1 and
3.0 4.0 5.0 6.0
API 650 Petroleum Acts/Rules where applicable. API 620 API 650 API 620 API 2508 ASME Sec. X, ASME RTP-1 TEMA, ASME Sec. VIII Div 1, API 660 API 661 ANSI, API 610 / ASME B 73.1 / 73.3 API 674 / Non-API API 675 / Non-API API 676 / Non-API API 682 / Non-API ANSI, ASTM, IBR API, IBR, ISA API RP 520 (Part 1 and 2) and API 521 for Vessels and API 2000 for Storage tanks. IS, OSHA, Local regulations
7.0 8.0 9.0 10.0
PROCESS DESIGN CRITERIA 11.0 Water effluent 12.0 13.0 14.0 15.0 Air emissions Noise Fire protection Compressors Centrifugal Reciprocating Rotary Type Lubricating oil systems Steam turbines Gas Turbines Boilers Architectural Electrical
Central and State Effluent Regulations Central and State Effluent Regulations OSHA, API 615 (Rotating Machinery), BASF SHE Standards G-S-CL-100-M Tariff Advisory Committee (TAC), National Building Code (NBC). API 617 / Non-API API 618 / Non-API API 619 / Non-API API 614 API 611 and API 612 API 616 IBR IS / NBC, GIDC Indian Electrical Rules, Indian Explosive Rules, Tariff Advisory Committee, National Building Code (NBC). IS ASTM, ASME ASME IX IS ASHRAE IS ANSI, ASME, ASSE, ASTM, AWS, AWWA, UPC, CISPI, PDI, IPC ASHRAE, SMACNA, ARI, NFPA90A, 90B, 91, 92A, UMC, ASME, ASTM, ANSI IS,CEMA IS IS IS
16.0 17.0 18.0 19.0 20.0 21.0
22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0
Civil Work Materials Welding Sanitary Refrigeration Structural Plumbing HVAC Other Material Handling Insulation Painting Aircraft Warning
1.5
Physical Properties Physical properties for most streams are provided by BASF in their Heat & Material Balance (HMB) for the individual units. Any additional physical property data required for process design will be provided by BASF.
1.6
Noise Level Limitations The purchased equipment shall be governed by the noise level exposure limitations of the Occupational Safety and Health Administration (OSHA) as 85 dBA@ 1 meter and central / local acts / rules (e.g the environmental protection act, 1986).
1.7
Flexibility and Expansion
PROCESS DESIGN CRITERIA Considerations for plant flexibility and expansion shall be outlined in the Process Design Basis for the individual units.
1.8
Utility Design Criteria Pressure bar(g) STEAM High Pressure: Minimum (for thermal design) Normal Maximum (for mechanical design) Medium Pressure: Minimum (for thermal design) Normal Maximum (for mechanical design) Low Pressure (Note-1): Minimum (for thermal design) Normal Maximum (for mechanical design) COOLING WATER Cooling Water Supply: Minimum Normal Maximum (for mechanical design) Cooling Water Return: Minimum Pressure Required For Return Max Pressure Required For Return Max Temperature For Return RAW WATER Source Minimum Normal Maximum (for mechanical design) RAW WATER ANALYSIS Cations: Clacium Magnesium Sodium Bicarbonate Carbonate Anions: Hydroxide Chloride Sulfate Total Hardness Iron (Total) Silica 40 42 48/FV 16 17.5 20/FV 6.0 8/FV Temperature deg C 270 275 300 225 230 300 185 300
4 5 6 3
32 32 70
40 GIDC 1 3.5 6 Maximum
AMB AMB 70 Minimum 49.9 ppm as CaCO3 11.6 ppm as CaCO3 284.1 ppm as CaCO3 Nil 59 ppm as CaCO3 8.4 ppm as CaCO3 172.3 0.24 ppm as Fe 17 ppm as SiO2
PROCESS DESIGN CRITERIA Organic Matter (KmnO4 Consumed) PH Turbidity And System Used Color ( And System Used) Total Dissolved Solids
1.74 8.07 1.7 NTU < 5, (Pt. Co.Scale) 267.1
Pressure bar(g) BOILER FEED WATER Source (Deaerator) Minimum Normal Maximum (for mechanical design) STEAM CONDENSATE LP Condensate Minimum Use Design Pressure Required For Return Atmospheric Condensate Normal Use Design Pressure Required For Return PROCESS WATER Source (Storage Tank) Minimum Normal Maximum DM WATER Source (DM Water Package) Minimum Normal Maximum
Temperature deg C
43 45 56/FV
107 121 180
4 8/FV 0 3.4/FV
152 185 100 130
3 3.5 8
AMB AMB 70
3 3.5 7.5 Pressure bar(g)
AMB AMB 70 Temperature deg C AMB AMB 70 Temperature deg C 90 120
FIRE WATER Source (Fire Water Tank) Minimum Normal Maximum (for mechanical design) TEMPERED WATER Source (Storage Tank) Minimum Normal Maximum (for mechanical design)
5.3 8.8 12 Pressure bar(g) 6.5 9
PROCESS DESIGN CRITERIA COMPRESSED AIR PLANT AIR Source (Air Compressor) Minimum Normal Maximum (for mechanical design) INSTRUMENT AIR Source (Air Dryer) Minimum Normal Maximum (for mechanical design) Design Dewpoint At Normal Operating Pressure NATURAL GAS Source Molecular Weight Pressure (Normal) Temperature Lower Heating Value Higher Heating Value Composition
6 8 10 6 8 10 -40C @ ATM
AMB 40 70 AMB 40 70
GIDC Pipeline 18.96 6 barg 25 deg C 43500000 J/Kg 44500000 J/Kg 88.73 mol% C1, 4.13 mol% C2, 2.84 mol% C3, 1.49 mol% IC4, 0.78 mol% nC4, 0.14 mol% iC5, 0.12 mol% nC5, 0.072 mol% C6+, 1.15 mol% CO2, 0.53 mol% N2 Gaseous N2 supplied by third party AMB 7/10 barg 99.998 Vol% Nitrogen
INERT GAS OR NITROGEN Source Temperature (deg C) Pressure (Normal/ (Max.)Design) Composition Note:
1. The condition as specified is only for Infrastructure part of the project. Each business unit has different LP Steam conditions depending on requirements with in Business units. 1.9 Basis for Material Balance The individual units in the plant will be designed for batch or continuous operation as per the process and the material balance shall be prepared accordingly. 1.10 Economics Any economic analysis of technical options shall be based on local economic factors. 1.11 Electric Power Source Frequency Large Motors Over Small Motors Over Gujarat Electricity Board (GEB) 50 +/5 % (specify extent of Frequency Fluctuation) 160 kW 6600 V 3 0.18 kW 415 V 3
Hz phase phase
PROCESS DESIGN CRITERIA Fractional hp Motors Lighting Instruments Emergency 2.0 PROCESS FLOW DIAGRAMS 2.1 PFD Preparation
240 240 24 V DC / 110 415
V V V V
1 1 1 3
phase phase phase phase
Process Flow Diagrams (PFD) shall not define any operating conditions of the process. PFDs shall include the stream numbers only and the corresponding operating conditions shall be provided in the material balance. The material balance shall be provided in a document separate from the PFD. The material balance will be for the nameplate production capacity for each design case, multiple material balances may be required if applicable. PFDs for this project will include information on the plant control philosophy. Reasonable discretion will be used as to the degree of details shown on the PFDs in this regard. The intent is to convey the technology input and not to depict each and every control aspect on the PFD. 2.2 Piping and Instrumentation Diagrams (P&IDs) Preparation Following general considerations will be followed in the preparation of P&IDs. Symbology and line / instrument numbering philosophy shall be stated on the lead sheet for that particular design area. Line sizes will use the "mm" symbol. Instrumentation will be shown as stated on the lead sheet Depict the relative location of the equipment i.e. pumps below source vessel, reboilers below columns, condensers above associated receivers. All pumps shall be lined up if they are located at grade level. All process streams entering or leaving the drawing should be carried to the edge of the sheet. Vents to vent collection and treatment systems should also be carried to the edge of the sheet. The only exceptions should be vents to atmosphere and utility supply and return flags. Capture "typical" details on the lead sheets. For every equipment item, enter its equipment number directly adjacent to, or inside the graphical depiction of that equipment item. (Equipment Blocks with details will be located on the top of the drawing). All vessel nozzle sizes and designations will be shown outside the vessel, beside the nozzle. Nozzle connection type-flange, or special fitting -will be depicted. If a valve is to be located directly on the vessel nozzle, depict as such (i.e. no pipe between nozzle and valve). A line number and pipe specification for the vessel trim will be shown beneath the vessel description as the last entry required.
PROCESS DESIGN CRITERIA A pipe line spec break will be a cause for a new line number, a change only in line size will not require a new number. Safety relief valve and rupture disk pressure, size and set pressures will be shown per the lead sheet Symbology. Hardwired and software interlocks will be depicted on the P&IDs. Digital inputs and outputs will be identified per lead sheet symbology. Sloped lines should be labeled with the use of a slope arrow indication in the direction of slope with minimum slope identified, if critical. Lines that cannot be pocketed will be labeled as "Do not pocket". Lines that require gravity flow but can tolerate pockets shall be labeled "gravity flow". Dimensions shall be provided for seal legs. Where piping line length is dictated by the process, this shall be specified in terms of length (millimeters/ meter) or simply state minimum where applicable. Control valve installations shall be shown as per the Lead Sheet.
Instrument air supply to instruments should not be shown. However, instrument air or utility air serving a process function shall be shown and a line number provided. 3.0 EQUIPMENT The equipment numbering system shall conform to Project Job Bulletin JB-8-002, dated 18 April 2011 3.1 Design Safety Factors Safety Factors are required on each design to cover uncertainties inherent in the methods and correlated data used to develop the design. These safety factors increase the likelihood that the item will perform as intended. Fluor will neither modify nor apply any additional safety factors for the equipment included in the units designed by BASF. The safety factors for the units designed by Fluor are defined below. These factors are based on the reliability of the current design methods. The designer will assign safety factors that govern the critical factors in the design (e.g. column jet flood). Individual safety factors will not be systematically multiplied or added together. 3.1.1 Heat Exchangers Fouling factors are part of the design and are to be applied on an individual basis. In general place the dirtier fluid on tubeside unless other factors such as metallurgy or thermal coefficient dictate otherwise. These factors are not considered to be over design factors. For guidelines on recommended fouling factors for this project, refer to Section 3.5.3.
PROCESS DESIGN CRITERIA Safety factors in heat exchanger design are to be applied to the critical factor in each design case. Possible critical factors are area, tube length, tube diameter, heat duty, log mean temperature difference, process flow rate, and heat transfer coefficient. Be sure to apply safety to only one of the above factors. For example, do not multiply the HMB heat duty by a safety factor, then apply a 30% safety factor on heat transfer area. Choose one critical design specification and apply the safety factor to that one aspect. The type of safety factor applied should be clearly stated in specification. Safety factors may vary over a certain range depending on the reliability of design information and the importance of the heat transfer operation. They are expected to be in the following ranges, although exceptions may be identified: Heat Transfer Operation Liquid-Liquid Exchange Other Single Phase heating without phase change (ex. Vapor or liquid heating with steam) Pure Component Boiling Multi-component Boiling Pure-component Condensing Multi-component Condensing Safety Factor 10-15% 10-15% Critical Factor Overall Heat Transfer Coefficient Overall Heat Transfer Coefficient Duty Duty Overall Heat Transfer Coefficient Overall Heat Transfer Coefficient
15-20% 20-25% 15-20% 20-25%
Adding tube length is recommended in terms of minimizing heat exchanger cost and improved thermal performance. Tube velocities of less than 4 m/sec are recommended to avoid tube erosion especially for streams with possible solids (slurries). Also, it needs to be ensured that the pumps can deliver the required head to meet the increased pressure drop requirements. As far as over-design margins, allow 20% over-design for the max Q or HMB Q required by the exchanger to account for discrepancies in the HTRI design correlations for boiling and condensing. For condensing, HTRI over-designs (ratio of actual to required coefficient) shoot for 20% number which is pretty close to 20% excess area. For sensible units, relax the HTRI over-design required down to 10 or 15% over-design since HTRI correlations for sensible heat transfer have less variability. For boiling, usually do a Q versus Steam chest pressure plot and design for the exchanger to be able to do at least 20% more than the HMB required Q under fouled conditions. For example HTRI predicts 0% over-design for a thermosiphon reboiler running at fouled conditions and needs 34.5 barg chest pressure steam to deliver an HMB Q of 5,860 kW. However, if the steam chest pressure is turned upto full 41 barg chest, the reboiler rates in HTRI to deliver at least 20% more Q (7,030 kW) with HTRI over-design of 0%. We will generate a Q vs chest pressure plot (say 5 data points for fouled and non-fouled performance - 2 lines on the plot) for boiling or heating applications. This provides operations with an operability window (can see startup clean conditions). So design boiling based on 20% more Q (rather than area) and just have HTRI do it's most accurate attempt (+/- 5% over-design points on the plot) at modeling the thermal performance especially for thermosiphons or kettles. For
PROCESS DESIGN CRITERIA sensible heaters, back off to 10 or 15% more Q at max chest or utility (HTM) supply conditions. 3.2 Pressure Vessels (including Reactors & Columns) 3.2.1 Design Pressure Refer to Appendix A for design pressure of vessels. For jacketed vessels, the design pressure for the jacketed side should be consistent with the utility conditions as defined in Section 1.8 Design Pressure is at the top of vessel. Increased margins between operating and design pressures are often required for equipment protected by a rupture disk. Care should be taken considering the temperature at the rupture disc in relation to that of the vessel design (i.e., the rupture disk may or may not be at the same temperature as that of the process vessel due to the location. Consult with the Lead Process Engineer. Where margins between operating and design pressures of less than 10% are used, special relief valves are required to avoid premature leakage as the set pressure is approached. Vacuum breakers can be used to protect vessels, but shall not be used in lieu of Full Vacuum design specification. For low-pressure vessels, not normally subject to vacuum, consideration of the following special conditions is expected: If the vessel is connected to the suction of a compressor or ejector, vacuum may result. An overhead receiver connected to the outlet of an air cooler may drop below atmospheric pressure if rapid decreases in ambient temperatures (such as sudden rainstorms) drop the air cooler outlet temperature. Full vacuum shall be specified for equipment falling into following categories: (a) Equipment normally operating at pressures below atmospheric pressure (b) Equipment, which can have sub-atmospheric pressures due to pumping and drain-out. (c) Equipment that is subject to startup, shutdown and/or regeneration evacuation. (d) Equipment operating liquid full that can be blocked in and cooled down. (e) Equipment that can undergo vacuum condition through loss of heat input (f) Equipment containing a fluid with a vapor pressure less than atmospheric pressure at minimum ambient temperature or minimum operating temperature. This is not required for equipment open to atmosphere or an API storage tank fitted with a vacuum relief valve. (g) Vessels having steam as a significant feed component. (h) Equipment subject to steam out for cleaning or purging.
PROCESS DESIGN CRITERIA Specify maximum pressure drops across any internals for proper design of bed supports, shrouds etc. Liquid-filled vessels located on the discharge side of a pump should be designed for the larger of: The maximum suction pressure (corresponding to relieving pressure of suction line) of the pump plus its normal differential pressure. = 1.25 X (the maximum differential pressure (static, dead head or shut-off) of the pump) plus its normal suction pressure. (Refer Section 3.6.12)
Possibility of coincident occurrence of the shutoff pump and maximum suction pressure should be evaluated and considered as the design case, if this can occur. The internal design pressure may be lower than the source stream pressure provided that the relief valve is sized to pass the maximum flow of stream at the relieving conditions. Steam-out conditions should always be given separately on the specification sheets. Equipment items protected by a common relief valve shall have the same design pressure (adjusted for pressure drop during relief). A higher relief valve set pressure and hence a higher design pressure may be chosen in order to prevent or limit vapor relief during upsets or to preclude liquid relief due to transients in liquid filled systems. Special consideration shall be given to the design for external pressure for vessels normally subject to internal pressure but connected to the suction of a compressor or other evacuating equipment. Low-pressure vessels (such as overhead receivers operating at low pressure and receiving feed from an aircooled exchanger) that may be affected by decreases in ambient temperature should also be considered. Remember to design for unusual conditions such as start-up, shutdown, regeneration, etc. Consideration should be given to cyclic service operation. Paragraph UG-22(e) of the ASME Boiler and Pressure Vessel Code mandates that cyclic and dynamic reactions from any mechanical or thermal loading source be considered in design. 3.2.2 Design Temperature Refer to Appendix B for design temperature of vessels. While selecting the Min. Design Temperature, auto-refrigeration shall be considered and taken into consideration in selecting the Min. Design Temperature. Round off the Max. Design Temperature values to the next highest 5 C. Use a minimum of 65C as Design Temperature for non-heated equipment. For jacketed vessels, the design temperature for the jacketed side should agree with utility conditions as defined in section 1.8
PROCESS DESIGN CRITERIA For steam out conditions specify design conditions corresponding to 3.5 barg steam at 150 C). Minimum design metal temperature (MDMT) shall be shown on data sheets for pressure vessels. The MDMT is required on all vessels designed to the ASME Code. The MDMT shall be the lowest of: a. The minimum operating temperature expected during sustained normal operation. It may be determined by the lowest expected ambient temperature, if start-up can occur under such conditions. The MDMT should be set approximately 6C below the minimum normal operating temperature, considering expected variations in composition and SOR/EOR. The MDMT may be set at less than 6C below the normal operating temperature with the approval of the lead process engineer. This situation may occur when there is a substantial economic advantage and system safety can be maintained. If the design margin results in a MDMT colder than -29C, consider reducing the design margin, since temperatures colder than -29C will probably require impact testing. The minimum operating temperature during expected off-design conditions. Situations such as startup, shutdown, operating upsets, and depressurization need to be considered along with the effect of ambient temperature. A MDMT corresponding to the temperature resulting from depressurization of the normal contents of a vessel shall be used if this event results in the lowest temperature. Unless dictated otherwise, a Minimum Design Metal Temperature (MDMT) of -18.0C for Carbon Steel and -29C for other alloys shall be used.
