Gii Refineria Amuay PDF

COMPLEJO REFINADOR PARAGUANA
VENEZUELA
GENERAL INSTRUCTIONS
AND INFORMATION
COPY N°
CAUTIONARY NOTICE
This specification contains technical information

that is the property of PDVSA. It is furnished to
the recipient strictly for use in connection with the
activities concerned and is to be held
confidential.
GENERAL INSTRUCTIONS AND INFORMATION
Instructions
CRP-Amuay Rev. Dic. 2001
INDEX
ITEM PAGE
Introduction
I.1 General Requirements I-3
I.2 Design Requirements I-3
I.3 Unit Performance I-4
I.4 Other Requirements I-4
I.5 Reliability I-5
I.6 Economic Basis for Selection of Equipment and Design Alternatives I-5
I.7 Environmental Requirements I-6
SECTIONS
1 Characteristics of Utilities and Meteorological Data 1-1

2 Heat Exchange Equipment 2-1
3 Pumps 3-1
4 Compressors and Turbines 4-1
5 Instrumentation and Control Valves 5-1
6 Process Vessels 6-1
7 Furnaces 7-1
8 Safety Facilities 8-1
9 Electrical Design Criteria 9-1
10 Miscellaneous 10-1
11 Drawings and other project documents 11-1
These General Instructions and Information apply to the preparation of the

Process Specification Book and to the detailed engineering of the Amuay
Project.
Centro de Refinación Paraguaná PDVSA

1
Instructions
INTRODUCTION
These General Instructions and Information apply to the preparation of the Process
Specifications Book and/ or Detailed Engineering of the HNAY Cat Naphtha
Hydrotreatment Project.

2
Instructions
I.1 GENERAL REQUIREMENTS
The plant shall be designed in accordance with the applicable agreements, these
General Instructions and Information, the Design Basic Memorandum, and/or the
Process Specification Books, all as modified from time to time by agreement with
PDVSA. Any ambiguities or contradictions between any of these documents or
sections thereof must be resolved with PDVSA. None of the requirements set forth
in the aforementioned documents shall relieve the contractor of his responsibility to
design for additional requirements consistent with the usual and normal practices of
the profession.
I.2 DESIGN REQUIREMENTS
The plant and equipment design should incorporate all proven modern techniques.
The contractor will be expected to consider recent developments, but PDVSA must
be consulted before these are incorporated in the plant design.
The plant design shall allow as much routine maintenance as possible to be carried
out on the run or during downtime inherently necessary for process reasons. Areas
of high maintenance must be highlighted and advice given on possible solutions for
reducing maintenance. Facilities to minimize the time required for the start-up and
shutdown of the units shall be provided.
The contractor shall use uniform piping arrangements and instrumentation around
similar pieces of equipment to assist in case of operation. The contractor shall
make new equipment piping and instrumentation similar to existing equipment.
The maximum permissible noise level at worker exposure locations shall be 85 dBA.
The designation B.P. or I.P. refers to Exxon Basic Practices. The referenced
sections will be provided as necessary.
I.3 UNIT PERFORMANCE
All equipment and units must be capable of reaching and maintaining design
performance and throughput from mechanical completion. In addition, careful
consideration must be given to operability and safety under normal operation,

3
Instructions
startup, shutdown and emergency conditions.
I.4 OTHER REQUIREMENTS
° The contractor shall determine the final loads on utilities, waste disposal and
sewer and firewater systems.
° Built-in handling facilities shall be provided in accordance with BP4-2-1.
° Utility stations shall be provided through the process block where

maintenance work or operation clean up is required so that equipment can
be serviced using a maximum hose length of 75 feet.
Utility stations at grade shall have a one inch water, steam, air and nitrogen
hose connections with a valve immediately upstream. The hose connections
and valves shall be approximately 3 feet 6 inches above grade or floor level.
Structures and towers shall have stations at alternate levels with one inch
water and steam hose connections with valve.
° Branch connections from the headers to the utility stations shall be from the
top of the header.
° The number and location of utility stations and convenience outlets shall be
developed by the contractor and reviewed by PDVSA. The number and
location of utility stations, containing utility nitrogen outlets shall be developed
by the contractor and reviewed by PDVSA.
° Eye wash and emergency showers shall be provided at 50 feet or closer to

areas where operating personnel are subject to hazardous spray or spill,
such as: acid, caustic, etc.
° Drinking fountains shall be provided for all new units. The total number of
fountains will be according to the final layout.
I.5 RELIABILITY

4
Instructions
The following reliability philosophy shall be incorporated in the design of the new
facilities.
° Facilities must be designed to achieve a high service factor, a high degree of

reliability and have low operating and maintenance requirements.
° In the selection of individual components and materials, the contractor shall
err on the side of going beyond the optimum relationship of capital cost
versus future operating costs.
° In rotating equipment selection, the contractor shall be on the side of

providing more than just adequate quality.
° A high degree of standardization of components and parts is to be achieved.
I.6 ECONOMIC BASIS FOR SELECTION OF EQUIPMENT AND DESIGN

ALTERNATIVES
The contractor must base his design work on the Process Design Specification.
However, in the course of optimizing equipment within the limits permitted by the
individual Design Specifications, alternatives having different operating costs and
investment requirements shall to be considered. The contractor is also encouraged
to critically review the flow plans and equipment arrangements and to list separately
for PDVSA review all proposed alternatives that will make the project more
economical.
For these alternatives, incremental investment may be added provided annual

operating savings yield a minimum 40 percent return before taxes when calculated
as follows:
Minimum Return = Yearly Operating Savings (1) x 100

before Taxes Incremental Investment (2)
All alternatives which meet the above criteria are to be reviewed with and approved
by PDVSA before adoption. Information on incremental costs for this project is
given below. These costs include capital charges and delivery to the battery limits,
but not distribution within the unit. The specified cost for steam also includes credit
for production of condensate.

5
Instructions
Item Incremental cost of utility (3)
Year 2001-2005 2006-2016

Steam - 600 psig: 2.494 Nota 5 $/1000 lb
145 psig: 2.494 " $/1000 lb
60 psig: 2.0 " $/1000 lb
15 psig: 0.3 " $/1000 lb
Water - (RAW) 1.5 " $/1000 gals

(DEMIN) 3.1 " $/1000 gals
(Cooling) 0.018 " $/M3
Fuel - Natural gas 1.25 " $/1000 SCF

Refinery gas 1.44 " $/1000 SCF
Electrical Power - 0.0547 " $/KWH
Hydrogen (from CHP) 1.13 “ K$/MSCF
Air - 0.014 " $/NM3
Nitrogen 0.135 “ $/NM3
Efluentes 8.407 “ $/M3
Notes:
1. Operating savings are before taxes and depreciation.
2. Incremental investment shall include both utilities and process equipment

investment incremental above minimum cost required to meet the Job
Specification/requirements.
3. Incremental cost (Variable).
4. Based on 1.2 $/MMBTU.

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Instructions
5. Incremental cost to be supplied by PDVSA Service Center Project.
I.7 ENVIRONMENTAL REQUIREMENTS
The plant and equipment design shall comply with all environmental requirements
mandate by Venezuelan laws; or if more restrictive requirements are deemed
necessary, PDVSA will advise.

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Utilitis
CRP Amuay Rev. Dic. 2001
SECTION N° I
CHARACTERISTICS OF UTILITIES
AND METEOROLOGICAL DESIGN CONDITIONS
I-1
Utilitis
CHARACTERISTICS OF UTILITIES
AND METEOROLOGICAL DESIGN CONDITIONS
The utility characteristics given below for process design are the conditions at the
utilities generation units battery limits. The contractor shall design the distribution system
within utilities units and battery limit of the new unit to supply the requirements. Provide
flow meter at battery limits for all continuous utilities consumption.
1.0 UTILITIES
1.1 Water Systems Process Mechanical

Design Design
° Cooling Water (CW) (Sea Water)
EBAP
Supply Temperature, °F 85 125
Supply Pressure, psig 40 70
ANSI Flange Rating - 150
Cast Iron 125
Return, Cooler Outlet Temperature, °F 120 170

Return Pressure, psig
ANSI Flange Rating 125/150
Cooling Towers (two pass HDS system)

ANSI Flange Rating 150
Return (Cooler outlet) Temperature, °F 120 170

Return Pressure, psig 30(min) 125
ANSI Flange Rating 150
Process Mechanical
I-2
Utilitis
Design Design
EBAS-II
Return (Cooler outlet) Temperature, °F 120 (max) 170

Return Pressure, psig (at Battery Unit) 15 (min) 125
° Raw Water (RW)

Temperature, °F 85 130
Pressure, psig 90 100
Parameter
Ca (mg/l) 42.7
Mg (mg/l) 11.4
Na (mg/l) 10.6
Bicarbonate (mg CaCO3/l) 76.8
Carbonate (mg CaCO3/l) 102.5
Cl (mg/l) 22.6
Sulfates (mg/l) 48.8
Phosphates <0.01
Hardness (mg CaCO3/l) 153.3
Alkalinity (mg CaCO3/l) 93,9
Total iron (mg/l) 0.3
Potassium (mg/l) 4.3
Copper (mg/l) <0.02
Carbon Dioxide (mg/l) 7.3
Silice (mgSiO2/l) 0.83
Tubidity (UNT) 3.3
PH 7.25
Conductivity (mmhos/cm) 318
Total Suspended Solid 5.1
(mg/l)
Nitrates (mg/l) 0.35
Langelier Index -0.35
° Potable Water (PW)
I-3
Utilitis
° Boiler Feedwater (BW)
High Pressure BW BK-11

High Pressure BW BK-29

850 psig BW BK-29

I-4
Utilitis
Process Mechanical
Design Design
250 psig BW
° Demineralized Water (DW)
° Demineralized Water
to Hydrogen Units (DW)

Hardness 0
° Recovered Sewer Water (AR)

° Recovered Industrial Water (IR)

° Stripped Sour Water BK-30 (SW-3)

Parameter
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Utilitis
H2S (ppm) 39
NH3 (ppm) 1200
Process Mechanical
Design Design
° Stripped Sour Water BK-21 (SW-1/2)
Parameter
H2S (ppm) <10
NH3 (ppm) <50
MEA (ppm) 55
HCl (ppm) 15
° Fire Water (F.W)

Sea Water
1.2 Steam Systems
° 600 psig Steam (HS)

° 145 psig Steam (MS-145)

Process Mechanical
I-6
Utilitis
Design Design
° 60 psig Steam (LS)

° 30 psig Steam (LS)

° 15 psig Steam (LS) (Note 1)

