Sr. No.

PSV location PSV Tag

1 PSV 6

Splitting Column
(C-221)
Ground Floor PSV

2 PSV 7

3 PSV 1

HP boiler safety
valve
 HP boiler safety
valve

4 PSV 2

Blend oil pump

5 PSV 3
(P-221)

DM water pump
6 PSV 4
(P-222)
 Standby Oil and
7 Water pump PSV 5
(P-223)

8 MP steam PSV 9
9 K1 Heat exchanger PSV 8

Main Still
10 RD1
(C-251)
 Back end Still
11 RD2
(C-281)
 Assumptions to be made

Data provided by site's mail on 24/01/2018

a) The set pressure for PSV 7 & PSV 6 will be considered as 62kg/cm2 and 60kg/cm2 respectively.
b) Operating flow rates (Blend oil inflow: 4 tones/hr, DM water flow: 1.5 tones/hr)
c) Operating conditions of column : 56Kg/cm2 at 260 °C (Per PFD data)

Data reference from HUL kolkata site

a)Design pressure is 66.8kg/cm2 based on nameplate snap from field.
b)Operating flow rates ( Column top HP steam flow: 350 kg/hr, column bottom HP steam flow: 400 kg/hr, outlet CSFA flow
Water flow: 2.25 tones/hr)
c) Sweet Water composition for splitting column relief
Glycerol : 7% wt
Water : 93% wt
However, for analysis purpose 100%wt water concentration for Sweet Water will be taken considering PSV are in sweet wa
d) Blend oil properties :
Specific gravity :0.9 at 30°C
Boiling point : 353.8°C at 760mmHg
Viscosity : 7.8cp at 70°C
Molecular weight : 256.0
Please confirm to use these properties or else require detailed composition of Blend oil.

Assumptions based on data provided by site till date:

1. Upstream HP steam relief device limiting pressure will be considered based on concurrence on discrepancy raised abou
PSVs.
2. Upstream DM and Blend Oil Pump PSVs limiting pressure will be considered based on concurrence on discrepancy raise
PSVs.

Data provided by site's mail on 24/01/2018:

PSV size : 1.5 H2 3

Set pressure : 75kg/cm2
Flowrate in each equipment : 3.5 tons/hr

There is discrepancy in set pressure of PSV 1 and PSV 2. Per 'DFA PSV and RD list' sheet of provided spreadsheet; set press
kg/cm² and 70 kg/cm² respectively, while per 'HP Boiler Safety Valves' sheet of document; set pressure of both the PSVs is
SOP' spreadsheet; set pressure of PSV 1 and PSV 2 is 67 kg/cm² and 68 kg/cm² respectively. Hence require confirmation ab
PSVs.

Data provided by site on 12/02/2018:

a)There are three HP boilers with each boiler having capacity of 3.5 TPH. Therefore, maximum design capacity will be cons
listed boiler for blocked outlet scenario. Please confirm.
Flowrate in each equipment : 3.5 tons/hr

There is discrepancy in set pressure of PSV 1 and PSV 2. Per 'DFA PSV and RD list' sheet of provided spreadsheet; set press
kg/cm² and 70 kg/cm² respectively, while per 'HP Boiler Safety Valves' sheet of document; set pressure of both the PSVs is
SOP' spreadsheet; set pressure of PSV 1 and PSV 2 is 67 kg/cm² and 68 kg/cm² respectively. Hence require confirmation ab
PSVs.

Data provided by site on 12/02/2018:

a)There are three HP boilers with each boiler having capacity of 3.5 TPH. Therefore, maximum design capacity will be cons
listed boiler for blocked outlet scenario. Please confirm.

Data provided by site's mail on 24/01/2018:

Set pressure : 64 kg/cm2
Flowrate : 4 tons/hr
Operating pressure: 60 bar

Data reference from HUL kolkata site :

Blend oil properties :
Specific gravity :0.9 at 30°C
Boiling point : 353.8°C at 760mmHg
Viscosity : 7.8cp at 70°C
Molecular weight : 256.0
Please confirm to use these properties or else require detailed composition of Blend oil.

Data provided by site on 12/02/2018:

1. Operating temperature will be considered as 145 °C per 'Process Manual' Document. Please confirm.
There is discrepancy in set pressure of PSV 3. Per 'DFA SOP' spreadsheet; set pressure of PSV 3 is 61 kg/cm² , while per 'DF
set pressure of the PSV is 64.0 kg/cm². Hence require confirmation about set pressure of PSV.