b.
c. 3.2.3
Materials of Construction Materials of construction will be specified by BASF.
3.2.4
Corrosion Allowance Unless specified otherwise, the nominal corrosion allowance shall be: 0.0 mm for stainless steel, high-alloy steels and non-ferrous alloys. 1.6 mm for carbon steel and low alloy steels.
3.2.5
Shells and Heads Most of the vessel heads are ASME F&D. Dished heads shall normally be 2:1 ASME torispherical or ellipsoidal. Hemispherical, conical, or flanged and bolted heads (or covers) may be used when design conditions so dictate.
3.2.6
Connections All piping connections to vessels shall be flanged. The use of threaded connections is not recommended because of the potential for crevice corrosion and notch sensitivity. Nozzle sizes NPS 32 mm, 65 mm, 95 mm, and 125 mm shall not be used. Unless dictated otherwise a minimum nozzle size of 40 mm shall be used. Exceptions may apply on a case by case basis.
PROCESS DESIGN CRITERIA Auxiliary connection sizes shall be according to the Table 3.1.7.1. A vent and drain connection shall be provided for all vessels (although not necessarily as a vessel connection). The sizes of vent and drain nozzles will be governed by the vessel size and service. Typical vent and drain sizes, based on vessel volume, are given in Table 3.1.7.1. These represent minimum connection sizes - larger connections may be provided if service conditions so dictate. For vessels served by a pump, the drain is preferably located on the horizontal run, on the suction line, upstream of the block valve to the pump. Locate steam-outs and vents at opposite ends of horizontal vessels or drums. Table 3.1.7.1 Auxiliary Connection Sizes by Vessel Volume Vessel Volume, cu m 1.4 or less 1.4 to 17.0 17.0 to 56.6 56.7 to 283.2 Above 283.2 Vent 40 mm 40 mm 80 mm 100 mm 150 mm Drain 40 mm 50 mm 80 mm 100 mm 150 mm Steam-Out 40 mm 50 mm 50 mm 50 mm 80 mm Water Fill None 50 mm 80 mm 100 mm 150 mm
Vortex breakers shall be provided for all vessel outlet nozzles to pump suctions, except generally those in slurry service. The minimum number of manways should be provided in accordance with the following guidelines: Horizontal Vessels Under 900 mm diameter 900 mm and over Vertical Vessels Under 900 mm diameter 900 to 1350 mm 1350 mm and over Top head flanged One manway in head One manway in head or shell One head flanged One manway in head
Trayed Columns One manway at the top tray, at the feed tray, in the bottom surge section and one manway every 10 trays Packed Columns Packed Columns shall have manways or handholes at the top and bottom of each packed bed and at each distributor tray location. For packed columns less
PROCESS DESIGN CRITERIA than 900 mm diameter there shall be handholes or manway in the top head (in case a flanged head is not provided for process or other reasons). Reactors Manway at top (possibly integral with inlet nozzle). Nominal recommended manway size is NPS 600 mm. Nominal recommended handhole size in NPS 200 mm. It may be necessary to increase the size of manways for towers with structural packing. The actual size shall be decided in consultation with the structural packing vendor. For special services, such as catalyst loading or dumping or removal of large internals, the manway diameter shall be consistent with the required use. On skirted vessels, the bottom head nozzle connections shall be of all welded assembly extending laterally through reinforced openings in the vessel skirt to permit locating the first flange outside of the skirt whenever this practice is compatible with the intended service. Minimum one spare nozzle on top is to be provided, the size of this connection should be considered based on the other connection, else otherwise minimum as 40 mm. For reactor and column no additional nozzle is to be provided other than what is provided by BASF. Nozzles shall have the designations shown on the equipment data sheets. All nozzles should be flanged. Designation of Nozzles shall follow Fluor standard designation which is indicated below: The following system of nozzle symbols is intended to make it easier to quickly identify nozzles as well as give some hint as to their use. The symbols are to have a letter and an additional numeral if more than one of the same kind are used; that is, for three feeds, use "F1", "F2", and "F3", but if only one feed is used the symbol "F" is all that is required. A B C D E F G H J K L M N P R S T Inlet Outlet Condensate Drain, Draw-Off, or Flushing Feed Level Gauge or Gauge Glass Handhole Pump Out Spare Nozzle Level Instrument Manhole Reboiler Connection Pressure Connection Reflux Steam or Sample Connection Thermowell Connection
PROCESS DESIGN CRITERIA V W Vapor or Vent Relief Valve Connection
Symbol "E" may be used when none of the others apply. Do not use the letters "I," "O," "Q," "U," "X," "Y," or "Z". The nozzle designations in EM Unit are different from that indicated above. The nozzle designations are provided by Cognis/ BASF as part of their technology package and retained as per BASF instruction. 3.2.7 Nozzle Sizes and Piping 1. Sizing Nozzles shall be sized by line sizing criteria or the maximum velocity limitations (listed in the enclosed table), whichever is controlling. 2. Liquid level column connections shall be provided on the bottom section of all columns, accumulators, surge vessels, and coalescers. A control mounted on a separate liquid level column shall be provided for the high level shutdown of compressors. Bottom liquid level column connections shall be in a horizontal position, and located above the bottom of the vessel to prevent plugging and water pockets. Pump suction nozzles shall be provided with vortex breakers. Suction nozzles in horizontal vessels shall be located in the opposite end of the vessel from the inlet. Withdrawal from intermediate draw-off trays shall be from a sump directly through an external nozzle. Vessel nozzle sizes and attached piping sizes shall be same and not require a reducer at the vessel connection. ALLOWABLE VELOCITIES Nozzle Column Bottom Outlet 50 mm 80 mm 100 mm 150 mm 200 mm 250 mm 300 mm or larger Column Feed
* **
3. 4. 5. 6.
Maximum Velocity Velocity, m/sec 1.1 1.4 1.5 1.8 2.0 2.3 2.4 122*
- kg/m3, density of average mixture at flow conditions.
This limitation is set to prevent trapped vapors from getting into the pump. From a point of 3 meters below the draw-off nozzle, the connecting line can be reduced to its regular calculated size. All column side draws must turn down immediately for a minimum of 3 meters. A note to this effect should appear on P&IDs when required.
PROCESS DESIGN CRITERIA Column Draw-off to Pumps** Liquid Falling from Above From Quiet Zone
()0.5 Maximum Suction Box Velocity m/sec 0.30 0.6
Column Side-Draw to Pumps** (Minimum Liquid Height) Above Top of Draw-off Nozzle, millimeter) Liquid Falling from Above 900 750 600 300 150 Liquid from Quiet Zone 600 450 300 150 0 3.2.8 Instrument Nozzles
Maximum Nozzle Velocity, m/sec
1.2 0.9 0.6 0.30 0.15 1.2 0.9 0.6 0.30 0.15
Instrument nozzle sizes shall be specified by Control System Group. 3.2.9 Vessel Supports Type of vessel supports shall be determined by Mechanical Group. 3.2.10 Special Provisions for Horizontal Vessels On unlined horizontal vessels, an accessway will be provided on the side of the vessel at the horizontal centerline or in one of the heads/ends.. If the bottom half of the horizontal vessel is lined, the accessway will be located on the top of the vessel. Additionally, on all horizontal vessels, a ventilation nozzle, with blind flange, will be provided on the top of the vessel near the end opposite the accessway. The ventilation nozzle will be sized as follows: TABLE 3.2.10.1 Ventilation Nozzle Size Vessel Tangent Tangent Length 3 4.5 m 4.5 7.5 m More than 7.5 m Ventilation Nozzle Size 100 mm 150 mm 200 mm
PROCESS DESIGN CRITERIA A separate ventilation nozzle need not be required if a process nozzle of adequate size could be used, consult with the Lead Engineer. Boots shall be furnished on horizontal vessels in hydrocarbon service which have continuous water drains. High and low interface level switches will be provided on all boots. For elevated vessels, water draw off pots located at grade are preferred to vessel boots. The draw off pot should be connected to the vessel with an oversized line (sized for 0.15 m/sec maximum velocity) to permit self venting.
3.2.11 Liquid Hold up General guidelines on sizing tower bottoms and drums from control requirements are provided in Table 3.2.11.1 and Table 3.2.11.2 below. For case to case exceptions to the guidelines consult process lead engineer. TABLE 3.2.11.1 HOLDUP AND SURGE TIMES (1) (6) Holdup (min) Feed Surge Drum Wide Feed Variations Minor Short Term Feed Interruptions Steady Upstream Operations Feed to Distillation Column Feed to Pump (Low/High Head) Reflux Drum
(2)(3)(4) (5)
Surge (min)
30-240 15 5 4 3/7
10-100 5 3 2 2
Reflux on Flow Control Reflux (or Reboiler) on Temperature Control Reflux on Level Control Knock-out Drum Steam Drum Condensate Pot Water Boot Chimney Tray Column Bottoms
3 3.5 4 4 15 1 3 2
(7)
2 2 2 2 5 0.75 2 1
(7)
Notes:
PROCESS DESIGN CRITERIA 1. Holdup time is Normal Liquid Level (NLL) to Low Liquid Level (LLL). Surge time is Normal Liquid Level (NLL) to High Liquid Level (HLL). 2. To avoid sizing the vessel pressure relief valve for liquid relief (liquid overflow), an additional 10 minutes of surge time can be provided above the vessel high liquid level (HLL). This option may also result in a smaller unit flare knock out drum. The additional 10 minutes of surge time is over and above the surge times listed in the table. This option must be reviewed and approved by the Client. The flow is based on reflux and overhead liquid product. For reflux drum with no vapor product, set NLL at the centerline of the vessel. For a reflux drum with vapor product, set the NLL at the point of drum volume. Double the holdup time of above recommendations. High level alarm should be set at 60 % of drum volume. Compressor shutoff should be set at 90 % point of drum volume. If the material being processed deteriorates under any of these conditions, consideration shall be given to shortening the residence time specified above, e.g., vacuum column bottoms. Hold-up and surge time for liquid in column draw-off sumps is given below. Where hold-up time is critical and cannot be provided economically in the column, a separate drum venting back to the column may be required. TABLE 3.2.11.2 HOLD-UP AND SURGE TIMES FOR COLUMN DRAW-OFF SUMPS Holdup Surge (min) (min) Liquid is withdrawn by level 3 2 control and feeds another column directly by pressure. Liquid is withdrawn by level control and pumped away. - Spare pump starts manually 4 2 Spare pump starts 2 2 automatically Liquid is withdrawn by level 1.5 1.5 control 2 Liquid is withdrawn by level 5 control and feeds a unit that is some distance away or that has instruments on a different control room. Liquid is withdrawn by flow 3 2 control. Liquid flows through a 1 thermosyphon reboiler without a level controller to maintain a level in the sump
3. 4. 5.
6.
7.
PROCESS DESIGN CRITERIA 3.2.12 Level Controls and Gauge Glasses Consult with the Control Systems engineer to determine the requirements for gauge glass or level control details so that the appropriate nozzles can be provided on the vessel. 3.2.13 Other Special Requirements The process engineer should record the following information on the process datasheet: 1. List all known corrodents that may be present during normal operation, indicate concentrations (typically in wt% if liquid and mol% if vapor). Indicate mole % of acidic corrodents such as inorganic or organic acids and acid gases such as H2S, NO2, SO2 and CO2. Indicate Total Acid Number if naphthenic acid is present. Indicate wt% of acid salts (e.g., ammonium bisulfide or ammonium chloride). Indicate wt% of oxidants such as oxygen and chlorine. Other corrodents suspected of being significant (e.g., dissolved oxygen content in water).
2. List all crack inducing agents only if liquid water or other electrolyte is present (except for H2); indicate concentration of the following agents, if present above their threshold concentrations. Hydrogen: if partial pressure exceeds 6.9 bara; indicate either mole % or partial pressure in bara. Amines: present at greater than 2 wt%; indicate wt%. Carbonates & bicarbonates: either or both (combined) when the concentration exceeds 1 wt.%; indicate wt. % Chlorides: any concentration; indicate ppmw. Cyanides: present at greater than 20 ppmw; indicate ppmw. NaOH: any concentration, if T > 46C; indicate wt%. Hydrogen Sulfide: a. Gas Phase: The partial pressure of H2S exceeds 0.003 bara. Indicate either mole % or partial pressure in bara. b. Sour Water: H2S is dissolved in water at a concentration of at least 50 ppmw; indicate ppmw. Other known crack inducing agents (e.g., HF).
3. Indicate the presence of liquid water (or other electrolytic liquid) if present during either normal operation or upset condition. 4. For upset conditions, indicate auto refrigeration, liquid water, wet sour service, carryover of crack inducing agents or corrodents, loss of flow that could lead to overheating, etc. For short-terms conditions, consider startups, shutdowns, regeneration, presulfiding, hydrogen stripping of catalyst, loss of flow, etc. Both duration and frequency of short-term conditions should be included. 5. Lethal Service - only if specific by Client.
PROCESS DESIGN CRITERIA 6. Indicate multiple operating conditions for different products. 7. Cyclic Service: Fluctuations in temperature magnitude, duration, and frequency). and/or pressure (state
8. Indicate any special requirements such as PWHT; NACE hardness controls; special gasket materials for MTBE service; velocity limits; internal or external coatings; corrosion resistant cladding or weld overlay; neutralizing wash to prevent polythionic acid stress corrosion cracking during shutdown etc. 3.3 Storage Tanks 3.3.1 Tank Selection This shall be based on BASF reference plant experience on similar products stored. However where no reference plant data available from BASF the storage tank selection shall be based on the Table 3.3.1.1 for atmospheric tanks and Table 3.3.1.2 for pressure tanks. TABLE 3.3.1.1 ATMOSPHERIC TANKS Vapor Pressure (bara) 0.10 or below 0.10 to 0.76 0.76 to 63.5 mm w.g. Cone Roof Floating Roof Cone Roof with Vapor Recovery System Tank Type
TABLE 3.3.1.2 PRESSURE TANKS Operating Pressure (barg) 63.5 mm H2O to 0.17 0.17 to 0.34 0.17 to 0.34 0.17 to 0.34 0.34 to 2.1 0.34 to 1.0 2.1 to 207 1.4 to 20.7 Capacity (m3) Up to 3,180 3180 to 6,360 Over 6,360 Up to 6,360 Over 6,360 Up to 636 159 to 7949 Tank Type Dome Roof Plain Hemispheroid Noded Hemispheroid Noded Spheroid Plain Spheroid Noded Spheroid Horizontal Cylinder Sphere
3.3.2
Design Pressure Refer to Appendix A for design pressure of storage tanks.
PROCESS DESIGN CRITERIA 3.3.3 Design Temperature Refer to Appendix B for design temperature of storage tanks. Refer to Section 3.2.2 for Minimum Design Metal Temperature (MDMT) selection criteria. 3.3.4 Storage Tank Breathing Breathing requirements shall be as per API 2000. 3.3.5 Material of Construction & Corrosion Allowance Materials of construction and corrosion allowance shall be specified by BASF for the units designed by BASF. For the units designed by Fluor material of construction and corrosion allowance shall be specified by Fluor metallurgist. Unless specified otherwise refer to section 3.2.4 for nominal corrosion allowance for this project. 3.3.6 Connections 600 mm inside diameter shell and roof manways are recommended as normal standard size, but larger diameters may be used where required for special sizes and dimensions listed in the applicable API standard. The recommended number of 600 mm inside diameter manways is shown in the Table 3.3.6.1 below. Recommended Number of Manways TABLE 3.3.6.1 Tank Diameter (meter) 0 to 15.2 15.2 to 36.6 Over 36.6 No. of Shell Manways 1 2 3 No. of Manways 1 2 3 Roof
One roof manway shall be near the top of the stairway or ladder. Any additional manways shall be spaced equally around the tank. Tanks in services requiring frequent cleanout shall be provided with flush type cleanout openings of minimum 900 mm x 1200 mm. Flush type cleanout fittings shall be supported in accordance with most suitable method, depending on foundation design, shown in API Standard 650. All API Standard 650 storage tanks, with the exception of floating roof types, shall be equipped with pressure and vacuum relief valves per API Standard 2000. Gauge hatches shall be NPS 200 mm, gas tight, spark-proof type, aluminum being preferred. At least one gauge hatch shall be provided on all tanks. Tanks
PROCESS DESIGN CRITERIA 27,400 mm in diameter and larger in such services shall require four gauge hatches as a minimum. One draw sump is normally required for API 650 tanks. Construction details shall be per API Standard 650. For freezing climates, the sump nozzle shall be equipped with an antifreeze draw-off valve. All process connections shall be flanged with a minimum 40 mm size. Nozzles shall be sized on the basis of the connecting line size. Minimum one spare nozzle on top is to be provided, the size of this connection should be considered based on the other connection, else otherwise minimum as 40 mm. All tanks shall be provided with a water drain. Minimum size of the water drain (draw-off) shall be per Table 3.3.6.1 for atmospheric tanks and per Table 3.3.6.2 for pressure tanks. If the commodity to be stored is heavier than water, the tank shall be provided with a swing line to draw water. Generally, for clean service, two spare nozzles with blind flange, one is located on side and another on roof. For dirty service, only one spare nozzle is to be provided on the roof. The sizes of these nozzles are determined based on the sizes of the other nozzles located on the tank. TABLE 3.3.6.1
ATMOSPHERIC TANKS Tank Diameter (meter) 0 to 15.2 15.2 to 30.5 30.5 to 45.7 45.7 to 61 Over 61 80 mm 100 mm 2 x 100 mm 3 x 100 mm 4 x 100 mm Water Draw-off Size
TABLE 3.3.6.2 PRESSURE TANKS Tank Volume (cu meter) Less than 17.0 17.0 to 56.6 56.6 to 283.1 Over 283.1 50 mm 80 mm 100 mm 150 mm Water Draw-off Size
For large diameter tanks, multiple drawoffs are provided radially along the tank circumference.