° Steam Cond. Ret. HC MC LC VC
Nominal Condensing
Pressure, psig 600 145 60 4.5"Hg
Temperature Sat. Sat. Sat. Sat.
Min. Required Return
Pressure at Battery
Limits, psig 150 60 40 65
Mechanical Design
Temperature. °F 550 400 360 200
Mechanical Design
Pressure, psig 650 155 90 90
ANSI Flange Rating 400 150 150 150
Where:
- HC High pressure condensate
- MC Medium pressure condensate
- LC Low pressure condensate
- VC Vacuum condensate
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Utilitis
1.3 Air Systems

Process Mechanical
Design Design
° Instrument Air (IA)

Pressure, psig at BK-11 80 max 150
Dew Point, °F at Conditions
(DR-1700/1703/1704) 60
Dew Point, °F at Conditions

(DR-1750/1751) 50
° Utility Air (UA)

Pressure, psig at BK-11 90 max 150
° Process Air (PA)

Pressure, psig at BK-11 90 150
1.4 Electric Power (Frequency 60 Hertz)
I-8
Utilitis
Utilization
Drivers: Voltage Phase
Greater than 3,000 hp 13,200(Note 2) 3

151-3000 hp 2,300 3
1-150 hp, and critical 0.5-1.0
services 460 3
Other services below 1 hp 230 1
Welding Terminal Boxes 460 3

Convenience Outlets - 1
Lights 120 1
Instruments 120 1
I-9
Utilitis
Process Mechanical
Design Design
1.5 Nitrogen (N2)
° Service Nitrogen
Temperature, °F 60 - 100 150

Pressure, psig 50 - 80 min 150
° Purge Nitrogen
Temperature, °F 60 - 100 150

1.6 Fuel Systems
° Natural Gas (NG)
Pressure, psig 500/180 650/250
ANSI Flange Rating - 300/150
Composition, mol %
Carbon Dioxide 4.2
Nitrogen -
Methane 82.9
Ethane 10.3
Propane 2.1
Butanes and Heavier 0.5
100.0
Molecular Weight 19.46

Heating Value, Btu/SCF (LHV) 1094
Sulfur content, wppm 10(max)
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Utilitis
Process Mechanical
Design Design
° Refinery Fuel Gas (GF) (Note 3) (Note 3)

Pressure, psig at HDS 75 150
at Conversion 85 150
Typical Composition, Mole % Conversion HDS

Note 3 Note 3
Hydrogen 14.6 51.55

Nitrogen 3.8 1.38
Carbon Monoxide 0.6 3.76
Carbon Dioxide 1.2 0.35
Methane 35.3 27.34
Ethylene 7.9 0.29
Ethane 16.9 3.90
Propylene 5.0 0.47
Propane 7.8 3.76
C4 and Heavier 6.0 6.82
H2O - -
H2S 0.9 Traces
NH3 0.26
Oxygen 0.12
100.0 100
Molecular Weight 24.75 14.8

Heating Value, BTU/SCF (LHV) 1372 1050
° Flexicoker Gas (FX)(Note 4) Process Design Mechanical

Sour Clean Design
Temperature, °F 136 110 175

Pressure, psig 18 15 25
ANSI Flange Rating - - 150
I-11
Utilitis
Process Mechanical
Sour Clean Design
Typical Composition, Mole %
Hydrogen 16.18 16.25

Nitrogen 49.65 49.85
Carbon Monoxide 19.42 19.5
Carbon Dioxide 8.86 8.33
Methane 1.3 1.3
H2O 3.94 4.74
H2S 0.64 0.025
COS, wppm 101 101
Total 100.0 100.0

Heating Value, BTU/SCF (LHV) 118 118
° Pilot Gas (NG)
Composition, Mole %
Carbon Dioxide 4.2

Methane 82.9
Ethane 10.3
Propane 2.1
Butanes and heavier 0.5
100.0
Molecular Weight 19.46

Heating Value, BTU/SCT (LHV) 1094
Sulfur Content, wppm 10
I-12
Utilitis
Process Mechanical
Design Design
° Liquid Fuel (FO)
Temperature 100 130

Gravity API 33
Molecular Weight 330
Heating Value, BTU/lb (LHV) 18.000
Sulfur Content % 1.3 - 1.4
1.7 Hydrogen Systems
° Hydrogen Process Design Mechanical

HY´S CHP Design

ANSI Flange Rating
Process
HY´S CHP
Typical Composition, Mole %
Hydrogen 94.82 99.00

Nitrogen 0.11 1.00
Carbon Monoxide (ppm vol.) <10 <10
Carbon Dioxide (ppm vol.) <10 <10
Methane 4.62
H2O 0.45
Total 100.0 100.0
I-13
Utilitis
1.8 Other Systems
° Fresh Caustic (CL)
Gravity Degree Baume 20
ANSI, Flange Rating - 150
° Spent Caustic (CL)

° Flushing Oil (WO)
API 21.47
I-14
Utilitis
2.0 METEOROLOGICAL DESIGN CONDITIONS
° Temperatures
Maximum Design, dry bulb, °F 90

Maximum Design, wet bulb, °F 85
Summer Mean, dry bulb, °F 86
Minimum Design dry bulb, °F 70
Winter Mean, dry bulb, °F 83
Lowest One-Day Mean Atmospheric
Temperature, °F 70
° Precipitation
Precipitation Frequency (1 mm or
more), days/year 3-6
Design Precipitation Intensity,
inches/hr 2.0
Maximum Precipitation,
inches/24 hr 5.0
Snow Days, days/year 0
Precipitation Data see Table Nº 1
° Wind
Design wind velocity ("fastest mile"), mph 70
° Wind Rose
See wind direction and velocity distribution Table Nº 2
° Earthquake
PDVSA Engineering Design Manual, Volume 2, JA-221.
Notes: 1. 15 psig steam is only available in the utility block and is

used for feed water deaeration.
I-15
Utilitis
2. Eventhough 13.2 KV utilization voltage has been

tabulated to feed motor greater than 3000 HP, the final
decision should be referred to PDVSA for approval.
3. Refinery Fuel Gas Sources: Conversion drum D-2952,

HDS Drum D-1101.
4. Flexicoker gas conditions based on LFAY Project.
I-16
Utilitis
TABLE N° 2
WIND DIRECTION AND VELOCITY DISTRIBUTION

DURING 1983-1990
Velocity (MPH)
DIRECTION 1-3 4-7 8-12 13-18 19-24 25-30 TOTAL

N 0.080 0.257 0.856 0.267 0.498 0.288 2.25
NNE 0.107 0.413 0.259 0.028 0.002 - 0.81
NE 0.403 0.624 0.302 0.066 0.004 - 1.40
ENE 0.911 1.578 1.963 0.957 0.110 - 5.52
E 0.827 3.661 10.431 14.894 3.439 0.050 33.30
ESE 1.007 3.339 7.593 6.462 0.638 0.467 19.51
SE 0.458 2.227 6.842 9.045 2.101 1.129 21.80
SSE 0.279 0.776 2.296 3.446 0.615 0.532 7.94
S 0.175 0.317 0.579 0.549 0.484 0.064 2.17
SSO 0.797 0.863 0.786 - 0.736 - 3.18
SO 0.032 0.114 0.058 0.003 - - 0.21
OSO 0.005 0.140 0.045 0.007 0.005 - 0.20
O 0.018 0.201 0.145 0.004 - - 0.37
ONO 0.058 0.226 0.348 0.056 - - 0.69
NO 0.067 0.166 .154 0.046 0.003 - 0.44
NNO 0.024 0.047 0.098 0.044 - - 0.21
TOTAL % 5.25 14.95 32.76 35.87 8.64 2.53 100.00
MPH: MILES PER HOUR
TOTAL REGISTER HOURS: 59,758 HR
SOURCE: PROTECCION INTEGRAL, SECCION HIGIENE INDUSTRIAL PDVSA AMUAY
I-17
Exchangers
SECTION N° II
HEAT EXCHANGERS
II-
Exchangers
HEAT EXCHANGERS
1. DESIGN CODES
- ASME Pressure Vessel Code Section VIII - Div. 1. With stamp

- TEMA-R for shell and tube
- API 660 for those aspects not included in TEMA-R (for shell and tube)
- API 661 for air fins
Design Practices and Engineering Specifications
° PDVSA Engineering Design Manual, Volume 8, when is reference.

° Basic Practices BP6-1-1, BP6-2-1, BP6-3-1.
2. DESIGN CONDITIONS
2.1 Design Pressure
The design pressure shall be equal to the maximum anticipated operating

pressure plus 10% or 30 psig., whichever is greater. The minimum design
pressure for an exchanger is 51 psig. In some instance, it will be necessary
or there are incentives to specify design pressures less than 51 psig, these
cases shall be referred to the owner for review and approval.
In addition to the criteria outlined above, the design pressure of an exchan-

ger must reflect the location and set pressure of the safety relief valve
protecting it.
2.2 Design Temperature
Exchangers operating between 32°F and 750°F shall be designed for the
maximum anticipated operating temperature plus 50°F but not less than
150°F.
Exchangers operating at 32°F and below are to be designed for the minimum
anticipated operating temperature.
When, due to the possible loss of cooling medium, the tubes, tube sheets
II-
Exchangers
and floating heads may be subject to the full inlet temperature, these
components shall be designed for the maximum anticipated temperature of
the hotter medium, plus 50 °F.
3. CORROSION ALLOWANCE
3.1 Carbon Steel
All carbon steel pressure parts, except tubes, are to have a corrosion
allowance of 0.125 inch unless the conditions of service require a higher
value. A 0.0625 inch minimum corrosion allowance is acceptable for
services like steam or dry air.
No corrosion allowance is to be added to tubes, baffles, supports, spacers

and tie rods.
3.2 Alloy
A 0.01 inch corrosion allowance is to be added to alloy parts except when

more is required for specific applications.
4. GENERAL CRITERIA
4.1 Pressure drop
For shell and tube exchangers, pressure drop values must be calculated
based on a nominal ID equal to the nominal OD minus twice the wall
thickness shown on the exchanger specification sheet. They include
allowances for tube wall thickness variation and fouling as follows:
a.- Tube side:
The pressure drop is the sum of the frictional clean pressure drop
multiplied by the appropriate pressure drop allowance factor given
below plus the nozzle pressure drop and the entrance, expansion and
turnaround pressure drop.
Pressure Drop Allowance Factors
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Exchangers
Tube Tube
Diam. Thickness Carbon steel, Copper,
Inches Inches Alloy Tubes Copper Alloy Tubes
Plain Low Fin Plain Low Fin
1 0.083 1.28 1.35 1.12 1.15