Data provided by site's mail on 24/01/2018:

PSV size : 1D2

Set pressure : 66.6 kg/cm2
Flowrate : 1.5 tons/hr
Operating conditions: 60 bar and 40°C

There is discrepancy in set pressure of PSV 4. Per 'DFA PSV and RD list' sheet of provided spreadsheet; set pressure of PSV
'DFA PSV 4' sheet of document; set pressure of the PSV is 66.6 kg/cm² also per 'DFA SOP' spreadsheet; set pressure of PSV
confirmation about set pressure of PSV.
Data provided by site's mail on 24/01/2018:
PSV size : 1D2
Set pressure : 63.8 kg/cm2
Flowrate : 4 tons/hr
Operating pressure: 60 bar

Data reference from HUL kolkata site:

Blend oil properties :
Specific gravity :0.9 at 30°C
Boiling point : 353.8°C at 760mmHg
Viscosity : 7.8cp at 70°C
Molecular weight : 256.0
Please confirm to use these properties or else require detailed composition of Blend oil.

Data provided by site on 12/02/2018:

1. Operating temperature will be considered as 145 °C per 'Process Manual' Document. Please confirm.

Data provided by site's mail on 24/01/2018:

Data of PSV 9 provided:

PSV size : 1.5 F 2
Set pressure : 10 kg/cm2
Flowrate : 600 kg/hr

There is discrepancy in PSV tag. PSV tag given in scope list is PSV 9 and same is mentioned in Isometrics drawing, while da
Set pressure of PSV 9 is 8 kg/cm2 and Set pressure of PSV 10 is 10 kg/cm2, Kindly confirm PSV and its set pressure which is
header.

Upstream Control valve Cv will be considered as 50 based on data provided.

Data provided by site's mail on 24/01/2018 :

Set pressure : 7.5 kg/cm2

Data provided by site's mail on 24/01/2018:

Operating pressure : 748 mmHg (Per 'DFA SOP' Data)

Operating temperature : 200-250 deg C
Burst pressure : 0.54 kg/cm2 at 250°C
RD Manufacturer: BS&B with DV model
RD size: 4"

There is discrepancy in rupture pressure of RD1. Per 'DFA PSV and RD list' sheet of provided spreadsheet; rupture pressure
per 'RD1' sheet of document; rupture pressure of the RD is 0.54 kg/cm². Hence require confirmation about rupture pressu
Data provided by site's mail on 24/01/2018:

Operating pressure : 750 mmHg

Operating temperature : 200-250 deg C
Burst pressure : 0.492 kg/cm2 at 250°C
RD Manufacturer: BS&B with DV model
RD size: 4"

There is discrepancy in rupture pressure of RD2. Per 'DFA PSV and RD list' sheet of provided spreadsheet; rupture pressure
per 'RD2' sheet of document; rupture pressure of the RD is 0.492 kg/cm². Hence require confirmation about rupture pres
 Data still outstanding/pending

1. P&ID and PFD (Operating flow rate) of the

splitting column and associated equipment. a) Ok
Note that PFD will be required if Operating flow b) Ok
rate is not confirmed based on data from HUL c) Ok
Kolkata site.
2. PSVs inlet pipe length and outlet pipe length Data Reference
required (as details are not provided in a) Design Pressure mentioned in sheet 1
isometrics drawing). b) Top HP steam flow -0 , column bottom HP
3. Design condition of the splitting column and steam flow , outlet CSFA flow : 4.5 tones/hr ,
associated equipment. outlet Sweet Water flow : 1.1 tonnes / hr
4. Require confirmation about external fire
scenario applicability due to flammable liquid c) Ok
pool formation in the splitting column vicinity. d) Ok

1.Boiler design data (Design pressure, Design

Temperature, Manufacturer and design code)
and confirmation on Maximum design capacity 1. Ok
will be required. 2. Attached in sheet
2. PSVs inlet pipe length and outlet pipe length 3. Flammable material not available
required (as details are not provided in
isometrics drawing). PSV 1 - 69 kg/cm2 and PSV 2- 70 kg/cm2
3. External Fire scenario will be considered to be
less severe than blocked outlet if flammable
liquid is present inside HP boiler PSV area to form
pool of liquid. Please confirm. Or else require
dimension details of boiler for fire calculations if
fire needs to be performed.
will be required.
2. PSVs inlet pipe length and outlet pipe length
required (as details are not provided in
isometrics drawing).
3. External Fire scenario will be considered to be
less severe than blocked outlet if flammable
liquid is present inside HP boiler PSV area to form
pool of liquid. Please confirm. Or else require
dimension details of boiler for fire calculations if
fire needs to be performed.