3.3.7 Nozzle Projections Nozzle projections shall be determined by Mechanical Group. 3.3.8 Appurtenance and Internal Details Firewater and foam systems for fire protection, when required, shall be installed per industry practice. All tank process connections shall be valved immediately adjacent to the tank nozzle. Tank mixing and heating facilities, if required, shall be provided per Fluor practice for the units designed by Fluor. For the units designed by BASF, the tank mixing and heating facilities shall not be modified by Fluor. Tanks requiring temperature indication or control shall have thermowells provided at a point that is low enough to ensure continuous submergence. Tank vents shall be checked to ensure that a vacuum condition exceeding the tank external design pressure is not created when a drain is opened. 3.4 Fired Heaters The design of fired heaters, if any, should be based on API Standard 560. 3.5 Heat Exchangers 3.5.1 Codes and Standards In general, all shell and tube and double pipe heat exchangers for this project shall conform to TEMA Class "B" and/or Class R for critical service and Section VIII Division I of the ASME Pressure Vessel Code. API Standard 660 - Shell and Tube Heat Exchangers for General Refinery Services is a standard that specifically applies to the design of units with removable bundle, floating head or U - tube construction. Air cooled heat exchangers shall conform to API Standard 661 - Air Cooled Heat Exchangers for General Refinery Services. Surface condensers shall be designed in accordance with HEI (Heat Exchanger Institute Standards) for Steam Surface Condensers and applicable parts of the TEMA and ASME Codes. 3.5.2 Arrangement of Services
PROCESS DESIGN CRITERIA Arrangement of services shall be based on BASFs experience in reference units for the units designed by BASF. For the units designed by Fluor following guidelines shall be used. Unless approved otherwise, water-cooled units shall be constructed with water on tube side.
Except for economic reasons or if fluid is assigned to tube side because of fouling problems, shell and tube side fluid assignments may be interchanged for the most effective heat transfer and most economical overall design. Tube-side/shell-side selection shall be made using Table 3.5.2.1 as a guideline.
TABLE 3.5.2.1 SHELLSIDE OR TUBESIDE SELECTION Service Shell side Tube side Cooling Water x Condensing Vapors x Lower Allowable Delta P x Larger Flow with Similar x Properties On Both Sides Clean Viscous Fluids x High Pressure Fluids x Corrosive Fluids/Alloy x Construction High Fouling Factors x Vaporizing Fluids x High Viscosity/Laminar Flow x
3.5.3
Shell and Tube Heat Exchangers 3.5.3.1 Design Pressure Refer to Appendix A for design pressure of heat exchangers. Exchanger tube or shell side design pressures shall be set at the set pressure of the safety relief valve that protects the exchanger. In cases where this relief valve is mounted on other equipment, the liquid head and pressure drop (at relieving conditions) between the relief valve and the exchanger, should be added to the relieving pressure. Typically heat exchangers will be designed to be in compliance with the 10/13 Rule and tube rupture will not apply. In any shell and tube exchanger design case where tube rupture is a consideration, the low-pressure side of such heat exchangers will be designed for 10/13 the design pressure of the high-pressure side in accordance with API 521. Further, the hydrostatic test pressure for the low-pressure side shall in no case be less than the Design Pressure of the high-pressure side. This requirement for hydrostatic test pressure (on the low-pressure side only) in accordance with the 10/13 rule above, shall be clearly specified on the process data sheet.
PROCESS DESIGN CRITERIA In cases where designing the system to this rule would entail excessive cost with no appreciable safety benefit then it will not be followed. Exchangers are treated as ASME vessels. Where a safety relief valve is not used the design pressure shall be the highest of the following: Heat exchange equipment located on the discharge side of a pump should be designed for the maximum suction pressure of the pump plus the maximum pump differential. This would be pump shutoff pressure in case the exchanger can be shut in against pump shutoff pressure. Pump curves may not be available at early stages of project. In such cases assume shut off head as 125% of the normal pump differential. Any upset operating condition that can be identified. If the hot side fluid is a liquid at low operating pressure which can be blocked in, the liquid could conceivably cool sufficiently to pull a vacuum. In such cases the exchanger shall be designed for full vacuum. In determining the maximum operating pressure to arrive at design pressure, variations in pressure that may be expected to arise because of operating fluctuations, other than upsets, shall be accounted for. Liquid static head, fluid friction losses under clean and fouled conditions, pump and compressor head characteristics, pressure pulsation, etc. shall all be considered.
3.5.3.2
Design Temperature Refer to Appendix B for design temperature of heat exchangers. Refer to Section 3.2.2 for Minimum Design Metal Temperature (MDMT) selection criteria. When, due to the possible loss of flow of the lower temperature fluid, exchanger components may be subject to the inlet temperature of the higher temperature fluid, and should be designed for this consideration. In the selection of design temperatures for exchangers in series, considerations shall be given to the maximum anticipated temperature, resulting from either fouled or clean operation, for each side of each exchanger. For refrigerated exchangers, considerations shall be given to the minimum anticipated temperature, under the same circumstances.
3.5.3.3
Exchanger Fouling Resistances Unless specified otherwise, following fouling factors are recommended. Individual fouling factors specified by BASF in the units designed by BASF may vary.
The following tabulated values of fouling resistances allow for oversizing the heat exchanger so that it will meet performance requirements with reasonable intervals between shutdowns and cleaning. These values dont recognize the time related behavior of fouling with regard to specific design and operational characteristics of particular heat exchangers.
TABLE 3.5.3.3.1 RECOMMENDED FOULING RESISTANCES (m2-C/kW)
FOULING RESISTANCES FOR CHEMICAL PROCESSING STREAMS Fluid Fouling Resistance, m2-C/kW Gases and Vapors: Acid Gases Solvent Vapors Stable Overhead Products Liquids: Stable Side Draw and Bottom Product Caustic Solutions Vegetable Oils 0.352 - 0.528 0.176 0.176 0.176-0.352 0.352 0.528
TABLE 3.5.3.3.2 FOULING RESISTANCES FOR INDUSTRIAL FLUIDS Fluid Fouling Resistance, m2-C/kW Gases and Vapors: Steam (Non-Oil Bearing) Exhaust Steam (Oil Bearing) Refrigerant Vapors (Oil Bearing) Compressed Air Natural Gas Flue Gas Natural Gas Liquids: Refrigerant Liquids Hydraulic Fluids Industrial Organic Heat Transfer Media Calcium Chloride Solutions Sodium Chloride Solutions Methanol Solutions Ethylene Glycol Solutions
0.088 0.264-0.352 0.352 0.176 0.880 0.176-0.352 0.176 0.176 0.352 0.528 0.528 0.352 0.352
PROCESS DESIGN CRITERIA TABLE 3.5.3.3.3 FOULING RESISTANCES FOR WATER, m2-C/kW Temperature of Heating Medium Temperature of Water Up To 116C Upto 52 C Water Velocity m/sec Over 1 m/sec 1 m/sec 116 to 204C Over 52 C Water Velocity m/sec Over 1 m/sec 1 m/sec
Cooling Tower and Artificial Spray Pond: Treated Make-up Untreated City or Well Water River Water: Minimum Average Muddy or Silty Hard (Over 15 Grains / Gallon) Distilled or Closed Cycle: Condensate Treated Boiler Feedwater Boiler Blowdown
0.176 0.528 0.176 0.352 0.528 0.528 0.528 0.088 0.176 0.352
0.176 0.528 0.176 0.176 0.352 0.352 0.528 0.088 0.088 0.352
0.352 0.880 0.352 0.528 0.704 0.704 0.880 0.088 0.176 0.352
0.352 0.704 0.352 0.352 0.528 0.528 0.880 0.088 0.176 0.352
If the heating medium temperature is over 204 C and the cooling medium is known to scale, these ratings should be modified accordingly. In the absence of any specific information, the fouling factors shall be selected based on TEMA guidelines. TABLE 3.5.3.3.4 FOULING FACTORS FOR PLATE HEAT EXCHANGERS TYPICAL FOULING FACTORS FOR PHE'S Fluid Water Demineralized or distilled Municipal supply (soft) Municipal supply (hard) Cooling tower (treated) Sea (coastal) or estuary Sea (ocean) River, canal, borehole, etc. Engine jacket Oils, Lubricating Solvents, organic Steam Process fluids, general 0.002 0.004 0.009 0.007 0.009 0.005 0.009 0.011 0.004 -0.009 0.002-0.005 0.002 0.002-0.011 Fouling Factor m2-C/kW
PROCESS DESIGN CRITERIA 3.5.3.4
Allowable Velocities and Pressure Drop To minimize corrosion and fouling, water velocities in tubes shall not fall outside ranges listed in the Table 3.5.3.4.1. Exceptions may be made where pressure drop limitations govern. TABLE 3.5.3.4.1 ALLOWABLE VELOCITIES FOR SHELL & TUBE HEAT EXCHANGERS Tube Material Inhibited Admiralty Aluminum Brass 90-10 Cu Ni 70-30 Cu Ni Monel Carbon Steel 304 SS 316 SS 1.2 to 1.8 1.2 to 2.4 1.8 to 3.0 1.8 to 3.6 1.5 to 2.4 1.8 to 2.4 4.6 4.6 Velocity (m/sec)
Allowable pressure drop may be redistributed in a complete train for the most economical overall selection. As a guideline, pressure drop per shell for shell and tube exchangers in pumped liquid service are shown in the Table 3.5.3.4.2 TABLE 3.5.3.4.2 ALLOWABLE TUBESIDE AND SHELLSIDE PRESSURE DROP FOR SHELL AND TUBE EXCHANGERS Viscosity (cp.) Allowable Allowable P** (bar) Shell side P**(bar) Tube side Less than 1.0 0.17-0.34 0.34-0.7 1.0 to 5.0 5.0 to 15.0 15.0 to 25.0 25.0 to 50.0 0.34-0.52 0.52-0.7 0.7-1 1 0.52-0.7 0.7-1 1-1.4 1.7
** Maximum allowable P is for fouled exchangers and is inclusive of the pressure drop through inlet and outlet nozzles.
PROCESS DESIGN CRITERIA Allowable pressure drop for shell and tube exchangers condensing service shall be considered as shown in the Table 3.5.3.4.3. TABLE 3.5.3.4.3 ALLOWABLE TUBESIDE AND SHELLSIDE PRESSURE DROP FOR SHELL AND TUBE CONDENSERS System Pressure (barg) Allowable P** (bar) Up to 3.4 3.4-13.7 13.8 and above 0.1-0.17 per shell 0.17-0.34 per shell 0.34 per shell
** Maximum allowable P is for fouled exchangers and is inclusive of the pressure drop through inlet and outlet nozzles. Notes: a. b. c. d. Where excess pressure is available, exchanger pressure drop may be specified accordingly. Allowable pressure drop for water coolers should be 0.7 bar maximum on the cooling water side. For vacuum column operation, this pressure drop allowance may be lower if vacuum column pressure dictates such a deviation. For horizontal thermosyphon reboilers, allow 0.03 0.07 bar for the process (shell) side available pressure drop including nozzle loss. For vertical thermosyphon reboilers the allowable pressure drop must consider static head loss.
e.
In case an exchanger has alternate operating conditions, the pressure drop shall apply to the worst condition. Allowable pressure drops for multiple units in series should be for the entire train rather than for individual units. 3.5.3.5 Exchanger Approach Temperature Use 5 C for the minimum approach temperature. For maximum economic heat transfer the following guidelines for approach temperature shall apply. However, bear in mind that the specific factors for each heat exchange service must be taken into account while using these guidelines - for instance control requirements may require a different approach temperature than indicated below: Steam reboilers shall have a minimum approach temperature of 22 C with exceptions on a case to case basis. They may operate as low as 17C, but the design should be based on 22 C.
PROCESS DESIGN CRITERIA Cooling water exchangers can typically be designed to a minimum approach of 7C with the cooling water supply. In water cooled exchangers, process inlet temperatures above 93C or cooling water outlet temperatures above 46C should be avoided to minimize water side fouling. 3.5.3.6 Material of Construction & Corrosion allowance Materials of construction and corrosion allowance shall be specified by BASF for the units designed by BASF. For the units designed by Fluor material of construction and corrosion allowance shall be specified by Fluor metallurgist. Unless specified otherwise refer to section 3.2.4 for nominal corrosion allowance. 3.5.3.7 Tubes Typical tube sizes used in the chemical process industries are 20 mm, 25 mm, 40 mm and 50 mm, with standard tube wall thicknesses ranging from 18 BWG to 10 BWG. (Tube-wall thickness is frequently measured in Birmingham Wire Gauge, BWG units.) For clean streams, or if chemical cleaning is feasible and tube-side pressure drop is not a critical consideration, smaller diameter tubes are more economical since more surface area is provided for the same bundle diameter. However, practical considerations for mechanical cleaning limit the minimum tube diameter to 20 mm for straight tubes and 25 mm for U - tubes. Tubes of 25 mm dia. are normally used when fouling is expected because smaller ones are impractical to clean mechanically. Falling-film exchangers and vaporizers generally are supplied with 40 mm and 50 mm tubes. Generally, the longer the tubes, the lower the cost of a given surface, as a smaller number of tubes is required, and the size of tubesheets and flanges is reduced. (The maximum length which can be handled by most manufacturers is in the order of 12 meters.) This does not imply, however, that the longest possible tube always produces an optimum exchanger, as other length-dependent factors will influence the efficiency of the overall design. The preferred tube length is 4.5 6 meters for straight tubes. The practical length of tube cleaning drills limits tube length to these values. There may be some exchangers with more than 6 meters tube length for process reasons, which will be an exception and will require approval of lead process engineer. 3.5.3.8 Piping and Connections All connections NPS 40 mm and larger shall be flanged. Thermowell connections will normally be NPS 40 mm flanged connections. Pressure connections will normally be added to the blind flanges on chemical cleaning connections. Unless dictated otherwise a minimum nozzle size of 40 mm is recommended. Exceptions may apply on a case by case basis.
PROCESS DESIGN CRITERIA The minimum nozzle sizes used in EM Unit is smaller than that indicated above. The nozzle sizes are provided by Cognis/BASF as part of their technology package and retained as per BASF instruction. Chemical cleaning connections shall be installed on the shell and/or channel nozzles of exchangers in services conductive to chemical cleaning. The connections shall be flanged with a minimum size NPS 40 mm for both the shell and tube sides. Generally, for all exchangers with steam on the tube side, vent connections with valves shall be provided on the channel cover at the high point of all passes, except the first pass, to allow venting of noncondensable gases. Process vents with valves shall be provided where necessary to prevent gas binding or to relieve vapor from either the tubes or shell. All total condensers shall be provided with vents to allow periodic purging of inert gases. Vents shall be piped to an appropriate place in the process. Steam out and/or purge connections shall be provided when required by the process design. Vent and drain connections for hydrostatic test purposes shall normally be plugged with valves. Stacked units operating with shell sides in common service shall have only the top unit vented and the bottom unit drained unless the shell cover is of a larger diameter than the shell or the exchanger is of floating head design. For these exchangers, vents and drains shall be provided on all shell covers. Stacked units (shells in series) should be piped to fill each side from bottom up if sufficient velocity is not present to sweep entrained vapor downward through the units in series. We do want to maintain countercurrent flow through the shells in series, but avoid the potential for a vapor pocket to build in the units if a straight down flow shells in series piping is used. Where valves are to be directly attached to the process nozzle of heat exchangers, the vent or drain shall be located on the nozzle neck. If there is no valve attached, and a vent or drain is required, it shall be preferably located on the piping rather than on the nozzle neck. All vent and drain valves provided on shells and shell covers shall be NPS 20 mm unless larger connections are required for process reasons. All heat exchangers, coolers, condensers and reboilers designed to be removed from service without unit shutdown shall have block valves and isolating spectacle blinds on or adjacent to all inlets and outlets. Spectacle blinds need not be installed in cases where the piping is "flexible" and can be "sprung". If a unit shutdown is required for isolation, block valves need not be provided. Where fouling is anticipated to the extent that an exchanger will require cleaning at more frequent intervals than scheduled plant shutdowns, block and bypass valves will be provided to permit cleaning during plant operation. Note that heat exchangers in fouling service may be
PROCESS DESIGN CRITERIA spared for this purpose. If not spared, the plant will usually need to be operated at an appropriate reduced rate while the exchanger is being cleaned. For a large diameter exchanger, over 450 mm, then request an A / L bonnet design for ease of cleaning. This is also good to have for vertical thermosiphon reboilers that are anticipated to foul often. Advantage is that large tubeside process nozzles (such as a column vapor return nozzle on a reboiler) will not need to be disconnected for high pressure tubeside cleaning. The end caps can be removed and the unit can be high pressure cleaned before being brought back online, especially good to have A and L heads for online spare exchangers. For flooded and partial condensers, the vent nozzle shall be at the opposite end of the shell from the inlet nozzle. Where the shell inlet is in the center, two vent nozzles shall be provided, one at each end of the shell. For all steam reboilers, a vent nozzle should be provided below the channel baffle, or for steam on shell side vertical units, a vent should be provided just below the last/bottom baffle. 3.5.3.9 Construction The construction shall be as per the heat exchanger standards specified in section 1.4 3.6 Pumps 3.6.1 Codes and Standards Refer to Section 1.4 for codes and standards for pumps. 3.6.2 Rated Capacity and Head Normal operating capacity of a pump is the design case PFD heat and material balance value and contains no extra margin. Pump rated capacity is the maximum flow rate required by the process. Pump rated capacity for continuous service is listed in Table 3.6.2.1. Exceptions are determined on a case by case basis. TABLE 3.6.2.1 RATED CAPACITY Service Rated Capacity over Normal, % Flow Control Level or Temperature Control Unit Feed Pump 5% 10% Feed Booster Pump 10% 15% Product Pump 10% 15% Reflux Pump 15% 20% Pump around Reflux Pump 20% 20% Intermittent Service 0 0 Reboiler Feed 15% 20% Boiler Feed 10% (1) SurfaceCondenser Condensate 10%(2) Chemical Injection 20% -