1 0.109 1.35 1.43 1.15 1.19
3/4 0.065 1.34 1.42 1.17 1.23
3/4 0.083 1.31 1.53 1.20 1.30
b.- Shell side:
The pressure drop for all liquid and for vaporizing services shall
include a 15 percent allowance for fouling. The pressure drop for all
vapor and for condensing services shall not include an allowance for
fouling (fouling allowance is not required).
4.2 Cleaning and maintenance
a. When is required, chemical cleaning nozzles shall be 1-1/2" threaded and

plugged provided only in nozzles 4" φ and larger.
b. Heat exchangers with Stationary Head End type C and removable cover
shall be provided at least with two lifting lugs on the removable cover (see
figure 2).
4.3 Air fin heat Exchangers
For cooling services, air fins shall not be used for the following services:
° For viscous materials where tube side heat transfer coefficients are
low.
° For services where air fins are clearly not economical.
° For services where low process temperatures are required (120°F or

less), a combination air/water cooling system shall be considered.
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Exchangers
4.4 Approach temperatures
For shell and tube heat exchangers the normal cold end temperature
approach should not be less than 18°F. For reboilers, a temperature
difference of at least 25°F shall be used between condensing steam
temperature and the process fluid.
4.5 Overdesign
In general, no overdesign shall be specified for exchangers with the

exception of reboilers, condensers and product rundown coolers. For
these exchangers an overdesign factor of 1.10 shall be specified. Other
exchanger services may require over-designing and should be dealt with on
a case by case basis.
4.6 Exchanger in Wet H2S Service
° Carbon steel in wet H2S service shall be tested in accordance with

NACE
TM-02-84 but using the test solution of NACE TM-01-77.
In addition to the reporting requirements of NACE TM-02-84,
photographs of the examines surface of all test samples showing
cracking, if present, shall be submitted to the owner.
Photomicrographs of the examined surface also be submitted
unetched to show the type of inclusion and etched to show the
microstructure.
° Where HIC Resistant Steel has. been specified, the plate steel used
shall be fully killed made to fine-grain practice and normalized.
4.7 TEMA for shell and tube.
Type AET for shell and tube exchanger is preferred. If type AES is specified
in an individual design specification, the contractor shall submit the design for
owner approval (GIG and Maintenance).
5. DESIGN CRITERIA
II-
Exchangers
All shell and tube heat exchangers shall be designed to the following guides unless
otherwise specified:
5.1 Tube size and layout selection:
Shell Tube Pitch Heaviest

Side Side Tube and
Fouling Fouling O.D. Layout Recommende
d
Wall
0.002 Less than 0.003 3/4" 15/16" Triangular (1) (2) 0.095
except salt water 1" Square or Triangular (1) 0.109
service
0.003 and 1" 1-1/4" Square or Triangular 0.134
greater, and for (1)
salt water service
0.002 Less than 0.003 3/4" 1" Square 0.109
except salt water
service
0.003 and 1" 1"-1/4" Square 0.134
greater, and for
salt water service
(1) Square pitch shall be used if shell side mechanical cleaning is required.
(2) 15/16" triangular pitch layout may be considered only for nonferrous alloys.
5.2 Minimum tube wall thickness for process heat exchangers shall be 0.109
inch for carbon steel, 0.083 inch for nonferrous alloys, 0.049 for titanium shell
and tube condensers and 0.028 for titanium fixed tube sheet coolers. Lube
oil coolers may use 0.049 inch tube wall thickness for nonferrous alloys.
5.3 Maximum weight of removable tube bundles shall normally be limited to 15

tons (30,000 lbs.). However, larger bundles (up to 35 tons) may be used in
clean services requiring little maintenance. Location of these large bundles
is to be brought to the attention of the refinery to account for handling and
II-
Exchangers
removal facilities. Maximum exchanger tube sheet diameter shall be limited

to 84 inches.
5.4 Preferred tube length is 20 feet. If process considerations or economics

favor shorter tube lengths, 16 foot or 12 foot lengths may be used.
5.5 Unless otherwise noted, fixed tube sheet exchangers in which the difference
between the average shell metal temperature and the average metal
temperature of any one tube pass is less than 50°F shall be designed for
50°F differential. The owner shall be notified if this requirement results in an
unconventional design. Startup, shutdown, emergency conditions or other
unusual operations (e.g. steam out) must be considered when determining
the design temperature difference.
5.6 The position of the baffle chord is to be based on the following:
Tube Layout
Square: Vertical for condensing and vaporizing services.
Horizontal or 45° rotated when cooling a sediment-free fluid

through a wide temperature range (200°-300°F) in one shell.
Triangular: Horizontal when cooling a sediment-free fluid through a wide

temperature range (200°-300°F).
Vertical for all other services.
5.7 Unless otherwise specified, baffle cut for segmental baffles shall be 25
percent of the shell inside diameter. Unless otherwise specified, baffle cuts
for double segmental (modified disc and donut) baffles shall be such that the
sum of the window area for the single central baffle and the area of the hole
in the double baffle are equal and shall be 40 percent of the exchanger cross
sectional area.
5.8 Modified disc and donut (double segmental) baffles or divided flow (TEMA
Type J) shall be considered where pressure drop is critical. First choice shall
be modified disc and donut baffles.
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Exchangers
5.9 For salt water coolers, water should be placed on the tube side. Fouling
resistance to be used for salt water cooling exchanger design are shown in
Figure 1 of this section. Tube side water velocity shall be between 6 and 12
ft/sec., and preferably 7 to 8 ft/sec (for 90/10 Cu Ni or 70/30 Cu Ni).
For Aluminum Brass the corresponding velocities are 4 to 8 ft/sec. and

preferably 5 ft/sec.
For titanium the corresponding velocities are 6 to 15 ft/sec and preferably 10

to 12 ft/sec.
5.10 The maximum outlet bulk salt water temperature is 120°F, provided the
highest water film temperature (not average film temperature) does not
exceed 140°F.
5.11 Unless otherwise noted, materials for shell and tube exchangers with salt
cooling water on the tube side shall be as follows:
Channel and Cover CS + 1/8" Monel Cladding, or Solid Monel if more

economical (1)
Tubes Aluminum Brass. (2)
Tube Sheets and Aluminum Bronze + 1/8" TCA

Floating Heads
Baffles Same as tube sheets or tubes
Notes:
(1) Full face cathodic protection is required with aluminum brass tubes
(see drawings on page 2-16,17).
(2) If more economical, or required for process side conditions the

following tube materials may be used; 90/10 Cu/Ni, 70/30 Cu/Ni or
titanium. Tube-sheets would be 90/10 Cu/Ni, 70/30 Cu/Ni or titanium
respectively for these tube materials. A titanium tube-sheet may be
substituted with CS + 1/8" monel cladding water side if more
economical.
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Exchangers
5.12 Shell and tube exchanger components subjected to both shell and tube side
pressures shall be designed for the most severe condition of the specified
pressure with atmospheric pressure on the other side. Proposals for the
differential design shall be submitted to the owner for approval.
5.13 If drumless flooded condensers are used, they shall be designed according
to the following guides:
° The condenser surface provided shall be 110 percent of the required

surface.
° A vapor/liquid separation pot shall be located on the exchanger outlet.

Pots up to 14 inch diameter shall be sized to limit liquid velocity to 1
ft/sec. Larger diameter pots shall be limited to 1.5 ft/sec. liquid
velocity. The pot shall be 3 to 5 feet long, and shall be provided with
an anti-vortex baffle.
° The condenser shall be equipped with a gauge glass covering the

entire condenser and pot.
° The condenser shall be elevated sufficiently to satisfy pump NPSH

requirements with the pot empty. In any event, the bottom of the
condenser shall be a minimum of 20 feet above grade.
° The condenser shall be positioned with its liquid outlet end on the
pump side of the structure.
Pump suction lines shall slope continuously down towards pump at a

minimum slope of 2 inches per 100 feet. In addition, long horizontal
suction lines should be avoided. If this is not possible, consideration
must be given to the possibility of vaporization due to friction pressure
drop.
° Pump suction lines shall be limited to the following velocities:
3 inch diameter and smaller - 1.5 ft/sec maximum.

4 inch to 8 inch diameter - 2.25 ft/sec maximum.
10 inch diameter and larger - 3.5 ft/sec maximum.
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° Pumps shall be of the heavy duty refinery type or API 610 last edition.
° Reflux pumps shall be equipped with a recirculation line returning

upstream of the condenser. The recirculation line shall be provided
with a block valve and restriction orifice or valve control sized to
maintain at least 20 percent of the pump flow rating. When the
recirculation is over 20 percent a local control loop is preferred, see
section 3, item 1.17.
° A 2 inch vent shall be located on the condenser as close to the liquid

outlet as practical.
5.14 Reboilers shall be designed according to the following notes unless

otherwise specified:
° Maximum heat density for hydrocarbon reboilers is to be 15,000

Btu/hr-ft2
for natural convection and 20,000 Btu/hr/ft2 for forced convection.
Higher heat fluxes may be specified if the vendor has previously
demonstrated successful operation in the same service at the higher
fluxes and if approved by the owner.
° Thermosyphon reboilers are to be restricted to a maximum of 50

percent vaporization (based on exchanger feed) and are to be
avoided for viscous fluids and services where the liquid head on the
reboiler feed system is variable. When there are gum or polymer
deposition due to the fluid, the maximum percent of vaporization shall
be 40.
° If 600 psi steam is used for reboiling, the tubes must be strength
welded to the tube-sheet.
° Kettle reboilers are to be designed in accordance with the criteria

shown on Page 2-14. The items referred to in Page 2-14, Note 4, are
calculated as follows:
"A", the minimum vapor area above liquid level, sq.ft.
A=
0.25Ac
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Exchangers
"B", the minimum vapor area above spray baffle, sq.ft.
B= 0.10Ac
N
"D", the minimum outlet nozzle diameter, inch.