1. P&ID and PFD (Operating temperature if it's

not confirmed based on process manual data) of
the blend oil pump.
2. PSV inlet pipe length and outlet pipe length
required (as details are not provided in
isometrics drawing).
3. Design condition (Casing Design pressure) of
the blend oil Pump. Or else require confirmation
about using set pressure as design pressure.
4. PSV size is not confirmed as manufacturer
catalog is not available for listed SEBIM safety 1. Ok
valve. Please confirm the model number, orifice 2. Data reference from Kolkata site :Ok
size and coefficient of discharge or provide the 3. Operating temp -Ok
manufacturer catalog mentioning these details. Set pressure - 61 kg/cm2

1. P&ID of the DM water pump.

2. PSV inlet pipe length and outlet pipe length
required (as details are not provided in
isometrics drawing).
3. Design condition (Casing Design pressure) of
the DM water pump. Or else require 1.Ok
confirmation about using set pressure as design 2.Ok
pressure. 3. Set pressure - 61 kg/cm2
4. Design pressure - 64 kg/cm2
1. P&ID and PFD (Operating temperature if it's
not confirmed based on process manual data) of
the Standby pump.
2. PSV inlet pipe length and outlet pipe length
required (as details are not provided in
isometrics drawing).
3. Design condition (Casing Design pressure) of
the Standby pump. Or else require confirmation
about using set pressure as design pressure. 1.Ok
4. Please confirm that analysis for this standby 2.Ok
pump will be done for Blend oil composition 3. Set pressure - 61 kg/cm2
only. 4. Design pressure - 64 kg/cm2
5) Oil

1. As PSV on MP steam header, details of

upstream PSV will be required for limiting
pressure check.
2. PSV inlet pipe length and outlet pipe length
along with line size of inlet and outlet piping and
MP steam header connection point is required
(as details are not provided in isometrics
drawing).
3. Operating condition(flow, pressure &
temperature) & P&ID will be required.
4. Control valve has bypass per photo snap
attached. Hence require its size for bypass 1. PSV on MP boiler PSV 1- 17 KG/CM2 , PSV
opening scenario. 2- 18 KG/CM2 , PSV 3-18.5 KG/CM2 ,PSV 4-
5. Also require confirmation on whether control 19 KG/CM2
valve plus bypass simultaneous failure opening
scenario needs to be identified or not.
1. PSV details like manufacturer, model number,
inlet & outlet nozzle size, coefficient of discharge
and orifice size of PSV will be required.
2.Confirmation on PSV location whether on
exchanger's tube side or shell side is required.
3. P&ID and PFD (Operating flow rate, pressure
and temperature) of the heat exchanger is
required.
4. Isometrics of PSVs.
5.Design condition of heat exchanger.
6. Require confirmation about external fire
scenario applicability due to flammable liquid
pool formation in the K1 Heat exchanger vicinity. Not Required
Also require its elevation details from solid
decking if fire needs to be performed.

1. P&ID and PFD (Operating flow rate, pressure ,

temperature and composition) of the main still
and associated equipment of the main still
system.
2. Design conditions of main still along with
associated equipment of the system.
3. Rupture Disk inlet pipe length and outlet pipe
length required (as details are not provided in
isometrics drawing).
4. Require confirmation about external fire
scenario applicability due to flammable liquid
pool formation in the Main Still vicinity. Also
require its elevation details from solid decking if 4. No
fire needs to be performed.
1. P&ID and PFD (Operating flow rate, pressure ,
temperature and composition) of the Back end
Still and associated equipment of the Back end
Still system.
2. Design conditions of Back end Still along with
associated equipment of the system.
3. Rupture Disk inlet pipe length and outlet pipe
length required (as details are not provided in
isometrics drawing).
4. Require confirmation about external fire
scenario applicability due to flammable liquid
pool formation in the Back end Still vicinity. Also 4. No
require its elevation details from solid decking if
fire needs to be performed.
3.6 5.1428571