PROCESS DESIGN CRITERIA Notes: 1. Above rated boiler capacity 2. Above rated surface condenser capacity. 3. No additional capacity is included for pumps used in batch operations. The rated pump head is that required, at pump rated capacity, to overcome process pressure, line and equipment pressure losses, static head and control valve pressure drop. This head shall be the required differential head. Total developed head shall be based on lowest suction pressure, highest discharge pressure and fully fouled equipment. Line friction losses shall be set at 20% over the calculated value. Equipment pressure losses (exchangers, etc.) shall be set at the values specified on the equipment data sheets. Head capacity curves that rise continuously to shutoff are preferred for all centrifugal pumps, and are required for pumps operating in parallel. The minimum required capacity shall be specified where it is known that the pump will operate, even for short periods of time, at capacities well below its normal capacity. Where parallel operation is specified, the characteristic curves shall be such that the capacity of each pump shall be approximately a constant portion of the total capacity at all heads from shutoff to 120% of rated capacity. A note shall be added to the pump datasheet highlighting that parallel operation is required. All pumps shall be suitable for operating at the specified operating conditions and at off-design conditions occurring at plant startup, shutdown, process upset, power outage, etc. as applicable. Pumps charging fractionation systems should be checked for adequate differential head to maintain a substantial flow rate to the column during upsets when maximum pressure may approach relief valve setting. The system control valve should be able to give up enough pressure drop to maintain a substantial flow rate to the column. For boilers, ASME code requires pumping at the relief valve set pressure plus 3% accumulation. The maximum discharge pressure should not be the sum of maximum suction pressure plus maximum differential pressure unless it is certain that these conditions can occur simultaneously. For reflux, charge and recycle pumps, check for cold start-up with high densities to ensure that there is enough head available to get started.
PROCESS DESIGN CRITERIA All pumping systems shall be rechecked when a certified performance curve for the pump and the approved piping layout is available. Revisions to system pressure shall be compensated by the system control valve. Rated suction pressure is the pressure existing at the pump suction with the pump operating at rated capacity with the liquid level at bottom tangent line. The maximum pump suction pressure shall be determined from the following: 3.6.3 Relief valve setting plus maximum static head from the suction to the pump centerline. Do not take into account the suction loss. For a system unprotected by a relief valve, the shutoff pressure of the upstream booster pumps. For a gravity flow system, the maximum static head.
Pump Sparing Sparing philosophy to be in accordance with that considered by BASF. In other case Fluor has sparing philosophy can be utilized as given below. All pumps in continuous service shall be 100 percent spared. Common spare may be considered for non-critical service. In large capacity services where parallel pumps are required, a common spare shall be used. A common spare shall normally not spare more than two pumps. Spares in critical service shall be automatic start, with the spare pumps actuated by loss of discharge pressure or flow rate of the regular pump. Typical services may be: Fired reboiler circulating pumps Reflux pumps Pump around pumps Steam generation circulating pumps Refrigeration pumps Continuously operating charge pumps Surface condenser condensate pumps
3.6.4
Net Positive Suction Head (NPSH) Pump selection can be affected considerable by NPSH values, therefore, they shall be determined initially as accurately as possible.
PROCESS DESIGN CRITERIA The NPSHA (NPSH available) to be shown on the pump data sheet must include adjustments to the actual calculated NPSH as follows: 10% or 1 meter, whichever is greater. For vacuum service or low temperature (below 0 C) the margin shall be at least 2 meter. NPSH margin used shall be indicated on the pump data sheet to avoid double accounting of NPSH margin when the Mechanical Engineer selects the pump. Pump available NPSH shall be calculated from the tangent line of vertical suction vessels. The NPSH required for pumps shall be based on water. No hydrocarbon correction factor shall be used. The economics of increasing suction line size versus adjusting vessel elevation shall be considered in providing sufficient NPSH. The suction line losses shall be based on rated flow capacity of the pump. Pressure drop through any permanent strainer required shall be based on 50% clogging. Use L/D=250 for a strainer and assume the suction nozzle one size smaller than the suction line size. For this, include a reducer in line loss calculation. For subcooled liquids, the source pressure shall be the minimum normal operating pressure and the vapor pressure shall be at the maximum normal process temperature. Consider blanket gas solubility in pumped liquids as appropriate. Static head shall be measured from the bottom of horizontal drums, from the bottom tangent line of vertical vessels and columns with bottom drawoffs, and from the bottom elevation of the outlet nozzle for side drawoffs, to the centerline of a horizontal centrifugal or rotary pump, or to the suction nozzle of a vertical centrifugal pump or reciprocating pump. The design of storage tank suction lines shall be based on the available NPSH from the lowest specified liquid level in the tank at which rated pump capacity is required. If vortex breaker is required, the pressure drop through it shall be considered. For horizontal centrifugal pumps, the elevation of the pump centerline shall normally be 1 meter above grade, unless the actual elevation is known. In cases where the pump handles mixtures whose components have widely differing density, viscosity and volatility, NPSH calculations should be made for each individual fluid in addition to the normal mixture composition. 3.6.5 Shutoff Pressure In estimating the shutoff pressure of centrifugal pumps for initial setting of downstream equipment design conditions, the following shall be used: For centrifugal pumps with medium to high head, the assumed shutoff pressure shall be the normal suction pressure plus 125% of the differential pressure at normal capacity, or the maximum suction pressure plus the
PROCESS DESIGN CRITERIA differential pressure at normal capacity, whichever is greater. The shutoff pressure assumed shall be rechecked when certified pump performance curves are available. For low head centrifugal pumps or steam turbine driven pumps, estimate the shutoff pressure as above except 135% of the differential pressure should be used in the calculation (instead of 125% mentioned above).
For some high head and vertical pumps, the shutoff pressure may be higher than 125% of the normal. In such cases, check with the pump specialist for specifying the appropriate pump shutoff head. 3.6.6 Minimum Flow Pumps are typically suitable for continuous operation at a flow of 30% of normal capacity. If flow conditions necessitate flow for less than 30%, minimum flow provisions may be required. Some pumps require a minimum flow as high as 45%. Minimum flow required shall be based on the pump manufacturer's recommendations, but 30% of normal flow may be used for initial sizing of the minimum flow line. Specify the minimum flow requirement, if it exists as a process requirement in normal operation, in an emergency, or during start-up and shutdown of the unit. Minimum flow provisions for centrifugal pumps shall consist of a line from the pump discharge to the suction source (vessel), or to the suction line through a cooler. Even if there is no specific minimum process flow requirement, pumps in the following service are likely to need the minimum flow bypass: High differential pressure multistage pumps Boiler feed water pumps. Where there is a possibility of no-flow conditions occurring in a pump discharge system (such as a control valve failing to a closed position or controlled to be so by a logic).
Minimum flow bypass provision for centrifugal pumps is to be made with a modulating control valve. Note that a cooler will be required if the minimum bypass flow does not return to the suction vessel. No additional capacity shall be added to pump flow rate for minimum flow bypass rate except for continuous minimum flow situations Minimum flow bypass control valve sizing shall be based on 110% of the flow requirement. Control valve shall be designed to prevent erosion / cavitation damage due to flashing across the bypass valve caused by high differential pressure.
PROCESS DESIGN CRITERIA The bypass should be used only in upset, non continuous operation to protect the pump. Continual operation of the bypass is discouraged as it serves no useful purpose. 3.6.7 Pump Selection The following are specific Fluor criteria that should be met when selecting a pump: Wherever conditions will allow, horizontal centrifugal pumps shall be the preferred installation. Vertical pumps shall be limited to services where NPSH or head / capacity make a horizontal pump impractical or for services less than 150 C and 37 kW driver size where a vertical pump will result in considerable piping savings. High speed in-line pumps are preferred to reciprocating pumps for low capacity, high differential pressure services. Injection pumps in acid, chemical and caustic service shall preferably be the proportioning type, and should be capable of flow control by adjusting the stroke while the pump is in operation. Sealless pumps are used for handling hazardous and highly toxic liquids. Rotary screw or gear pumps are preferred for high viscosity service. All equipment shall be suitable for operation at an outdoor installation unless otherwise specified. If the process fluid is highly erosive or corrosive or process temperature is 93 C or above, pumps shall not be vertical in-line type. The diameter of the impeller(s) provided shall not be greater than 95% of the maximum impeller diameter that may be installed in the pump.
3.6.8
Pump Piping Temporary bathtub type strainers shall be provided in all suction lines (with the exception below). They shall be located between the pump suction flange and the pump block valve. It is recommended that the strainer open area shall be at least equal to the cross sectional area of the pipe. For large water circulating pumps (350 mm and larger suctions) basket strainer needed for pump under routine operation shall be provided in the suction line. Suction lines on such pumps shall be thoroughly cleaned. Bathtub strainers shall be arranged to permit cleaning without interrupting the pumping service. For pumps with spares, this shall be accomplished by providing strainers in the suction lines of the service pump and the spare pump. For pumps without spares, twin strainers may be used as applicable.
PROCESS DESIGN CRITERIA The process engineer should specify the pump nozzle rating to confirm to the piping specification for the particular service involved. This should be indicated on the pump specification sheet. In unusual circumstances, the pump manufacturer may not be able to adhere to the piping specification. Positive displacement pumps shall normally be provided with a relief valve in the discharge line, unless the relief valve is furnished as an integral part of the pump. Specify the relief valve as an integral part of the pump only if it is a vendor standard. Reciprocating pumps shall normally have pulsation dampeners on the discharge side. The approximate minimum size of pulsation dampeners for pump speeds up to 100 rpm is given by the equation below: V=CQ 60 N Where: V Q N C = = = = volume of dampener, m3 discharge rate, m3/h pump speed, rpm constant given below Constant 5 2.5 1.3 0.45
Pump Type Simplex, single-acting Simplex, double-acting Duplex, double-acting Triplex, single and double-acting
If the pump speed exceeds 100 rpm multiply the above derived volumes at 100 rpm by (pump rpm)/100. On high speed power pumps the chamber air volume can be at least 1 to 1 times the pump displacement per revolution. 3.6.9 Seal Flushing Pumps that require seals are typically provided with mechanical seals as specified in API 610 or API 682. A tandem seal arrangement shall be provided, if specified on the data sheet, or if pumped product: Is benzene, gasoline, or lighter hydrocarbons Will auto-ignite Will vaporize upon exposure to atmosphere.
PROCESS DESIGN CRITERIA The barrier fluid system shall have a sensor that will detect failure of the seal system, the barrier fluid system, or both. The non-pressurized fluid barrier system shall be vented to the flare. In all seal systems, whether they have mechanical packing or mechanical seals, lubrication and cooling is essential to prolonged seal performance. With some mechanical packing, the process fluid leaking between the packing and the shaft is sufficient but in other systems special arrangements are necessary. Provision of mechanical seal flushing fluid is the joint responsibility of the process and mechanical engineers. External flushing shall be provided for mechanical seals under the following conditions: If the mechanical seal design temperature is exceeded by the pumping temperature of the fluid Abrasive solids, such as catalyst, coke, dirt, etc. are present in the pumped liquid (provide cyclone separator). The seal operation will be impaired by a pumped liquid which tends to polymerize, solidify, coke or decompose at the seal. The pumped liquid is highly corrosive. The pumped liquid is a poor lubricant. The pump operates at vacuum suction pressure.
The flushing liquid shall be compatible with the pumped liquid, shall be available at all times including plant startup and shutdown, and shall not flash at the pump operating conditions. It shall also be clean, relatively cool and supplied at least 1.5 bar above the maximum stuffing box pressure encountered during normal startup and shutdown operations. The pumped liquid may be used as flushing liquid after it is cooled and filtered. API-610 and Hydraulic Institute Standards (HIS) show several piping arrangements that may be used for primary seals. In case of external flushing, recirculation, recovery or discharge to drain/ETP of flushing liquid is to be considered based on properties of flushing liquid used. Where operating pressure is less than atmospheric, the design shall provide means for maintaining positive pressure on the stuffing box. 3.6.10 Cooling Water Cooling water shall be supplied when specified by the pump vendor. If cooling is required for bearings, seals, stuffing boxes or pump supports, the vendor shall specify the required flow rate of water. 3.6.11 Pump Strainers Specific requirements, where applicable, have been called out in P&IDs. 3.6.12 Motor Rating
PROCESS DESIGN CRITERIA In general, pump motors shall be sized for largest impeller at the end of curve. Specific deviations to this general requirement will be made on a case by case basis. Pumps shall not be installed with the maximum size impeller without specific approval. In the absence of specific performance curves during the preliminary design stage, 25% margin over normal head requirement shall be used for fixing the design pressure of the downstream equipment for pumped systems. This needs to be reviewed / revised during detailed engineering. 3.6.13 Reciprocating and Rotary Positive Displacement Pumps The pump stalling pressure shall be checked to ensure that the maximum allowable pressure of piping and equipment is not exceeded. In case the stalling pressure is higher than the system pressure, either the system pressure should be suitably enhanced or a pressure relief valve shall be installed on the pump discharge. The relief valve set pressure must be sufficiently high to eliminate the possibility of relieving during the high pressure pulsation peaks. The following table gives the recommended discharge relief valve settings (as a multiplying factor to be applied to the normal pump differential pressure) for various types of reciprocating pumps: Pump Type Simplex Duplex Triplex Multiplying Factor 1.30 1.25 1.20
The maximum allowable pressure is defined as the highest pressure which can occur in the pump when bypassing the full capacity of the pump through its relief valve with an accumulation of not more than 15% above the maximum set pressure. Materials selection for reciprocating pumps is affected not only by the type of fluid being pumped but also by the pumping pressure and temperature. A process engineer should generally refer to a specialist for materials selection guidance in the absence of clear direction from the Client. However, the following guidelines from API 674 are provided below for information: Cast iron pump cases should not be used under the following conditions: Pumping temperature above 135 C Rated discharge pressure above 8.6 barg Subject to severe thermal shock Subject to severe pressure pulsations Fluid pumped is flammable or toxic
Ductile iron pump cases should not be used under the following conditions : Pumping temperature above 225 C Rated pump discharge pressure above 20.7 barg Indicate on the pump datasheet if H2S concentration is more than 10 ppm or if toxic substances are being handled.
PROCESS DESIGN CRITERIA 3.7 Compressors & Fans 3.7.1 Codes and Standards Refer to Section 1.4 for codes and standards for compressors & fans. 3.7.2 Compressor Selection and Rating 3.7.2.1 General Selection Considerations Based on BASF past experience in reference units for units designed by BASF. Fluor standards shall be used for the units designed by Fluor.
3.7.2.2 Selection of Process Gas Compressors Based on BASF past experience in reference units for units designed by BASF. Fluor standards shall be used for the units designed by Fluor. 3.7.3 Design Pressure Refer to Appendix A for design pressure of Compressors & Fans. 3.7.4 Design Temperature Refer to Appendix B for design temperature of Compressors & Fans. 3.7.5 Material of Construction and Corrosion Allowance Materials of construction and corrosion allowance shall be specified by BASF for the units designed by BASF. For the units designed by Fluor material of construction and corrosion allowance shall be specified by Fluor metallurgist. Unless specified otherwise refer to section 3.2.4 for nominal corrosion allowance for this project. 3.7.6 Compressor Specifications Compressor specifications shall include all applicable operating cases, such as, Pre-commissioning/Startup, Start of Run (SOR), Middle of Run (Normal operation), End of Run (EOR), and Regeneration. Compressor vendor and Advanced Control vendor will be requested to recommend anti-surge protection system/configuration for centrifugal compressors. The surge point of a centrifugal compressor should preferably be less than 60% of the rated capacity of all operating speeds regardless of the type of driver, unless advance surge control is applied. Pulsation dampeners shall normally be provided for both the suction and discharge of reciprocating compressors.