0.5
D =3.03 0.25Ac
N
Q
Where: Ac=
Vc
0.5
ρl - ρv
Vc=0.15 ρv
and: Ac = critical vapor flow area, sq.ft.

N = number of vapor outlet nozzles
Q = design vapor rate at operating conditions, ft3/sec.
Vc = critical velocity, ft/sec
ρl = liquid density at operating conditions, lb/ft3
ρv = vapor density at operating conditions, lb/ft3
5.15 For all heat exchangers specified in the individual design specifications, the
contractor and/or vendor shall confirm:
° That the pressure drops (dirty) of the units selected are not greater
than shown in the design specification.
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Exchangers
° That the surface required to meet the process specifications is not

greater than that shown in the design specification.
6.0 AIR FIN HEAT EXCHANGERS
All air fin heat exchangers shall be designed according to the following:
6.1 The maximum design air temperature (dry bulb) for air cooled exchangers, if
not specified, is 95°F for coolers and 105 °F for condensers (These values
include a 5°F allowance for hot air recirculation).
6.2 The minimum design dry bulb is 70°F (for fan motor rating per BP6-4-1).
6.3 Manufacturer shall design air cooled exchanger units for the most
economical combination of surface and power, using the economic criteria
given in the Economic Basis for Selection of Equipment section of this
specification.
6.4 The Contractor shall supply air fin vendors with the following information:
° Site elevation above sea level.

° Unit elevation above grade.
° Orientation of unit with respect to predominant wind direction.
° Relative location of air fins, furnaces, and all other sources of air heat.
6.5 Single tube pass condensers shall be sloped down a nominal 1/8 inch per
foot toward the outlet. For total condensers the slope shall be 1/4 inch per
foot. Multipass condensers shall be horizontal.
6.6 Maximum tube length shall be 34 feet.
6.7 Minimum tube diameter is 1 inch.
6.8 Minimum tube wall thickness shall be 0.109 inch for carbon steel, 0.083 inch
for nonferrous alloys and 0.049 inch for titanium.
6.9 Air coolers shall be provided with galvanized frames and galvanized wire
mesh fan protectors.
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6.10 Air coolers shall be provided with HTD pulleys and belts for all motor drives:
° Louvers are preferred to variable pitch fans for air fin control, but their
use shall be minimized and require owner approval.
° Piping to and/or from air cooled exchanger headers shall be offset to

allow bundles to be lifted vertically for maintenance. Bundles shall be
provided with permanent lifting lugs.
° A lubrication station should be located in accessible location, where

fan bearings and motor bearing can be greased while operating.
° The motor driver arrangement shall be shaft up vertical mounted

motor, see figure 3.
7. STEAM GENERATORS
Steam Generators are to be provided with:
° Top vent valve(s).
° Non return valve (Stop Check) in steam production line. This valve shall be
calculated. Whenever the size of this valve is not standard line size (see
section 10 page 10-7 item 2.10) flange connections to the standard size line
are required to permit easy valve removal and maintenance without cutting of
the line.
° Lines and angle valves for continuous and intermittent blowdown.
° Level gauges and high and low level alarms.
° Flow meter continuous blowdown.
FIGURE 1
FOULING RESISTANCE FOR SALT COOLING WATER
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TO BE READ TO NEAREST 0.0005
0.006
0.005
(1)
0.004
3FT/SEC (1)
0.003
5FT/SEC (1)
0.002
10FT/SEC
0.001
0
100 200 300 400 500 600
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Exchangers
FIGURE 2
CHANNEL INTEGRAL WITH TUBE-SHEET AND REMOVABLE COVER
LIFT LUG
REMOVABLE
TUBE
BUNDLE
ONLY
FIGURE 3
SUSPENDED BELT DRIVE, MOTOR SHAFT UP
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FIGURE 4 NOZZLES & CONNECTIONS
NOTES: Nº SERVICE
1. BAFFLES EXTEND ACROSS WIDTH 1N CHANNEL INLET
OF SHELL. 2N CHANNEL OUTLET
3N H.C. LIQUID INLET
2. LEVEL TAPS MAY BE EITHER ON 4N H.C. VAPOR OUTLET
SHELL OR HEAD. 5N H.C. LIQUID OUTLET
3. DIMENSION "L" REFERS TO TUBE 1CN LIC (2) NOTE 2
LENGTH. 2CN LG (2) NOTE 2
4. FOR AREA "A" AND "B" AND CRP. AMUAY REFINERY
NOZZLE DIAMETER "D" REFER TO GENERAL SKETCH FOR KETTLE
THE TEXT. REBOILERS DETAILS.
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Exchangers
FIGURE 5. CATHODIC PROTECTION
FOR SEA COOLING WATER,

CHANNEL COVER SHALL BE
CLADDED WITH ¼ INCH
MONEL.
NOTES:
1) WHERE FULL FACE CATHODIC PROTECTION IS SPECIFIED, THE ANODE SHALL BE PER
FIG. 1 INCLUDING DETAIL A. THE ANODE SHALL BE ELECTRICALLY CONNECTED BY
ATTACHING ONE END OF A PIECE OF No. 12 AWG COPPER WIRE TO THE ¼ IN. BRASS
MACHINE BOLT ON THE ANDE AND THE OTHER END TO THE TUBE SHEET WITH THE ¼ IN.
BRASS CAP SCREW.
2) GASKET I.D. SHALL BE EQUAL TO CHANNEL I.D. LESS ONE INCH.
3) WIDTH OF WEB SHALL BE ONE INCH THICKER THAN TIP OF PARTITION PLATE.
DIMENSIONAL CONTROL/TUBE FLARING D
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Exchangers
NOTE:
+1/32”
1) TUBE PROJECTION AT BOTH ENDS (A) SHALL BE 3/16" - 0”
2) TUBES SHALL BE FLARED BY ROLLER EXPANSION AT 15 DEG. WITH TUBE CEN-TERLINE
@ BOTH ENDS.
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SECTION N° III
PUMPS
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PUMPS
1. CENTRIFUGAL PUMPS
1.1 Codes and Standards
° API-610/ API 682.

° Hydraulic Institute Standards
Design Guidelines and/or Engineering Specification
° Basic Practices BP10-1-1, BP10-1-2, last issued.

° PDVSA Engineering Design Manual Volume 8.
1.2 Design Capacities
Centrifugal pumps shall normally be rated for 110% of the maximum process
flow. Reflux pumps shall be rated at 115% of maximum process flow. For
pumps in controlled systems, the rated head shall be that calculated at 100%
of normal process flow. For pumps in uncontrolled systems, transfer pumps
and pump-out pumps, the rated head shall be calculated on the basis of the
rated flow and the driver specified for 115% of rated pump power.
Higher over designs due to process considerations shall be established on a

case by case basis.
Where maximum pump discharge pressure is limiting, pump casing design

pressure shall be at least equal to the following:
(Max. Suction Pressure) + (A) x (B) x (∆P at rated capacity & max SG*
conditions)
A= 1.0 for motor driven and 1.21 for turbine driven pumps.
B= 1.2.
*= Maximum SG may not be the same as design case.
1.3 Net Positive Suction Head (NPSH)
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NPSH available should be specified as follows:
a) Pump centerline is assumed to be at 3 feet above grade.

b) Source elevation at LLL in suction vessel.
c) Pump suction line total equivalent length, ft= 32 x (NPS in inches) +
200.
d) Other allowances include: 1 psi if a permanent suctions strainer is
provided.
NPS= Nominal Pipe Size.
The contractor shall confirm that the actual values of items a, b and c do not
negatively affect NPSH values specified. Inform owner if adjustments of
available NPSH values are necessary.
The contractor shall insure that the pump requirement is compatible with
actual available NPSH.
Margin between NPSHA and NPSHR shall be at least 3 feet, otherwise a

witnessed NPSH test shall be required.
Owner approval is required for pumps which more than 25 ft of NPSHR.
1.4 Pump casing as well as downstream equipment might have been designed
based on a pump shutoff head of 120%. Owner shall be informed if the
shutoff head of any pump head exceeds 120% of specified differential head.
1.5 Casing design temperatures are normally based on maximum operation

temperature plus 50°F, except where minimum temperature is more critical.
1.6 The minimum continuos stable flow shall be less than the minimum operation
flow. If a recirculation is required to get this condition, it should be less than
25% of the normal operation flow. The contractor shall advise the purchaser
of any pumps which require a recirculation system for continuous operation
at flows down to the 30 percent level. The recirculation system shall be
approved by the owner. The vendor shall specify the minimum stable flow
and the minimum thermal flow for each pump. The suction specify speed
(NSS) shall be less than 11000. In case of NSS greater than this value, the
pump shall be submitted to owner for review and approval.
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For pump selection shall be checked suction specify speed (NSS) at the best
efficiency point (BEP) as it is shown on figure 3-1.
1.7 Casings which are not self-venting type, pumps handling C4 and lighter,
pumps handling liquids containing dissolved toxic gases, or pumps operating
under vacuum shall be vented back to the vessel from which the pump
draws suction. Vent line shall have a valve at the pump and slope up
continuously to suction vessel.
Pump drains are to be provided for all pumps. Drain disposal should be
as follows:
° Light ends - 3/4" connection to closed drain system or safety location.

Closed drain system only available in Conversion Area and in HDS
Area after 1996.
° Heavier than lights ends at temperature above flash point and no pour
point problem - pipe to the funnel connection to the sewer.
° Heavier than light ends at a temperature above flash point with a pour
point problem - pipe to the funnel connection and provide flushing oil
to a 2 inch connection upstream of the pump strainer.
° Heavier than light ends at a temperature below the flash point and no
pour problem - provide a valved drain to the baseplate (which drains
to the funnel connection).
° Heavier than light ends at a temperature below the flash point with a
pour point problem - provide a valved drain to baseplate and flushing
oil to a 2 inch connection upstream of the pump strainer.
The location of pump vents and drains are to be per BP3-3-2; i.e., casing
vents and drains are not required if adequate venting and drainage can be
obtained via piping vents and drains, otherwise vendors must ensure that the
valves at the vents or drains are as close to the casing as possible.
1.8 Remote start and auto-star pumps must be self-venting.
1.9 The vendor shall provide pump curves for maximum and minimum impeller
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diameters as well as for impeller size supplied.
1.10 Temporary strainers shall be installed unless permanent strainers are

specified. Where permanent type centrifugal pump strainers have been
specified, they shall be as shown on figure 3-2, of this specification, use two
plane gussets at the drain valve. Do not use slip on flange. Pressure
indicators shall be provided to measure pressure drop across the strainer.
Permanent suction strainers shall be provided for fouling and corrosive

services. Strainers shall be provided for the following services:
- Tank suction.
- Tower overhead reflux and distillate.
- Sour water.
- Corrosive chemicals such as Noah, HCL, MEA, NMP, etc.
- Kerosene.
- Naphtha.
- Vacuum bottoms.
1.11 All onsite pumps in critical service shall be spared. Critical service is defined
as any service required to prevent a unit shutdown or required for an orderly
and safe unit shutdown during an emergency. A common spare may be
used for two non critical services.
1.12 Pump drivers are normally specified in individual design specifications.

Where drivers are not specified, in general, pumps are to be motor driven
unless the use of a steam turbine is dictated by special safety, steam
balance, operability considerations, or unless economics clearly favor steam
drivers. This selection must be approved by the owner.
1.13 For pumps where oil cooling is mandatory, radiator air coolers are preferred
instead water coolers. Oil cooling with salt water must be approved by the
owner. Oil cooling with raw or recovered water shall be avoided.
1.14 General purpose type steam turbines shall be provided with Woodward TG-
10 or equal hydraulic type governors except where NEMA C or D class
governors are required.
1.15 Oil mist lubrication shall be provided for all onsite and utility block general
purpose type equipment such as centrifugal pumps, fans, gears, and
steam turbines which have nonpressure oil feed type bearing lubrication.
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Oil mist lubrication of offsite centrifugal pumps and their drivers shall be
considered where a number of pumps are centrally located, the required
utilities are available, and the system installation can be justified.
Oil mist systems shall be designed for wet sump lubrication "purge mist".
Purge mist installation method shall be per the original Figure 2 of BP3-3-12,
last edition. Future conversion to dry sump lubrication "pure mist" shall be by
the Owner. Grease lubricated antifriction bearing type electric motors shall
be designed to be compatible for future conversion to dry sump lubrication
"pure mist" by the Owner.
1.16 Pumps requiring water quench shall be referred to the owner for approval
and selection of the water system available. The use of raw water (RW)
should be minimized by providing rotameter indication and globe valve
control of the raw water quench. If recovered water (AR) is used provide a
double filter.
1.17 Reflux pumps from the condenser shall be equipped with recirculation line
returning upstream of the condenser. The recirculation line shall be provided
with a block valve and restriction orifice or a control valve sized to maintain at
least 20 percent of the pump capacity at the best efficiency point. When the
recirculation is over 20 percent a local control loop is preferred. These
pumps shall be of the heavy duty refinery type. Choke-tube on recirculation
line required be approved by owner.
1.18 All sump pumps shall be fitted with an automatic on-off switch on level
control.
1.19 Oil flingers shall be provided. Oil cups shall be "Trico" constant level oiler
type.
1.20 "Labour" horizontal self priming pump is preferred for sump service of suction
lift up to 10 ft.
1.21 All onsite pumps shall be equipped with a wet sump oil mist system. System
shall be "Alemite" or equal.
1.22 (API 610 exception) Pumps shall be capable of at least a 10% head increase
at rated conditions by replacement of the impeller(s) with ones of larger
diameter.
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2.0 PUMP SHAFT SEALING
2.1 Contractor shall use the update Table 1, and Attachment 3.1, to develop
mechanical seal specification and selection. Seal details shall be approval
by owner. In general, the following sealing control levels (arrangements)
shall be used:
Control Level 5: Pressurized or unpressurized dual seal with appropriate

auxiliary system(s) an 1 leakage detection alarm.
Control Level 4: Unpressurized dual seal with appropriate auxiliary

system(s) and leakage detection alarm.
Control Level 3: Low emission single mechanical seal with abeyant seal
backup and leakage detection alarm. Low emission
indicates the vendor can provide test and/or experience
data proving the seal will emit less than 1000 ppm on a
continuous basis in the intended service as measured
by an organic vapor analyzer per established
procedures.
Control Level 2: Single mechanical seal with floating carbon bushing.
Control Level 1: Single mechanical seal with fixed, API 610 clearance
bronze throtte bushing.
As a minimum, streams classified as R-1 or R-2 shall use control Level 5.

Streams classified as R-3 shall be control Level 3. Hydrocarbon streams
and aqueous streams above 150 °F shall be control Level 2. Aqueous
streams below 150 °F shall be control Level 1.
The sealing control level shall be increased (but never decreased) as needed
to provide appropriate control for the considerations in attachment 3.1.
Detailed construction of control level 3 and 5 seals and their associated

auxiliary equipment such as barrier fluid reservoir. level gauges, safety
valves, abeyant seal, etc., shall be approved by Owner's Engineer.
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2.2 Sealing systems shall be design using section 4 of the fourth draft of API
Standard 682, "Shaft Sealing Systems for Centrifugal and Rotary Pumps".
2.3 Approved seal vendors are: "John Crane", "Borg Warner" and "Sealol".
2.4 All seal gland plates shall be of the distributed inlet (multiport or peripheral
inlet) design. This applies to both rotating and stationary flexible element
seal designs. particular attention shall be paid to installations where the
radial clearance between the seal OD and seal chamber bore is less than 6
mm in order to avoid high inlet velocities which can cause erosion on
stationary seal components. The contractor shall advise the owner this
requirement causes a reductions in flush flow rate or reduced cooling
effectiveness due to space limitations in the gland or seal chamber.
2.5 Cartridge design mechanical seals shall be provided for "between bearing
pumps", to facilitate seal installation and removal.
2.6 Mechanical seal materials and construction requirements and approved

vendors:
Pumping Temperature: Low Temperature (≤ 350 °F) High Temperature (> 350 °F)
a.- Secondary Packing Viton or Kalrez (unless not Graphite

compatible with pump fluid)
b.- Seal Faces per Seal Program Silicon Carbide and Antimony impreg-
nated Carbon
c.- Gland Plate Gasket Spiral Wound Type
d.- Additional seal sleeve Kalrez O'Ring

packing
e.- Approved Seal Vendor "John Craine" "Sealol" and "Born Warner"
2.7 Whenever a metallic gasket or graphite is used to seal the sleeve to the
shaft, a second sleeve to shaft sealing element (an o-ring) shall be installed
in order to prevent the buildup or foreign material under the sleeve. For
service below 350 °F this o-ring shall be Viton, over 350 °F the o-ring shall be
Kalrez. The seal vendor shall advise alternate material recommendations in
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Pumps
the event these materials are incompatible with the sealed fluid.
2.8 The contractor shall ensure that the seal chamber conditions of pressure and
temperature meet the seal vendor's requirements for satisfactory margin to
vaporization to provide reliable, low emission performance and long life.
Where special provisions must be added to the real seal chamber or pump
(such as close clearance floating throat bushings) to achieve satisfactory
seal chamber conditions. These provisions shall be submitted to the owner
for review and approval.
2.9 The sleeve drive shall be capable of transmitting full seal torque and
resisting seal axial forces under all operating and standby conditions.
Designs which utilize six or more set screws require submission of the
highest axial and radial load developed by the seal versus the capability of
the drive system for approval of the owner.
2.10 Final seal selection and seal system design shall be approved by owner.
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TABLE 1
GUIDELINES ON PUMP SEALS
Service Recommended Pump Sealing.
LEVEL 1.
Non-Sour, Clean or Dirty Water, Default: Single mechanical seal
<150 ºF. with API throttle bushing.
High Pressure Option 1: Single seal with floating
carbon bushing.
Option 2: Single seal with segmented,
floating carbon bushing.
LEVEL 2.
Minimum Requirement for All Default: Single mechanical seal services
except services except Water <150 ºF with floating carbon
bushing.
- Use if little chance of
forming an explosive vapor
cloud.
- use if emission limits are
>10000 ppm.
Sour Water, Caustic Default: Single seal with floating carbon

bushing.
Option : Sealles pump with appropriate

monitoring if technically feasible
and economically justified.
LEVEL 3.
Absolute Minimum Requirement Default: Single seal with for services which
can
Form and Cloud. segmented floating Explosive
Vapor carbon bushing & leakage
detection alarm (usually a
pressure switch).
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Option 1: Single seal with abeyant backup

seal (contacting or non-contacting)
& leakage detection alarm (usually
a pressure switch).
Option 2: Single seal with floating carbon
bushing & leakage detection alarm
(usually a pressure switch).
Option 3: Single seal with lip seal backup
connected to low pressure
disposal system and leakage
detection alarm (usually a
pressure switch).
LEVEL 4
Preferred Minimum Requirement Default: Single seal with for contacting
abeyant.
Services which can form Explo- back-up seal & leakage detection
alarm
sive Vapor Cloud. (usually a pressure switch).
Bearing monitoring should also be
considered and is recommended
when there is high potential for
leakage to form a vapor cloud.
Option 1: Dual seal, pressurized or

unpressurized, with appropriate
gauges and leakage detection
alarm(s).
LEVEL 5
Minimum Requirement for Ser- Default: Dual seal, unpressurized with
appropri-
vices Where no Material Should ate gauges & leakage detection
alarms.
be Released to the atmosphere Primary Seal. Bearing
monitoring
on Failure (HF, H2S, Methanol). should be strongly considered with
local readout for on-site units and
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Pumps
alarms for offsite/remote units.

Bearing monitoring is
recommended for services with a
high potential to form a vapor
cloud.
Option 1: Dual seal, pressurized; with

appropriate gauges and leakage
detection alarms. Bearing
monitoring should be strongly
considered with local readout for
on-site units and alarms for
offsite/remote units.
NOTES:
1.- Unpressurized dual seals and some abeyant seals commonly require the space
between the primary and backup seals to be vented to a safe location or a collection
system. If such a vent is required, the user must ensure a suitable disposal site is
available. If not, then a pressurized dual seal may be more economical/required.
Note that for vents on emission regulated services, activated carbon canisters and
filters are available to dispose of vapor before it enters the atmosphere. The
problem of finding a suitable vent location for reservoirs and abeyant seals is
specially acute in offsite areas.
2.- Continuous bearing monitoring should be considered an integral part of reducing the
potential hazard of seal leakage.
3.- Alternate means to a pressure switch for leakage detection such as a thermocouple
for auto-refrigerating service or a hydrocarbon detector can be considered.
4.- Any sealless pumps must be referred to PDVSA for approval. When sealless
pumps are used, the contractor must provide the appropriate instrumentation.
3.0 STEAM TURBINES
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Steam turbine shall be fitted with oil relay "Woodward" governor. Mechanical
governor is not acceptable.
4.0 SPECIAL REQUIREMENTS
4.1 Dry seals are not allowed in any service with solids. Use of dry seal required
PDVSA approval.
4.2 Oil heater for lube system reservoir is not required.
4.3 Pump seal and flushing connections and drains shall be piping instead of
tubing and not be seal welded at the pump connection.
4.4 Mechanical seals shall be selected to agree with "The Mechanical Seals
Standard Project of Amuay Refinery".
Mechanical Seal Models:
- John Crane: Models 8AB, 8B1 y 715.