PROCESS DESIGN CRITERIA Relief valves shall be provided on reciprocating compressors to prevent over pressuring in the event that the compressor is blocked in while operating. For reciprocating compressors, maximum theoretical (predicted) or actual discharge temperatures shall not exceed 135C. The maximum discharge temperature shall not exceed 118C for hydrogen rich services (those with molecular weight of 12 or less). Unloaders for reciprocating compressors shall be pneumatically operated and provide for step capacity control. Five steps of 0%, 25%, 50%, 75%, and 100% capacity are preferred. 3.7.7 Rated Capacity Rated capacities for all compressors shall be a minimum of 10% greater than the maximum normal material balance flow. Capacity of the compressor for cases that occur infrequently will be evaluated jointly by the Process and Mechanical Engineers. 3.7.8 Rated Head For all compressors, the rated discharge head shall be 100% of the system pressure drop at the rated capacity. The head-capacity characteristic curve shall rise continuously from the rated point to the predicted surge for each impeller/diffuser stage, and each compressor section. The compressor, without the use of a bypass, shall be suitable for continuous operation at any capacity at least 10 percent greater than the predicted surge capacity shown in the vendor proposal. 3.7.9 Compressor Sparing Centrifugal compressors in process service shall not be spared. However, spare rotating elements shall be supplied for the compressor. If the compressor is driven by a steam turbine, spare rotor should be supplied for the turbine as well. Reciprocating compressors in process service shall be spared such that 100% or more of required capacity is available with one machine off-line. Compressor sparing shall normally be per the Table 3.7.9.1 TABLE 3.7.9.1 COMPRESSOR SPARING Compressor Type Axial Centrifugal Reciprocating, 373 KW and over Reciprocating, Under 373 KW None None 3 @ 60% 2 @ 110%
Sparing
PROCESS DESIGN CRITERIA 3.7.10 Compressor Knockout Drum All reciprocating compressors shall be provided with K.O. drums in the suction lines as close as possible to the compressor. Centrifugal compressors require suction K.O. drums, however, consideration may be given to taking suction from an accumulator, provided the vessel is close to the compressor and has the same type of operating safeguards as a suction K.O. drum. The compressor suction drum shall be provided with a high liquid level alarm and a separate connection for compressor shutdown at high liquid level. 3.7.11 Compressor Piping Compressor suction line shall be heat traced and insulated if the process gas is within -4 C of its dew point at suction conditions. Personal protective insulation for compressor discharge piping shall be provided for temperature above 60 C. Compressor suction piping shall have no low points in the line between the suction knock out drum and the compressor. Compressor suction line shall be internally cleaned from the suction knock out drum to the compressor inlet. 3.8 Filters The performance specification and selection of filtration equipment including the type of filter, type of filter media, material of construction etc. shall be based on previous experience and process requirements. In other cases, the process engineer is advised to review the process filtration requirements with the equipment vendor in addition to the mechanical specialist. Each filter shall have an inlet and outlet block valve and pressure gauges or taps to a pressure differential monitor, all of which should be located as close to the filter housing as possible. Large filters will also be provided with relief valves per ASME Code requirements. Normally, the filter housing will be tapped to provide a vent and drain, but this may be fitted to local piping, inside the block valves on some units. Valves vents and drains shall be installed on the low high and low point respectively of the filter housing. Minimum vent and drain size shall be 20 mm. The pressure drop across the entire filter must be specified. Typically a maximum pressure drop in dirty condition that would warrant cleaning, backwashing or change of media is one of the determining factors in filter construction and sizing. In quantitative terms, allowable pressure drops across filters are typically in the range of 0.5 - 2 bar: Strainers/Cartridge Filter (liquid service) Pump suction : 0.07 bar for basket type strainer
PROCESS DESIGN CRITERIA Pump discharge : 0.3 bar clean 0.5 bar dirty Cartridge Filter (gas service) : 0.01 bar clean 0.3 bar dirty
Note that the allowable pressure drop depends on inlet pressure as well as the filtration application. As stated above, these factors need discussion with specialist and vendor. 3.9 Packaged Units The specification of Packaged Units will often be necessary so that performance and practical economic considerations are met. The following points about packaged equipment shall be considered during specification: Specify completely the package battery limits Specify the process performance and warranties expected at the battery limit Specify all documentation and drawings to be provided by the package vendor (P&ID, relief valve calculations, etc.) Specify all equipment, piping and instrumentation to be included in the package State any site-specific requirements. Provide all available utility information at the battery limits Require all utility needs and usages of the package at the battery limits Require all effluent discharge or emission characterizations and treatment requirements of the package at the battery limits Provide all necessary tie-in information to the package Specify all the field erection, construction and/or start-up services to be provided by the package vendor
The package battery limits should be clearly marked on all PFDs and/or P&IDs to provide consistent references. This must include the equipment, piping and instrumentation. Failure to properly identify these as part of the package may result in double design and/or purchases. All equipment inside the package shall be tagged as per project equipment numbering system. Available utilities at the package battery limits should be specified for the vendor's use; however, utility demands and usages must be given by the package vendor. Unusual or irregular utilities or demands must be handled separately.
PROCESS DESIGN CRITERIA Effluents or emissions from the package battery limits must be given by the package vendor together with required treatment or handling. Special cases may require additional permit considerations by the plant or treatment by the package vendor. 3.10 Drivers 3.10.1 Codes and Standards Refer to Section 1.4 for codes and standards for Drivers. 3.10.2 Driver Selection Driver selection shall generally be in accordance with Table 3.10.2.1 TABLE 3.10.2.1 DRIVER SELECTION Service Compressors, under 75 kW Compressors, over 75 kW Fans, Air Cooler Fans and Blowers Fans, Boiler Generator, Electric Generator, Electric (Standby) Mixers Pumps Pumps, Critical Services (1) Pumps, Fire Water Notes: 1. Critical services such as cooling water, fired heater charge, steam generation circulation, and refrigeration. 3.11 Vacuum Equipment Vacuum systems for critical systems shall be based on BASF past experience in reference units for units designed by BASF. Fluor standards shall be used for the units designed by Fluor. 4.0 PIPING SYSTEMS Process design data for the classification of piping systems will be specified on a line list prepared by piping. The line sizing shall be done by process. The sizing data must be consistent with that from the design basis or PFDs. Driver Motor Motor Motor Motor Motor Gas Turbine Diesel Engine Motor Motor Motor with Emergency Power Supply Motor or Diesel Engine
4.1
Pipe Line Sizing
PROCESS DESIGN CRITERIA The fluid quantities to be used in determining line sizes shall be those called for by the process design conditions on the Material Balances. However, additional consideration may be given to equipment capacity (pumps, etc.) or other special conditions, which shall be so noted on the P&IDs. Line sizing should be appropriate to the application, which may include determination with respect to least annual cost, available friction losses or allowable velocities based on noise, vibration and erosion. The minimum size of any pipe line on the pipe rack shall be no smaller than 25 mm. The minimum size of 25 mm is also applicable for distribution headers. Minimum line size on rack is fixed from pipe support considerations. Lines outside the pipe racks, etc. but which require supporting shall be 25 mm minimum size. This does not apply to piping such as instrument leads, steam tracers, auxiliary piping on pumps, compressors, turbines, or other mechanical equipment, etc. Any special piping more expensive than 300 series stainless steel shall be considered excluded from the above criteria. Lines running underground shall have minimum sizes as follows: Process Utility Lines Sewer Lines Drain Lines 50 mm 100 mm* 50 mm
The minimum line size in EM Unit is smaller than that indicated above. The line sizes are provided by Cognis/BASF as part of their technology package and retained as per BASF instruction. * All sewer lines should be at least 100 mm in diameter with few exceptions, such as for handling a clean process waste stream in which case 80 mm diameter steel pipe may be acceptable. All lines shall be sized for maximum anticipated flow rates. 4.1.1 Friction Losses and Velocities in Straight Pipe A safety margin of 20 % shall be added to all friction loss calculations for single phase lines and a safety factor of 30% shall be added to all friction loss calculations for two phase lines, with the exception of steam systems, for which no margin is to be added. A safety margin should only be added to frictional losses, and not to pressure losses due to elevation changes or acceleration. Refer Table 4.1.1.1 for roughness factor. Table 4.1.1.1 Material Riveted Steel Concrete Cast Iron Galvanized Iron Asphalted Cast Iron Commercial steel , mm 0.9144-9.144 0.3048-3.048 0.25908 1.524 0.12192 0.04572
PROCESS DESIGN CRITERIA 4.1.1.1
Process Fluids - Boiling Liquids 4.1.1.1.1 Pump Suction Lines
Liquids shall be considered as boiling liquids if the operating pressure is less than 110% of the liquid vapor pressure at the operating temperature. Care shall be taken that the static head to suppress the vaporization always exceeds the line pressure drop in order avoid vaporization. This is particularly important in pump suction lines, where the static head must always exceed the line pressure drop plus pump NPSH requirement as well. In general, pressure drop in short pump suction lines should be in the range of 0.02 to 0.07 bar per 100 meter. Generally, this will limit the velocity to a maximum of about 1.5 m/sec for small lines and about 2.1 m/sec for large lines. 4.1.1.1.2 Pressure Lines
Pressure lines such as pump discharge lines, liquid transfer lines from high pressure to low pressure vessels should be sized using recommended velocity ranges as given below: Line Size, mm 25 40 50 80 100 150 200 250 300 Velocity, m/sec 0.9 1.5 1.1 1.7 1.2 -2.1 1.5 2.4 1.8 3.0 2.4 3.6 2.7 3.6 3.0 4.0 3.3 4.3
Alloy lines, because of their higher cost, have economic velocities in the upper end of these ranges, if all other factors permit. Fluid viscosity can have a major effect on economics of pressure drop and should be considered in sizing lines. 4.1.1.1.3 Liquids
PROCESS DESIGN CRITERIA The Table 4.1.1.1.3.1 below presents velocity and pressure drop guidelines for sizing liquid full lines in common services. Pipe diameters that satisfy both the pressure drop and velocity recommendations at the process flow rates expected during normal operation should be selected.
Generalized Allowable Piping Velocities and Pressure Drop TABLE 4.1.1.1.3.1 Small Lines (25 mm-200 mm) Velocity Friction Loss Type of Range Range Service meter / sec bar/100 meter Boiling Fluids Process Fluid Pump Suction Process Fluid Pressure Lines Pump boiling water suction Pump boiling water discharge 0.02 0.07 0.11 0.45 See Section 4.1.1.1 above See Section 4.1.1.2 above 0.6 1.5 2.1 4.3 0.9 1.8 0.9 3.0 0.02 0.07 0.11 0.22 0.04 0.11 0.11 0.22 See Section 4.1.1.1 above See Section 4.1.1.2 above 1.2 2.1 1.5 3.0 1.5 2.4 2.1 4.3 Large Lines (250 mm & larger) Velocity Range Friction Loss meter / sec Range bar/100 meter
Below Boiling Point Fluids Process Fluid 0.04 0.11 Pump Suction Process Fluid Pump Discharge Pump cold water suction Pump cold water discharge Gravity lines flow 0.02 0.09 Notes: 0.11 0.45
0.04 - 0.11 0.11 0.45
0.9 1.8 0.9 3.0 0.61 (min)
0.04 0.11 0.11 0.22 0.02 0.09
1.5 2.4 2.1 4.3 0.61 (min)
1. Velocity Limitations - Every calculated line size must be checked to ensure the resulting velocity is reasonable. If the available pressure drop or economics does not govern the line size, then velocity limits are usually the deciding factor. Enclosed table contains recommended velocity limits for various liquid systems. The velocity limits presented can be quite arbitrary and are intended as guidelines only. In addition to
PROCESS DESIGN CRITERIA these guidelines, other velocity limitations - erosional velocity, sonic velocity, entrainment velocity and noise - must be considered when sizing lines. 2. Because of acceleration effects some positive displacement pumps do not follow these guidelines. Consult with process lead engineer. 3. Vortex breakers may be required on draw nozzles where vapor entrainment affects performance. 4. Higher velocities are okay in the inlet nozzle if the internal piping allows a reduced velocity at the point of release to the tray. 5. Pump suction lines are sized primarily by NPSH considerations, the above values are typical operating ranges. 6. For reciprocating pumps, maximum instantaneous flow shall be used. 4.1.1.1.4 Special Limitations - Noise
Liquid velocities in straight run piping in excess of 4.6 m/sec will generally produce objectionable noise levels. For sizes 500 mm and larger, this velocity limit may be increased to about 6 m/sec. Where there are numerous bends, tees, valves, and discontinuities, the velocity limit for noise may be in the order of 2.4 to 3 m/sec. 4.1.1.1.5 Gases and Vapors
Vapor lines shall be sized to deliver the required quantity within the pressure limits available. The maximum velocity shall be limited to 122/ where is the density of the vapor in kilograms per cubic meter at flowing conditions. This is empirical limit to limit objectionable noise, vibration, and erosion. The general procedure for sizing a vapor line is to compute the density and determine the maximum velocity. Then, select a reasonable velocity less than maximum, using it to calculate a trial pipe size. The Reynolds Number can then be computed and a friction factor determined. The pressure loss per 100 meter is then calculated, and a check can then be made to see if the total loss is within the limits available in the system. Economics should be a controlling factor in some cases, such as where a gas must be compressed. Lines with excess noise shall be provided with insulation for noise protection. Vapor Hydraulics TABLE 4.1.1.1.5.1 Type of Service - Vacuum 0 1 bara - Low Pressure 0 6.9 barg - Med Pressure 6.9 20.7 Friction Loss Range bar/100 meter 0.01 - 0.02 0.02 -0.11 0.09 0.22 Velocity Range m/sec 38.1 60.9 15.2 30.5 9.1 30.5
PROCESS DESIGN CRITERIA barg - High Pressure 20.7 69 barg Steam Steam at 1.4 barg Steam at 6.9 barg Steam at 41.4 barg Instrument and utility air Natural Gas Fuel Gas Two Phase Flow (Note 2) Minimum Maximum 0.16 0.45 6.1 15.2
0.11 - mains 0.22 branches 0.22 - mains 0.45 - branches 0.45 0.90 0.11 0.22 0.11 0.22 0.07 0.20
22.9 25.4 22.9 25.4 22.9 25.4 15.2 45.7 15.2 45.7 15.2 45.7
V=73.2/() V=122/()
Notes: 1. Excludes vacuum transfer lines which are sized based on critical velocity limitations. 2. V is velocity in meter/sec and is the vapor density in kg / cubic meter 3. Pressure drop in ducts will be calculated according to ASHRAE criteria. 4.1.1.1.6 Liquid-Vapor Mixtures/Slurries
Due to the complex nature of these types of flow, no single correlation is adequate. Each area should be reviewed independently and the appropriate correlation used. In general, use correlations which include kinetic energy changes in the fluid mixture, particularly for horizontal and vertical piping runs, and have methods of checking for compressibility and sonic velocity of the vapor or gas fractions. Special care should be taken to examine viscosity and friction loss functions when fluids, slurries or mixtures can exhibit or become nonNewtonian in behavior. The average velocity of the mixture shall be greater than the calculated entrainment velocity, but less than the calculated erosion velocity. It is recommended that the friction pressure drop for a two-phase line should be limited to 1.1 bar/100 m. This is a general guideline. It may be better to operate outside of slug flow at the expense of a higher pressure drop, as long as the erosional velocity limits are not exceeded.
PROCESS DESIGN CRITERIA When calculating the line size for a two-phase system, consider potential minimum flow and expected maximum flow as well as the normal flow. Within limitations of available pressure drop, specify a line size that will yield stable flow for all cases considered. Annular and mist (dispersed) flows are stable and preferred for both horizontal and vertical flows. Stratified and bubble flows are stable in horizontal run. Bubble and churn flows in vertical run are also stable. Avoid slug, plug and wave flow regimes. If a compromise must be made, the normal operation requirement should dictate the line size followed by the maximum case. The minimum flow, with some exceptions, exists usually in standby or turndown conditions of short duration. Vertical risers shall be minimized and shall not be pocketed. For static calculation, weighted average density of vapor and liquid should be used. Be aware of full liquid head in the line during startup or shutdown operation. 4.1.1.1.7 Gravity Flow
Effective gravity flow through piping systems depends on the recognition of two regimes: self-venting flow and siphon flow. Liquid in a self-venting line occupies a portion of the pipe cross section, and gas moves freely with, or counter to, the liquid. Siphon flow refers to a liquid or two-phase downflow where pressure increases in the direction of flow. At lower liquid velocities, small quantities of gases rise freely, counter to the liquid flow. At higher velocities, gases are pulled down with the liquid. As the liquid velocity increases, gas rates first increase, then decrease as the frictional head approaches the elevation head. At the self-venting limit, long pipe-size bubbles are trapped inside the piping. Unless liquid, or a bend or obstruction seals the bottom of the pipe, a falling film will develop and the transition to siphon flow will occur. For gravity flow piping, siphon flow must be avoided, or provisions to break the siphon (e.g. vent lines) made. For vertical piping, self-venting criteria can be expressed as a function of velocity and gravity or reduced to pipe diameter as a function of flow (the Froude Number (Fr) shall be the main design criteria, which must always be smaller than 0.30). d > 43.496 (Q)0.4 , d, pipe diameter in mm Q, flow rate in m3/h 4.1.1.1.8 Condensate Systems
Condensate lines must be sized considering two phase flashing flow.
PROCESS DESIGN CRITERIA Flashing Condensate Pipe Size mm (sch) Capacity (kg/ h) From 1.4 barg to Atmosphere P = 1.4 bar 513 1,270 2,087 5,262 9,072 20,593 35,380 56,200 Capacity (kg/ h) From 6.9 barg to 1.4 barg P = 5.5 bar 662 1,633 2,722 6,804 11,340 26,580 46,085 72,620 Capacity (kg/ h) From 41.4 barg to 6.9 barg P = 34.5 bar 930 2,268 3,810 9,525 16,420 37,394 66,224 101,741
25 (80) 40 (80) 50 (80) 80 (80) 100 (40) 150 (40) 200 (40) 250 (40)
Note that max allowable velocity < 25.3 m/sec 4.1.2 Velocity Limits 4.1.2.1 Vortexing Velocity Liquid drawn out of the bottom of a vessel where liquid and vapor are in equilibrium or where a two phase liquid exists can entrap vapor or the lighter liquid by a vortex. In general, vortexing occurs when the static head above a liquid draw off connection is less than two (2) velocity heads. The simplest solution to a vortex is to install a vortex breaker in the draw off connection and to limit the line to a maximum outlet velocity of 1.8 m/sec 4.1.2.2 Steam Trap Condensate The condensate line from a steam reboiler to continuous drain shall be sized for a maximum velocity of 0.3 m/s. This limitation is set so that vapors will not get into the trap and affect its operation. Lines to and from bucket traps should be sized for the maximum capacity of the trap which is usually 2 or 3 times the average calculated flow. Keep in mind that during start-up, abnormally high flows will be handled by the trap. 4.1.3 Special Considerations In general, for atmospheric and higher pressure columns, 0.3 % of the operating absolute pressure shall be used as a maximum pressure drop per 100 meter of overhead piping. Overhead lines in vacuum service are generally sized on an available pressure drop, or least annual cost basis. Pulsation dampeners shall be provided on all reciprocating compressor suction and discharge piping. Allow 1% of the discharge operating pressure for the dampener pressure drop; this may require reduction for high pressure and multistage machines.
PROCESS DESIGN CRITERIA Suction and discharge lines for positive displacement pumps shall be sized for 160% of the pumping rate. Suction and discharge lines of proportioning pumps shall be sized for 300% of the pumping rate. Pulsation dampeners should be provided on at least the discharge piping and in some cases the suction piping. Allow 1% of the discharge operating pressure for the dampener pressure drop; this may require reduction for high pressure and/or multistage pumps. Start-up, shutdown, fill, off-test and unit by-pass lines may be required in operating units. Start-up and shutdown lines shall generally be sized for 50% of normal flow. Fill lines shall be sized to fill system in a reasonable time, depending upon service. Likewise, with pressurizing lines, an off-test header shall be sized for 50% of the flow of all products into the header. Unit by-pass piping shall generally be sized for full flow. Lines in these services shall be sized to consume all available pressure drops. 4.1.4 Vacuum Piping Most vacuum applications in the chemical process industry pertain to systems operating at absolute pressures of 1 torr (1 mm Hg) and above. At these pressure levels, the conventional methods applicable for laminar and turbulent flow may be used. Modifications to pressure drop calculation methods are necessary in medium and high vacuum regions (below 1 torr) since the mean free path of molecules approaches or exceeds the pipe diameter at these low pressures. All flanges > 100 mm on vacuum service shall be weld lip sealed except where noted by BASF. 4.1.5 High Viscosity Fluids There are several services in the process where the viscosity of the fluid can be very high causing the flow regime to fall into the laminar flow region. These cases may require special analysis where the piping layout etc may be critical. Where it has been decided to perform a detailed analysis it will be necessary to use appropriate design methods to ensure that line sizing and pressure drops in these laminar services do not result in oversized or undersized pumping equipment. Based on previous Fluor experience the preferred method to estimate the head loss in the laminar flow regime to use is the Two K method. The following procedure should be used to estimate the pressure drop in the laminar flow regime using the two-K method: 4.2 Calculate the equivalent length of the piping and fittings using the two-K method Plug in this value of equivalent length to calculate the pressure drop
Pipe Line Design Conditions The pressure and temperature design criteria for piping systems, shall conform to the piping specifications 4.2.1 Design Pressure In general the design pressure of piping shall be set by one of the following
PROCESS DESIGN CRITERIA The set pressure of the relief valve when mounted on the line. The set pressure of the relief valve on equipment when connected to the line plus the static head and friction loss. The maximum pressure that the equipment connected to the pipeline can generate, such as the shutoff head of centrifugal pumps or the stalling pressure of reciprocating pumps. The shutoff condition should consider the normal suction pressure plus 125% of the differential pressure at normal capacity, or the maximum suction pressure plus the differential pressure at normal capacity, whichever is higher. If a shutoff condition can also cause maximum suction pressure, then use the maximum suction pressure plus 125% of the normal differential head. For high head and vertical pumps the shutoff pressure may be more than 125 % of the normal differential. In such cases, special considerations may apply.
Piping downstream of a control valve station shall have a line class selected for the downstream design conditions. When block valves are installed downstream, the downstream piping through the block valves shall have a line class selected for the design conditions of the control valve station, unless protected by a relief device. Pump suction piping inside block valves shall be rated for pump discharge pressure. Compressor suction piping, including pulsation bottles, shall have the same pressure rating as the discharge piping up to and including the first suction block valve. If positive displacement pumps are not equipped with a built-in pressure relieving device and if the stalling pressure of the pump is greater than the maximum pressure rating of the discharge piping and pump casing, a separate relief valve from discharge to suction must be installed. The following table shall be used for relief valve setting for positive displacement pumps, which, in turn, sets the pressure rating of the piping. The table gives multiplying factors to be applied to the normal pump discharge pressure. Table 4.2.1 Relief Valve Settings For PD Pumps Pump Type Simplex Duplex Triplex Without Dampener 1.5 1.4 1.3 With Dampener 1.3 1.25 1.2
Utility system design criteria will be established on the basis of required operating pressures and the resulting design pressures. As a general practice, most pump suction lines down stream of the suction valves should be rated for the same pressure as the pump discharge line ( for the case where the pump suction could be pressurized though a non-return valve malfunction).
PROCESS DESIGN CRITERIA 4.2.2 Maximum Operating Temperature Maximum operating temperature (pipe design temperature) is defined as the metal temperature representing the most severe condition of coincident pressure and temperature. Some general guidelines for pipe design temperature are: Normal fluid temperature plus 28C A minimum temperature of 150C for lines to be steamed out. The control temperature setting for steam or electrically traced lines Abnormal conditions, such as regeneration or start-up conditions.
Note that failure shall not be considered as a criterion for setting maximum operating temperature. The maximum operating temperature is normally set above the normal operating temperature because it is usually impossible to be able to calculate the exact flowing fluid temperature. Variations in compositions and operating pressures will influence the operating temperature in the system. Fouling of heat exchangers and furnaces has a great influence on the fluid temperatures. Heat exchangers, when new and clean, will usually have a much higher transfer rate and consequently higher temperatures. The temperature in the clean (unfouled) state should be considered while fixing the design temperature. In cases where a heat exchanger or an equipment in which heat is being applied can be removed or bypassed, the line downstream of the equipment or heat exchanger should be designed for the high temperature, with the heat exchanger or equipment in service. Some instances may arise where the design of the line with respect to wall thickness, etc., is not influenced too much by the temperature selected and, therefore, designers may be tempted to arbitrarily apply a high design temperature. This practice is discouraged because these temperatures are used for other purposes such as stress checks, supports design, hydro test setup, etc 4.3 Piping Details The following piping details shall be used wherever applicable. Battery limit block valves shall consist of a double block and bleed. Spectacle blinds shall be included for cases where the piping installation is too stiff to "spring" the line. Start-up and shut-down bypass and circulation lines should be provided with each unit to reduce slops production. Lines that are normally used only during start-up and shutdown should be double valved out of service. Bypass and circulation lines should be sized for 50% of the normal flow. Facilities for removal of air before introduction of hydrocarbon feeds should be provided.
PROCESS DESIGN CRITERIA Piping in vacuum service shall be as short as possible and the use of bends and fittings shall be minimized to keep pressure drop low. Piping joints will also be minimized to reduce the possibility of leakage. To prevent overpressure during blocked-in condition because of heat input, lines shall be provided with thermal relief. Typically, steam traced liquid lines, cold solvent lines, refrigerant lines, and long transfer lines to docks, storage areas and loading areas would require thermal relief. The minimum line size to be used is 20 mm. Line sizes of 32 mm, 65 mm, 95 mm, 125 mm, 175 mm, and 225 mm shall only be used in special applications such as jacketed pipe or pneumatic conveying systems.. Additional information on piping is also provided in section 3 (Equipment) of these criteria. Thermal Expansion Relief Valves are generally not required for: Process piping Storage or transport piping sections which are not normally shut off for operational or emergency purposes Lines normally containing two phase flow Heat traced lines, not blocked in as part of normal operation
Thermal Expansion Relief Valves are normally required for: 4.4 The cold side of heat exchangers, which can be blocked-in Sections of piping containing light hydrocarbons (lighter than gasoline) or toxic material which could normally be blocked-in. Piping in storage areas or transport lines which will be regularly blocked-in during normal operation. Large vessels or exchangers operating liquid full (unless administrative controls prevent blocking-in the vessels liquid full).
Piping Requirements for Sampling When sampling corrosive liquids, flush sample to an appropriate recovery sump. A drain funnel to the appropriate sewer (oily sewer, chemical sewer, etc.) shall be provided at all sample connection points. Drain pipe shall be of appropriate material of construction considering corrosion. Typical design for slurry samples includes ram valve followed with spring return valve, with lock-ability (so can lock open for LOTO purposes). The use of sample removal systems (e.g. Dopak or equivalent) will be decided on a case by case basis.
PROCESS DESIGN CRITERIA 5.0 INSTRUMENTATION Process design data for the sizing and selection of instrumentation will be specified by the Process Engineer. The data must be consistent with that from the design basis or PFDs.
5.1
Control Valves 5.1.1 Control Valve Sizing Sufficient pressure drop must be allowed for control valves to obtain good regulation, maintain flow characteristics, and obtain desired maximum capacity. It is important that a valve pressure drop allowance be made in specifying pumps, blowers, compressors and reboilers. The following minimum control valve pressure drops are for normal applications. A check should be made for hydrostatic head, but this should not be included in the variable system pressure drop. Control valve sizing on pumped systems will be for 50125% of the normal flow in concert with the pump curve for the system and include start-up, shutdown, and catch-up conditions. The valve design should take 20% of the total dynamic system pressure drop at design conditions, including the Cv (or 50% of the dynamic or friction system pressure, excluding the Cv) or 1 bar minimum. For control valves in the steam line to reboilers, the allowable pressure drop shall be 5% to 10% of the initial absolute steam pressure. When operating with low pressure steam, at a pressure of 2 barg or less, a minimum drop of 0.28 bar shall be used. For automatic pump start-up where the control valve is in the steam line to the pump driver, the control valve shall be line size. The resulting pressure drop is not a factor for sizing and should be 0.28 bar or less. For self-contained control valves, the maximum allowed pressure on the outlet side should be checked and the control valve should be protected by a relief device if necessary.
5.2
Pressure/Temperature Elements Selection of pressure and temperature elements will be coordinated by the instrumentation engineers. Standard sizes and types will be used to provide consistency. Consult with Instrumentation for this information. Spans and ranges must be suitable for all parts of the operating, startup, shutdown, and, where applicable, regeneration services. These and materials of construction, tracing, etc. must be coordinated with the instrumentation engineers.
6.0
RELIEF / VENTING SYSTEMS BASF and Fluor have agreed on systems/methods & format for Pressure Safety Valve (PSV) calculations and Data Sheets.
PROCESS DESIGN CRITERIA 7.0 MATERIALS OF CONSTRUCTION Materials of construction and corrosion allowance shall be specified by BASF for the units designed by BASF. For the units designed by Fluor material of construction and corrosion allowance shall be specified by metallurgist. 8.0 WINTERIZATION Winterization refers to measures taken to prevent failure of plant operations due to excessive heat loss to the environment. Excessive heat loss can cause problems as a result of : - Freezing or congealing of liquids - Increased liquid viscosity - Condensation of liquids from vapor streams - Crystallization of solids from liquid solutions - Separation of a single liquid phase into two liquid phases - Formation of ice crystals or hydrates in gas streams These phenomena become more pronounced as the ambient temperature falls. Winterization techniques are applied in such cases to ensure continuity of plant operation. The common techniques used for winterization are: -operating techniques -insulation -protective heating by tracing (steam or electric) or use of liquid media heating systems -heated buildings Winterization covers all on-site, utility and off-site systems which may be affected. In order to ensure a uniform approach by the various project disciplines, the winterization requirements for this project shall be reviewed with BASF, and documented as the basis for detailed design efforts by each discipline. 9.0 Utility Conditions Refer to Section 1.8 for Utility Conditions
PROCESS DESIGN CRITERIA APPENDIX A: DESIGN PRESSURE FOR EQUIPMENT AND PIPING
DESIGN PRESSURE FOR EQUIPMENT AND PIPING (1) (2)(4)(5)(14)(15) MAXIMUM OPERATING PRESSURE (3), BARG Vessels/Columns/Reactors (21) Full or Partial Vacuum(2) 0-2.4 2.5-10.3 2.5-6.9 7-10.3 10.4-17.2 17.3-34.5 34.5-68.9 68.9+ Centrifugal Compressors Casing/Discharge Piping (Ref. API RP 617) Reciprocating Compressors Casing/Discharge Piping(18) 0-10.3 10.4-172.3 172.4-241.3 241.4-344.7 344.7 Heat Exchangers For Pumped Systems: Heat exchangers shell-side and tube-side; Air cooled exchanger tubes For Non-Pumped Systems: Heat exchangers shell-side and tube-side; Air cooled exchanger tubes Full or Partial Vacuum(2) 0-2.4 2.5-10.3 2.5-3.4 3.5-10.3 10.4-17.2 17.3-34.5 34.5-68.9 68.9+ Fired Heaters Heater Tubes in Pumped Systems Heater Tubes in Non-Pumped Systems Full or Partial Vacuum(2) DESIGN PRESSURE, BARG
-1.0/3.4 3.4 MOP + 1.0 MOP + 1.7 MOP + 1.7 110% MOP MOP + 3.4 105% MOP 125% Maximum Pressure (13)
(19)
Discharge
MOP + 1.0 110% MOP 108% MOP 106% MOP (Note 20)
(5)(6)(7)(8)(9)
(5)(7)(8)(9)
-1.0/5.2 5.2 5.2 MOP + 1.7 MOP + 1.7 110% MOP MOP + 3.4 105% MOP
(5)(6)(7) (5)(7)
-1.0/10.3
PROCESS DESIGN CRITERIA DESIGN PRESSURE FOR EQUIPMENT AND PIPING (1) (2)(4)(5)(14)(15) MAXIMUM OPERATING PRESSURE (3), BARG 0-9.3 9.4-68.9 68.9+ Pumps, Centrifugal and Reciprocating Pump Suction Pump Discharge Tankage(10,11,12) Atmospheric Tankage Pressurized Tankage Refrigerated Tankage Piping (2) Full or Partial Vacuum 0-2.4 2.5-10.3 2.5-6.8 6.9-10.3 10.4-17.2 17.3-34.4 34.5-68.9 68.9 + Relief and Flare System PSV Discharge Piping to Unit Flare Knockout Drum Flare Knock-out Drum and Downstream Piping Notes: (1) This table provides guidelines for specifying design pressure (also referred to as mechanical design pressure). This pressure corresponds to the design pressure at the high point in any system (e.g. top of vessel in vapor space). The design pressure at the low point in the vessel or piping system shall be equal to the design pressure at the high point plus static head at maximum liquid level and any additive pressure drop (including trays). The design pressure is equal to or less than the Maximum Allowable Working Pressure (MAWP) as calculated by the Mechanical Engineer after actual components used to fabricate the vessel are selected. (2) Guidelines for External Design Pressures (also referred to as Lower Design Pressures) are provided below: a. Only equipment and piping that operate with full or partial vacuum during process start-up, normal operation, or upset modes shall be designed for an external pressure. b. Equipment and piping in the following services will be designed for full vacuum: Equipment operating under partial or full vacuum during normal operation Suction drum for a compressor or vacuum pump Equipment containing steam or stripping steam during normal operation, such as sour water strippers and amine regenerators. DESIGN PRESSURE, BARG 10.3 110% MOP MOP + 7
(13)(14) (13)(14)
63.5 mm w.g. 110% MOP MOP