- Sealol:Models 604 and 670.
- Borg Warner: Models UC, UKC, BX, BXW, BXRH.
4.5 Flexible disc coupling METASTREAM type are preferred.
5.0 ADDITIONAL REQUIREMENTS FOR WET H2S SERVICE
5.1 All pumps in wet H2S service shall meet the requirements specified in BP10-
1-1 or BP10-1-2.
5.2 Carbon steel pressure containing parts in wet H2S service shall meet the wet
H2S requirements of BP5-1-1 (paragraph 8.5 and 9.23). Avoid use of carbon
steel plate. Use forgings and castings instead.
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FIGURE N° 3.1
SCREEN OPEN AREA EQUAL TO 300% FIGURE 3.2

OF SUCTION PIPE AREA. SCREENING
SHALL BE 304 OR 316 STAINLESS PDVSA AMUAY REFINERY
STEEL 4 x 4 x 0.063" MESH PERMANENT STRAINER FOR PROCESS
REINFORCED, OR A PERFORATED PUMPS, AMUAY.
STAINLESS STEEL PLATE.
ATTACHMENT 3.1
SEAL CONFIGURATION TO MEET SAFETY
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Pumps
AND ENVIRONMENTAL REQUIREMENTS
SERVICE EXAMPLE OF SERVICE TYPE OF SEAL
Auto Ignition Potential - Bottoms pump around (PA). High temperature metal bellows
where normal pumping - ATM and Vacuum bottoms. with restriction device and steam
temperature exceeds - (APS and VPS). quench for secondary
600 °F. containment.
Vapour Cloud Potential. - C5 and lighter. Single mechanical seal with tight
- APS and Fractionator Overhead shut off short life auxiliary con-
Product, Reflux and tainment seal plus seal failure
Unstabilized alarm.
Naphtha.
- APS light ends processing. OR
° Deethanizer Feed.
° Deethanizer O/H Product and Liquid Tandem Seal with seal pot
Reflux. plus seal failure alarm.
° Debutanizer O/H Product and * Guidelines:
Reflux. If Pv > 200 psia @ 100 °F and
° Depropanizer O/H Product the fluid is a Narrow Boiling Point
and range or a Medium/Wide Boiling
Reflux. Point range in which more than
° Depropanizer Btms. 40% of the fluid vaporizes at PT
- Hot Naphtha. and atmospheric conditions use
Liquid Tandem Seal.
Potential for fatality rom - Phenol an Phenol extracts. Liquid Tandem seal with clean
short team exposure. - Sulphuric Acid. barrier fluid from sealpot plus seal
- H2S. failure alarm (Standard selection
° Rich MEA. for Phenol).
° GO hydrofined naphtha.
° Fractionator O/H product OR
reflux.
° Stream from fractionator up- Liquid Double seal with clean
stream of sweetening process. barrier fluid from process stream
- HF acid. or seal pot plus seal failure alarm
(Standard selection for HF-acid)
ATTACHMENT 3.1
(Continue)
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Pumps
Potential for burns - Crude and Refined Benzene Liquid tandems seal with clean
from skin contact or Extract. barrier fluid from seal pot plus seal
asphyxiation from - Powerformer Product. failure alarm.
absorbed H2S. - Streams from APS units
upstreams of sweetening
process.
° APS fractionator Product and
Reflux.
° Deethanizer Feed.
° Deethanizer O/H Product and
Reflux.
° Debutanizer O/H Product and
Reflux.
° Depropanizer O/H Product
and
Reflux.
° Depropanizer Btms.
° Spent Caustic.
Congested layout (fire Not covered by any of the previo- Single mechanical seal with tight
risk). usly mentioned services but with shut off short life auxiliary contain-
spacing less than Section 10 ment seal plus seal failure alarm.
requi-rements of the design
specification or difficult fire
fighting access.
Proximity to high risk Proximity to Chlorine area. Single mechanical seal with tight
equipment. shut off short life auxiliary contain-
ment plus failure alarm.
Remote location (with LPG Shipping or loading pumps See "Vapour Cloud Potential".
potential for vapour in offsite area. Also remote monitoring and/or gas
cloud). detection to be considered.
ATTACHMENT 3.1
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Normal risk (other Services not listed above. - Single mechanical seal with
Hydrocarbon services). lipseal or floating carbon bushing.
- Steam quench is required for ser-

vices with pumping temperatures
above 350 °F.
Caustics Solutions Aqueous solutions of Sodium Single mechanical seal with lipseal
Hydroxide between 10% and water quench. Plan 32 flush for
60% with temperatures up to 140 start-up and shut-down.
°F.
Sour Water (< 1% Sour water stream to sour water Single mechanical seal with lipseal
H2S) stripper. and water quench.
Refrigerated Storage - Butane, Propane at less than 32 Vertical Pumps: Tandem seal with
of Light Hydrocarbons. °F. Propanol or Zerice barrier fluid
system, and same liquid as barrier
- Propane dewaxing unit filtrate between outer seal and lipseal,
pumps. plus seal failure alarm.
Considered ice barrier.
Regulated Emissions To be identified. Liquid tandem seal with clean
and Industrial Hygiene. barrier fluid from sealpot, plus seal
failure alarm.
NOTES:
1) Alarm details to be defines by owner.

2) Auxiliary containment device to be contacting or non-contacting. Vendor to consult
owner for preference.
III-
Compressors and Turbines
SECTION N° IV
COMPRESSORS AND TURBINES
IV-1
COMPRESSORS AND TURBINES
1. CODES AND STANDARDS
- API 617
- API 612/614
Design Guidelines and/or Engineering Specifications
° Basic Practice as reference.

° PDVSA Engineering Design Manual Volume.
2. DESIGN REQUIREMENTS
2.1 Compressor installations shall be designed for minimum manning and

operator attention.
2.2 Remote manual tripout switches for emergency shutdown of each

compressor shall be provided both at the compressor and in the control
house.
2.3 Turbines operating in the nominal 600 psig steam system (STM-600) shall
develop rated horsepower with 580 psig, 700°F steam at the throttle valve
inlet.
Turbine exhaust system of 145 psig is preferred.
2.4 Turbines operating on the nominal 145 psig steam system (STM-145) shall
develop rated horsepower with 130 psig, 455°F steam at the throttle valve
inlet.
2.5 Backpressure turbines shall develop rated horsepower with the exhaust
steam header at the process design pressure plus 10 psi.
2.6 Compressors shall be located at minimum elevation above grade consistent

with safety, foundation, and piping requirements.
2.7 Lube oil coolers should be air fins. If water coolers are used materials must
IV-1
be approved by PDVSA. Use only sea cooling water.
2.8 Steam turbines for auxiliary lube and seal oil pump drivers shall be per BP10-
14-1 and API 614 and shall be provided with Woodward TG-10 hydraulic
type governors or equal. Model and "Nema Class" shall be referred to
PDVSA for review.
For Lube System, main oil pump only can be directly coupled to the shaft of
the turbine if the speed is less than 1800 r.p.m. Otherwise, a separate main
oil pump shall be required.
2.9 Automatic startup facilities shall be provided for both the electric motor and
steam turbines driven auxiliary lube and seal oil pumps. A selector switch
shall be provided to designate the pump in standby autostart service.
2.10 Thrust bearings for special purpose equipment shall be Kingsbury or

equivalent. For general purpose equipment PDVSA approval is required.
2.11 For critical and special purpose equipment, anti-surge system C.C.C.
(Compressors Control Corporation) is preferred.
2.12 Lubrication shaft- Sealing and Control Oil Systems for special purpose
applications shall follow API 614.
2.13 For transmitter vibration and bearing temperature systems, Bently Nevada or
equivalent is preferred.
2.14 An oil heater for the lubrication system reservoir is not required.
2.15 Lubrication skid shall be chemically cleaned passivated and sealed.
3. BLOWERS
When is required use Bently Nevada or equivalent for transmitter vibration and
bearing temperature system.
IV-2
Instruments and Control Valves
SECTION N° V
INSTRUMENTS AND CONTROL VALVES
Centro de Refinación Paraguaná V-1 PDVSA

INSTRUMENTS AND CONTROL VALVES

1. The Contractor shall be responsible for providing of adequate instrumentation to
ensure satisfactory, control, convenient operation, adequate safety and easy
maintenance.
2. All instrument measurements shall use the following units:
° Flow (Liquid) Hydrocarbon/Sour water barrels/day at 1 atm, 60 °F GPM

Water, Caustic
° Flow (Gas) Hydrocarbon standard cubic feet/day 1 atm., 60 °F

Nitrogen, Process air standard cubic feet/min 1 atm., 60
°F
° Flow Steam, Boiler Feed Water and pounds/hour

Condensate
° Pressure > 1 psig pounds/square inch gauge

< 1 psig inches of water
Vacuum inches of mercury
° Level (Storage Tanks & Vessels) feet, inches
° Level (Process Units) % of range
° Temperature ° Fahrenheit
3. Board mounted display stations, if any, shall be miniature electronic. Control valves
are to be pneumatically operated. Local control loops are to be pneumatic or
electronic depending on distance and application.
4. Final control elements shall drive in the direction indicated in the individual design
specification upon loss of instrument signal, power or instrument air failure. If no
direction is indicated, the contractor shall determine the fail safe position. On three-
way valves, the specified fail safe position and pressure drop are indicated for the

"exchanger port" of the valve.
5. Measuring Instrument
5.1 Orifice Meters
- Normal design flow rate shall be between 70 and 80% of capacity.
- Provide anticipated minimum and maximum flow rates between 30%

and 95% of capacity. If a different rangeability is necessary, the
individual specification will detail the requirements. Two differential
pressure transmitters connected to the same orifice tap shall be used
previous PDVSA approval.
- The minimum pipe size for conventional orifice is 2 in, and the
minimum flange rating class shall be 300 ANSI. The use of higher
rated flanges or of facing other than raised face shall be as required
by the piping specifications.
- The ratio of orifice diameter to internal pipe diameter does not exceed
0.7.
- Orifice meter differential range shall be 20, 25, 50, 100 or 200 in of
water. Differential range of 100 in of water is preferred.
- Differential pressure transmitters used for protective systems duty

shall be size such that the cut in or cut flow rate is at least 30 % of the
transmitter full-scale flow.
5.2 Variable Area Meter
- Normal design flow rate shall be between 60% and 80% of capacity.
-
Provided anticipated minimum and maximum flow rate between 10%
and 95% of capacity. The maximum rate should be selected to use
manufacturer's standard tube and float.
CONTROL VALVES

6. Control valves in flashing service are denoted on the design flow plans by the letters
"FS".
All control valves in flashing service shall be sized per I.S.A. Handbook of Control
Valve. For multicomponent liquids, use the same method but use the inlet pressure
for the vapor pressure and the critical pressure (i.e., ∆P max = 0.3 KmP1).
Contractor shall size control valves determined to be in cavitating service using

flashing service methods and shall be referred to the owner for review.
7. All control valves (including three-way control valves) shall be equipped with blocks
and bypasses unless approved by the owner. Those control valves not blocked
and bypassed shall be provided with handwheels.
8. In general, the minimum pressure drop for control valves (except three-way control
valves) at design flow shall be:
20 percent of the friction drop in the circuit (excluding the valve) plus 10 percent of
the static differential pressure in the circuit up to differential pressures of 200 psig,
20 psi from 200 psig to 400 psig, and 5 percent above 400 psig (this pressure drop
can be omitted in circuits such as recycle and reflux circuits in which any change in
pressure level in the receiver will be reflected through the entire circuit). However,
for these circuits the minimum valve pressure drop shall be 10 psi.
Lower pressure drops may be used in gas and vapor services where available
pressure is limited. These applications shall be stated as exceptions by the
contractor.
9. Minimum rating for process control valves shall be 300 psi for flanged and 600 psi
for screwed valves. Screwed end valves shall be limited to body size smaller than 1
inch.
10. The use of ODD size control valves, 1 ¼, 2 ½ and 5 inches shall be avoided.
11. Control valve piping manifold shall be in accordance with BP 3-6-2.

12. Control valves in sulfur service shall be jacketed in addition to internal steam tracing
to make sure that the heat transfer the valve body is adequate.
GENERAL
13. External displaced type instruments shall not be used in any level instruments with
very dirty service, or subject to high vibration.
14. Gauge glass column drains shall be provided with drain line to sewer or closed
system as appropriate. This is in addition to BP15-5-1. In addition a separate fill
3/4" connections shall be added to drain line of level instruments to allow testing.
Steam drums shall use Clark Reliance or equal water columns and level glasses
with Ball Type stop check valves.
15. When necessary to prevent corrosive or solids bearing fluids from entering
instrument or instrument lines, seals or purges will be provided.
16. Independent high level alarm shall be installed on high risk tanks:
° Atmospheric storage tank remotely controlled and handless crude or material

with a flash point of 100°F or lower.
° Pressurized and refrigerated storage tank or vessel.
17. Instruments in vapor or gas service shall be mounted above the sensing point.
18. Instruments in liquid, steam or condensable vapor service must be mounted below
the sensing point.
19. Instrument block valves (take off connections) at piping shall be accessible in

sequence of preference as follows: grade, platform, stairway, permanent or portable

ladder. Above 15'-0" accessibility shall be from platform or permanent ladder.

20. Instrument accessibility shall be as follows:
Accessibility Chart
Access Required
Type of Instrument I II III IV V
Transmitters X
Local Indicators X
Pressure Gauges X X
Thermowells X X
Self-Contained Regulators X
Control Valve X
Local Controllers X
Local Recorders X
Process Actuated Switches X
Frequently Adjusted Instruments X
Emergency Instruments X
Analyzer X
Thermocouples X
Where:
I. Grade , platform, stairway, or permanent ladder.

II. Grade, platform or stairway.
III. Grade only.
IV. Grade, platform, stairway, permanent ladder or portable ladder. Instrument
in pipeway will be considered accessible by portable ladder although the
height may vary.
V. Grade or Platform.
21. Temperature control loops shall be provided with duplex thermocouples.
22. All temperature probes shall be protected from process by thermowells.
23. Use API code for safety valve sizing.

24. For vibration protection system, Bently Nevada System is preferred.
25. In critical equipment for anti-surge system, Compressor Control Corporation (C.C.C)
system is preferred.
26. Analyzer Panel connections and sampling systems to process analyzers shall be
referred to PDVSA for review and approval.
27. On high pressure or high temperature process lines, flanged connections shall be
used. Union connections are not allowed.
28. All connections from process to instruments shall allow for rodding-out in case of
plugging. No elbows shall be used.
29. All entrances to Junction Boxes and Field Panels shall be from the bottom
(preferred) or side (alternative),no top entrance should be used.
30. Type of Backup Stations
Computer reliability has been excellent, but some computer downtime must be
expected and designed for. Therefore, a backup system which is capable of
keeping the units operating and on control during computer downtime must be
specified. The backup control systems must assure safe and stable operation of
the process units for extended periods (roughly up to six hours) although some
product giveaway and increased operator attention may be expected while on
backup. All control valves which are driven by the computer must have a backup
station from which the valve may be operated when the computer is unavailable.
Controllers requiring backup are identified by the symbol "X" next to the instrument
control function on the flow plans. Purchaser will provide guidelines for selecting
panel versus CRT backup station. The type of backup station is specified on the
instrument section of each design specification.

31. All annunciator panels and push button stations with associated lamp shall be
provided with a “lamp test” button.
32. Level glasses shall be identified with a tag number.
33. All instruments, except thermocouples, shall have dedicated connections.
34. Solenoid valve resetting shall be done manually at the local stations.
35. All MOV actuators require fireproofing. KMASS system is preferred.
36. All components and equipment related with local panels shall be provided by the
supplier including the integration to the DCS.
37. Sample taps for analyzers or instruments located in sulfur lines, shall be traced with
145 psig steam to achieve the temperature requirement of 266ºF or higher.
PROTECTIVE SYSTEMS AND CRITICAL INSTRUMENTS
38. Protective system shall move their protective positions on loss energy (e.g. electrical
power, instrument air). Protective system on rotating machinery are exceptions to
this and shall not move to the protective position on loss of energy.
Rotating machinery support and auxiliary equipment shall move to their protective
position on loss energy.
39. All sensors associated to the rotating machinery equipment shall be routed with rigid
conduit into the local control panel.

40. All system associated to the air flow measurement in blowers and compressors
shall use a primary element with an accuracy of 0.5%. A Venturi tube is
recommended for such applications.
41. Shared trend recording capability shall be provided only for critical instrument
signals which are brought into the control center. PDVSA will advise the number of
pens required for each project.
42. All manually or automatically initiated emergency trip, cut-in and cut-out systems
shall be provided with control center annunciators, logged into the computer system
(in control center and local panels). PDVSA will advise these requirements for each
particular project.
Annunciators on main Control Panels shall be of the high-density type in order to

maximize space. Annunciators on local panels shall be referred to PDVSA for
approval.
For local alarm systems with multiple alarm initiators, e.g., compressors and boilers,
one or more control center "group" annunciators shall be provided. Local
annunciator indication shall reveal which device caused the alarm First-out alarm
feature. Each time one of the local annunciators indicates an alarm condition, the
related control center group annunciator shall begin flashing and the warning horn
shall sound even if the alarm was initially active (reflash). When this group alarm is
acknowledged by the control center operator, the control center warning horn shall
stop and the annunciator shall continue flashing until the alarm is acknowledged at
the local panel, the annunciator shall provide a continuous light until all alarm
conditions are corrected. The group alarm shall sound on loss of power to the local
annunciator. The alarms to be logged into the computer will be selected for each
particular case.
43. All emergency trips, cut-ins and cut-outs shall be reset locally unless otherwise
specified. Process shutdown and interlock systems shall be reviewed with
purchaser for location of control equipment, detailed operation, development of
checkout procedure, test capability, and other items. Interlock systems must be

logged into the computer system.
44. Online testing of all manually or automatically initiated emergency trip, cut-in and
cut-out systems with a minimum of complexity and with minimum manpower is
required. Therefore, each input (initiating device) and each output (emergency
action) shall have the capability of being bypassed or defeated, unless otherwise
specified. One noncancellable control Center Flashing Light shall be provided for
each system indicating that a trip initiator or emergency action of the system has
been bypassed or defeated. All these actions shall be logged into the computer
system. Individual indication shall be provided to identify which component has
been bypassed or defeated.
45. The following is a list of general guidelines to be used in selecting an alarm display
priority with systems utilizing hardwired annunciators, instrument CRT's, and
computer CRT's (or printer):
° Priority 1 Alarm
- Definition
Critical alarms associated with immediate identification of conditions

that may result in injury to personnel, damage to process equipment,
or large operating debits.
- Examples
a. Cutout alarms when the effects of shutdown of that piece of

equipment will propagate to other pieces of equipment.
b. Pre-alarms which indicate that a shutdown conditions will occur
in a short period of time such as knockout drum LHA, furnace
feed FLA, etc.
c. Alarms which indicate toxic gas release.
d. Loss of a utility, such as cooling water, to critical process

equipment that may result in equipment damage.

- Display
Hardwired to annunciator on operator console, and logged into the

computer system.
- Electrical wiring
Unrelated with ESD: all alarms triggered by switches should be

directed first to the Ronan annunciator and then to the DCS. Alarms
triggered by transmitters will be directed first to the DCS and then
to the Ronan annunciator
Related with ESD. All the alarms are directed from PLC to the
Ronan annunciator and continue to the DCS by software link.
Bypass switches from the valves will be directed first to DCS and
then to the Ronan annunciator (Common alarm)
° Priority 2 Alarms
- Definition
All abnormal conditions which do not fit into the categories of Priority 1
alarms. Computer system shall have inherent alarm logging
capabilities.
- Display
Instrumentation/Computer CRT's.
46. On all critical on emergency installations DC solenoid valves shall be used.
47. Emergency Shutdown System (ESD) selection requires PDVSA approval.
48. On Programming Logical Controller (PLC) provides individual circuit protection

(fuse) for each inlet/outlet points (I/O).

49. Fuse protection shall be provided on an individual basis to all circuits feeding into
local panels. A shorted or grounded element should no propagate to the rest of the
circuits.
50. On local control panels with liquid crystal displays the roof should extend such that
sun's rays can not damage the instruments.
51. For equipment such as IPS, UPS, Fire Protection Systems, PDVSA shall advise
names of approved manufactures. All UPS systems shall be provided with an
external by-pass to permit on-line maintenance.
52. Terminations or splices to fiber optic cables shall be done in specially provided
junction boxes. Pig-tails shall be used at the terminations to allow easy
maintenance.
53. Bypass switches shall be normally closed. In general, there are two kinds of
bypasses that could be used: a general type for the final element bypass and a
particular bypass for each initiator which activates a common alarm at the panel
alarm.

Process Vessels
SECTION N° VI
PROCESS VESSEL
Centro de Refinación Paraguaná VI-1 PDVSA

Process Vessels
PROCESS VESSELS
1. DESIGN CODES
ASME Pressure Vessel Code Section VIII Div.1. With stamp.
Design Guides and/or Engineering Specifications
- Basic Practices BP5-1-1, BP5-1-2.