(13)(14)(15)(16)
-1.0/3.4 3.4 MOP + 1 MOP + 1.7 MOP + 1.7 110% MOP MOP + 3.4 105% MOP 6.9 Minimum (17) 6.9 Minimum
PROCESS DESIGN CRITERIA c. Special consideration shall be given to the design for external pressure for equipment normally subject to internal pressure but connected to the suction of a compressor or other evacuating equipment. Low- pressure equipment that may be affected by decrease in ambient temperatures should also be considered, such as overhead receivers operating at low pressure and receiving feed from an air-cooled exchanger. Specifically, the equipment shall be designed for the appropriate pressure rating, and the external pressure the equipment will withstand at this pressure rating shall be calculated by the Mechanical Engineer and shown on the equipment data sheet. d. Steam-out and Vacuum Design: Vessels that need steam-out as part of routine operations or require process steam during normal operation shall be designed for 1 barg external pressure. Vessels that require steam-out only during maintenance and do not require process steam during normal operation may be specified for an external design pressure of 0.5 barg instead of 1 barg. (3) Maximum Working Pressure (MWP) or Maximum Operating Pressure (MOP) as referred to in this table is defined as follows: a. The MWP or MOP is defined as the process operating condition that would give highest coincident fluid pressure and temperature calculated for steady balance operation or operations. Such conditions shall include anticipated variations in fractionation requirements, charge stock composition, and other process variations. b. Normal fluid operating pressure shall be determined for top and bottom of vessel and at intermediate sections (as necessary). Pressure for sections at lower elevations shall be top pressure plus any applicable liquid head and additive pressure drop. c. Alternate operating conditions shall be considered, such as, catalyst regeneration, short time operational upsets, and auto-refrigeration. Auto-refrigeration is a process in which liquid vaporizes and cools during depressurization. d. If more than one operation (blocked operation, start-of-run, end-of-run) or cyclic operations may occur, operating conditions for each operation or cycle phase shall be determined. (4) For establishing design pressures for equipment and piping in reactor loops (reactors, vessels, heat exchangers and piping), refer to the guidelines provided in API RP-520 Part I, Appendix B. The settle-out pressure of the system may control the design pressures of equipment in the reactor loop. Settle-out pressure is the pressure of the system when the compressor is shut down. (5) For equipment and piping subject to steam-out, a minimum design pressure of 3.5 barg at 150C shall be specified. (6) For pumped systems, if heat exchangers or other equipment could be subject to maximum pump discharge pressure at shutoff (existence of a block valve downstream of the exchanger), design pressure shall be 100% of the shutoff pressure. For cooling water, the design pressure shall be the shutoff pressure of the cooling water circulation pump. (7) For reactor loops, the design pressures of the heat exchangers and other equipment are typically set by the reactor loop design pressures (See Note 4 above). (8) When establishing design pressures for shell-side and tube-side of heat exchangers, considerations should be given to the application of API RP 521 "10/13" rule to prevent the likelihood of a tube rupture scenario. For incompressible fluids (liquid full systems), the "10/13" rule is generally applicable, i.e., the design pressure of the low-pressure side shall be at least 10/13 of the design pressure of the high-pressure side. For compressible fluids (vapor or two phase), a tube failure analysis is generally performed to determine the relief rate associated with a tube rupture case before the "10/13" rule is applied. The tube rupture relief loads for compressible fluids must be within the flare capacity of the unit. Some Clients may request that the "10/13" rule be applied for all services.
PROCESS DESIGN CRITERIA (9) Differential pressure shall be specified on the heat exchanger data sheet. The differential pressure shall be the maximum difference in operating pressures between the shell-side and tube-side considering normal, startup and shutdown conditions. (10) W.g - internal water pressure, mm gauge. W.v. - external water pressure, mm vacuum. (11) Design tank for a vacuum of 38 mm w.v. (12) Consult with Fluor Mechanical before specifying design pressures for tankage. (13) a. b. Design pressure of discharge piping for centrifugal pumps and compressors shall be at least equal to maximum discharge pressure for all operating conditions. For centrifugal pumps, design pressure for suction piping upstream of suction block valve shall be equal to the set pressure of the suction pressure safety valve plus static head at maximum liquid level in pump suction system, or maximum shutoff supply pressure from suction booster pump, whichever is applicable. For centrifugal pumps, design pressure for discharge piping and suction piping downstream of suction block valve shall be equal to maximum head at low or no flow based on purchased pump performance curve. Pump shutoff head can also be estimated as follows: Maximum suction (barg) + Normal P (bar), or Normal suction (barg) + 1.25 x Normal P (bar), whichever is greater.
c.
The shutoff head shall be determined at the maximum liquid density anticipated. d. For centrifugal compressors, the design pressure of the compressor discharge shall be at least equal to the specified relief valve setting; if a relief valve setting is not specified, the design pressure shall be at least 1.25 times the maximum specified discharge pressure (refer to API RP 617). This is an approximation of the maximum head at low or no flow to avoid the need for a relief valve. Maximum head for compressor shall be based on maximum molecular weight gas anticipated. e. Maximum driver speed shall also be considered in calculating the maximum head. (14) Design pressure of piping and equipment protected by a pressure relief valve (PSV) on an interconnected equipment system (i.e., several equipment items protected by a single relief valve) shall not be less than the pressure expected when PSV reaches set pressure. Protected piping and equipment located upstream of the PSV takeoff location shall have a design pressure sufficiently higher than the PSV set pressure to account for maximum system pressure drop between protected piping and PSV location. Protected piping and equipment located downstream of PSV takeoff location shall have a design pressure at least equal to PSV set pressure to account for minimum pressure drop of zero for no flow. Consideration should be given to the following conditions in specifying the design pressure of piping and equipment: Starting up operations, including any start-up procedure, operation, or routing. Shutting down operations, including shutdown procedures, operation, and pump-out. Switching operations, including any cyclic regeneration, spare pump switching, and coke drum switching. Regeneration procedures. Equipment bypassing. Turndown operations. Pump shutoff. Control valves in fully open or fully closed position.
(15)
PROCESS DESIGN CRITERIA Block valves in fully open or fully closed position, except for locked valves. Blocked exits. Equipment trip or shutdown. Misoperation. Maintenance, repair, or neutralization procedures. On-stream testing procedures. Steam-out or purging operations. Other causes of increased pressure. (16) Separate combination of design pressure and temperature may be considered to accommodate different modes of operation, e.g. regeneration versus normal operation, taking into consideration rating of the piping for short term condition in conformance with the ASME B31.3 piping code. PSV discharge piping shall be designed for at least the maximum back pressure. For reciprocating compressors, the MOP is equal to the rated discharge pressure, in barg. Based on API RP 618. Per API RP 618, for reciprocating compressors with a rated discharge pressure above 345 barg, the relief valve setting shall be as agreed to by the purchaser and the vendor. In the event the flare system is limited such as in a revamp situation, higher design pressure may be specified to minimize the relief load.
(17) (18) (19) (20) (21)
PROCESS DESIGN CRITERIA APPENDIX B: DESIGN TEMPERATURE FOR EQUIPMENT AND PIPING
DESIGN TEMPERATURE FOR EQUIPMENT AND PIPING(1)(2)(3)(4) DESIGN TEMPERATURE, C Vessels/Columns/Reactors(5) Compressors(6) Heat Exchangers S & T and Air Cooled Heat Exchangers Fired Heaters Heater Tubes Pumps Tankage Atmospheric Tankage Pressurized Tankage Refrigerated Tankage -23C to ambient Operating Temperature -62C to 23C Operating Temperature Below 62C Operating Temperature Piping(7) Relief and Flare System PSV Discharge Piping to Unit Flare Knockout Drum Flare Knockout Drum and Downstream Piping Notes: (1) This table provides guidelines for specifying design temperature (also referred to as mechanical design temperature). This design temperature should be equal to or lower than the Maximum Allowable Working Temperature (MAWT) to be calculated by Mechanical after actual components used to fabricate the equipment are selected. (2) Maximum Working Temperature (MWT) or Maximum Operating Temperature (MOT) as referred to in this table is defined as follows: (a) The MWT or MOT is defined as the process operating condition that would give highest coincident fluid pressure and temperature calculated for steady balance operation or operations. Such conditions shall include anticipated variations in fractionation requirements, charge stock composition, and other process variations. (b) Normal fluid operating temperature shall be determined for top and bottom of vessel and at intermediate sections (as necessary). (c) Alternate operating conditions should be considered, such as, catalyst regeneration, short time operational upsets, and auto-refrigeration. (d) If more than one operation (blocked operation, start-of-run, end-of-run) or cyclic operations may occur, operating conditions for each operation or cycle phase shall be determined. (3) Consideration should be given to the following conditions in specifying the design temperature of piping and equipment: MOT(2) + 28 MOT + 28 MOT + 28 MOT + 28 MOT + 28 MOT + 28 MOT + 28 Minimum Operating Temperature -14 Minimum Operating Temperature -6 Minimum Operating Temperature MOT + 28
(8)
(8)
PROCESS DESIGN CRITERIA Fouling of heat exchangers. Loss of utility. Starting up operations, including any start-up procedure, operation, or routing. Shutting down operations, including shutdown procedures, operation, and pump-out. Switching operations, including any cyclic regeneration, and coke drum switching. Regeneration procedures. Equipment bypassing. Turndown operations. Control valves in fully open or fully closed position. Block valves in fully open or fully closed position, except for locked valves. Equipment trip or shutdown. Misoperation. Maintenance, repair, or neutralization procedures. Steam-out or purging operations. Other causes of increased temperature. (4) For equipment and piping subject to steam-out, specify minimum design conditions of 150C and 3.5 barg. (5) If MOT is greater than 232 C, divide column into two or more zones. (6) For reciprocating compressors, the maximum allowable discharge temperature (MOT) shall not exceed the limits stipulated in API RP 618, Reciprocating Compressors for Petroleum, Chemical, and Gas Industry Services. Typically, the maximum predicted discharge temperature should not exceed 150C. This limit applies to all specified operating and load conditions (to be provided by the vendor). Special consideration shall be given to services with high-pressure hydrogen or applications requiring non-lubricated cylinders, where temperature limitations should be lower. Predicted discharge temperatures shall not exceed 135C for hydrogen-rich services (those with molecular weight of 12 or less). Note that recommended discharge temperature alarm and trip set points are 22C and 28C, respectively, over the maximum predicted discharge temperature; but in no case should temperature trip set points exceed 177C. To prevent auto-ignition, lower temperature set points limits should be considered for air because of its oxygen content, if the discharge pressure exceeds 20.7 barg. Use of synthetic oils, although not intended as a means to increase the allowable discharge temperature, should be considered for additional safety (Ref. API RP 618, para. 2.3). (7) Separate combination of design pressure and temperature may be considered to accommodate different modes of operation, e.g. regeneration versus normal operation, taking into consideration rating of the piping for short term condition in conformance with the ASME B31.3 piping code. (8) Design temperature for relief and flare system shall be based on temperature of fluid being relieved, taking into account temperature change across PSV and thermal effects in discharge piping. Discharge piping shall be designed for the expected temperature of the piping during relief.

G3ir 1000 25 SP 9001 - R1

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Client Name : BASF India Limited Project Name : Project GIR Project Number : G3IR

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PROCESS DESIGN CRITERIA

Business Unit Discipline Document Type

General Process Specification

PROCESS DESIGN CRITERIA

ISSUED FOR DESIGN

Issued for Design Purpose

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PROCESS DESIGN CRITERIA

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INSTRUMENTATION ................................................................................................................... 64 5.1 Control Valves ............................................................................................................. 64

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6.0 7.0 8.0 9.0

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PROCESS DESIGN CRITERIA

3.0 4.0 5.0 6.0

7.0 8.0 9.0 10.0

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16.0 17.0 18.0 19.0 20.0 21.0

22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0

Flexibility and Expansion

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40 GIDC 1 3.5 6 Maximum

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1.74 8.07 1.7 NTU < 5, (Pt. Co.Scale) 267.1

107 121 180

152 185 100 130

3 3.5 7.5 Pressure bar(g)

AMB AMB 70 Temperature deg C AMB AMB 70 Temperature deg C 90 120

5.3 8.8 12 Pressure bar(g) 6.5 9

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240 240 24 V DC / 110 415

phase phase phase phase

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15-20% 20-25% 15-20% 20-25%

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Materials of Construction Materials of construction will be specified by BASF.

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PROCESS DESIGN CRITERIA V W Vapor or Vent Relief Valve Connection

- kg/m3, density of average mixture at flow conditions.

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()0.5 Maximum Suction Box Velocity m/sec 0.30 0.6

Maximum Nozzle Velocity, m/sec

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Design Pressure Refer to Appendix A for design pressure of storage tanks.

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PROCESS DESIGN CRITERIA