BP5-2-1, BP5-2-2 for Internals.
BP5-3-1 for Hydrotest.
- PDVSA Engineering Desing Manual, Volume 21 when is referenced.
- BS 5500 (only for HDS reactor vessels).
2. DESIGN CONDITIONS
2.1 Design Pressure
The design pressure of vessels subject to internal pressure shall be equal to

the maximum anticipated operating pressure plus 10% or 30 psi which ever
is greater. The minimum design pressure for a pressure vessel is 30 psig.
When there are incentives to specify a design pressure vessel less than 30
psig, refer to the owner for review and approval.
Vessels normally subject to internal pressure shall generally be designed to

withstand a minimum external pressure of 2.5 psig.
Vessels for vacuum service, including those in which vacuum may be

created inadvertently, shall be designed for an external pressure differential
of 15 psi or an external pressure differential 25% greater than the maximum
design value, whichever is less.
2.2 Design Temperature

Process Vessels
Vessels operating between 32°F and 750°F shall be designed for the
maximum anticipated operating temperature plus at least 50°F.
Vessels operating at temperatures above 750°F shall be designed for a

temperature equal to the maximum anticipated operating temperature.
3. CORROSION ALLOWANCE
3.1 Carbon Steel and Low Alloys

Vessels constructed of carbon steel or low alloys (up through 9% Cr.) shall
have a design corrosion allowance of 0.125 inch. A 0.0625 inch corrosion
allowance is acceptable for steam or dry air.
3.2 Alloy
For vessels constructed of alloys, a 0.01 inch corrosion allowance shall be
specified.
4. WET H2S SERVICE
4.1 Carbon steel in wet H2S service used for vessels that are not fully lined shall
be tested in accordance with NACE TM-02-84 but using the test solution of
NACE TM-01-77.
- The acceptance criteria is a Crack Length Ratio of less than 15% for
each of the three sections from each coupon.
- One set of three speciments shall be tested from each end of each
plate as rolled.
- In the additional on the Reporting Requirements of NACE TM-02-84,

photographs of the examined surface of all test samples showing
cracking, if present, shall be submitted to PDVSA. Photomicrographs
of the examined surface shall also be submitted unetched to show the
type of inclusions and etched to show the microstructures.
4.2 Where Hydrogen Induced Cracking (HIC) Resistance Steel is specified, the

Process Vessels
plate steel used shall be fully killed, made to fine grain practice and
normalized.
4.3 It is required all vessels in amine service to be PWHT at all services

temperatures.
MANHOLES, NOZZLES, VENTS AND CONNECTION
5. Manholes are required for access to all process vessels 30 inches in diameter and
larger. Manholes shall have a minimum diameter of 20". All parts which are to be
installed or removal after fabrication shall be designed to pass through the
manholes provided on the vessel. Handholes and/or flanged heads shall be
provided for vessels less than 30 inches in diameter. Process nozzles shall not be
used as vessel vents. Vessel vent minimum sizes are specified in Paragraph 9
below.
Unless otherwise specified, manholes are to be located as follows:

5.1 Towers
- Clean service - one manhole above the top tray, one at the main feed
tray, and one at the bottom of the tower, and one at each product or
pump around drawoff tray.
- Moderately fouling service - the same as for clean service, plus

additional manholes as needed to provide at least one manhole every
10 trays.
Whenever a manhole (20”) is located between two trays, the minimum space
between the trays shall be 2 feet.
5.2 Drums
One manhole minimum to be provided where entry is required.
6. Process nozzles shall be line size and flush unless otherwise specified. It is
required that all vessels and piping in amine service including entrained amine, to
be PWHT at all service temperature.

Process Vessels
7. Vessel connections shall be minimized by placing safety valves, TI's, process vents
(not vessel vents), PI's and other connections (except level taps) on piping instead
of on vessels, wherever possible and will be by BP3-6-1. Contractor's vessel
drawings shall show all connections and nozzles. Level connections shall be 2 inch
minimum.
8. In addition to the vessel vent, all process vessels shall have a valved and blinded
process vent at least equal to the size shown below. This vent shall be located at
the high point of the overhead vapor line provided the vapor line take-off is from the
top of the vessel. If the vapor line is not from the top, then a vent with a block valve
must be provided on the top. Process vent lines shall be provided with a line size
block valve at the take-off point and the valve shall be readily accessible from an
operating platform.
9. All vessels shall have valved and blinded drain and process vent connections sized
according to vessel volume as shown below. These are minimum size. The drain
line may originate from a bottom liquid drawoff line of at least equal size. It should
terminate with a line size block valve, and blind. Vessel vent connections shall be
blinded without a valve.
Vessel Volume Drain Process Vent Vessel Vent.

(Cubic Feet) Line (in.) Connection (in.) Connection(in.)
Up to 7500 3 3 6
7500 to 15.000 3 4 6
15,000 to 25,000 4 6 6
Above 25,000 6 8 8
DRUMS
10. The following criteria shall be followed in designing drums:
° For drums with a continuous flow of vapor, the cross sectional area for vapor

Process Vessels
flow above high liquid level, or emergency high liquid level if applicable, must
be large enough to limit the vapor velocity to the values given below (split
flow may be used in horizontal drums to reduce vapor velocity by installing
inlet nozzles at each end with one center outlet nozzle):
Install Equation Editor and double-

click here to view equation.
Where: ρv = Vapor Density, lbs/ft3 at conditions

ρl = Liquid Density, lbs/ft3 at conditions
Maximum Allowable Vapor Velocity

(% of Critical Velocity)
Compressor Suction Liquid Surge

Knockout Drums Fuel Gas, or
Centrifugal Reciprocating Distillate Drums
No CWMS - - -
CWMS 150 120 100
CWMS refers to crinkled wire mesh screen. For vertical drums, the minimum
distance from the gas outlet nozzle to the top of the screen shall be equal to
one half the difference of the drum diameter and the outlet nozzle diameter,
all in inches. For horizontal drums, the CWMS shall be sized so that its
horizontal projected area is at least equal to the vertical cross section above
high liquid level. For horizontal and vertical drums, the minimum distance
from the screen to the outlet nozzle shall be equal to one-half the difference
of the screen diameter if a round CWMS, or the long side if rectangular, and
the outlet nozzle diameter, all in inches. The CWMS must be secured
sufficiently to withstand a minimum of 2 psi pressure differential without being
dislodged. CWMS shall be type 304 stainless steel unless otherwise
specified.
° The vapor space in two phase horizontal drums above high liquid level (or
emergency high liquid level, if present) must be at least 20 percent of the

Process Vessels
drum diameter, with 12 inches as a minimum value.
° Horizontal drum inlet nozzles shall terminate in a 90° bend pointing toward
the near end of the drum. For nozzles handling liquid and gas mixtures or
gas only, the bend shall be above high liquid level and discharge against a
wear plate. For nozzles handling liquid only, the nozzle shall be below
normal liquid level.
° All vessels that continuously accumulate water shall have water drawoff
connections. In addition, the oil outlet nozzle shall be provided with a straight
internal extension to a level above high water level or a water drawoff pot
shall be provided.
° Inlet distributors are to be provided for compressor suction knockout drums

and other services where entrainment is to be minimized. The distributor is
horizontal and in the shape of a tee with slots on the underneath portion of
the tee. Slots are to be placed at the end of the entrance leg. The slots are
to be designed for 1/4 psi pressure drop at the design vapor rate.
° For drums that contain two liquid phases, sufficient holdup must be supplied
to assure good separation. The maximum settling rate allowed is 10 inches
per minute. Vertical settling pots may be used on horizontal drums if they
meet these criteria.
GENERAL
11. The CET (Critical Exposure Temperature) for pressure vessels 2 inches or less in
thickness shall be 60°F in order to use a hydrotest temperature of 70°F per BP18-6-
1.
12. Anti-vortex baffles: All process vessels with liquid holdup shall be provided with
anti-vortex baffles located between the liquid outlet nozzle and low liquid level. It
shall be designed per BP-5-2-1.
13. For vapor/liquid towers the design pressure given on the vessel specification is the

Process Vessels
design pressure of the vessel at the tower top. The static head term represents the
additional loading at the tower bottom tangent line and includes the normal pressure
drop through the tower plus the static head of liquid when the level is at high liquid
level.
14. The following guides shall be used for establishing drum and tower hold up require-
ments:
14.1 Reflux drum residence time (low liquid level to high liquid level)
Basis for residence time defini- Recommended
Operating tion residence
Condition time, min
Volume Flow
Product goes to storage HLL to LLL Product 2
Product goes to another HLL to LLL Product 5
tower
Product goes to heater HLL to LLL Product 10 - 12
Product goes to heat HLL to LLL Product 10
exchanger along with other
process streams
Tower reflux HLL to LLL Product 5
Whichever is larger HLL to LLL Reflux + product 2
14.2 Residence time for liquid in the sump. (Bottoms).

Operating Condition Minimum residence
time, min
Liquid is withdrawn by level control and fedds another 2
column directly by pressure.
Liquid is withdrawn by level control and pumped away. 3

Process Vessels
Spare pump starts manually.

Liquid is withdrawn by level control and pumped away. 1
Spare pump starts automatically.
Liquid is withdrawn by level control and feeds a unit that has 5-7
its instruments on a different control board.
Liquid is withdrawn by flow control. 3-5
Liquid flows through a thermosiphon reboiler without a level 1
controller, to maintain a level in the sump.

Furnaces
SECTION N° VII
FURNACE
Centro de Refinación Paraguaná VII-1 PDVSA

Furnaces
FURNACES
1. CODE AND STANDARDS
API 530, 630, 665.

ASME (Boilers).
NFPA.
Design Guides and/or Engineering Specifications
- Basic Practices BP7-1-1, BP7-2-1.
- PDVSA Engineering Design Manual, Volume 6 as references.
2. DESIGN REQUIREMENTS
2.1 Every furnace with a stack temperature below 1,000°F shall be supplied with
a damper of 5 percent Cr steel. Damper shaft shall be 13 percent Cr alloy.
For all radiant furnaces or furnaces with stack temperatures above 1,000°F,
stainless steel dampers should be used. A pneumatic actuator shall be
provided on the stack damper operable from grade and from the control
house. The actuator shall be located at the damper level, connected directly
to the shaft. A damper position indicator shall be located at grade and in the
control house. The damper shall open 100% upon failure of the pneumatic
actuator.
2.2 Air tight flue gas sampling connections constructed of Type 316 stainless
steel shall be provided. These connections shall be designed for vacuum
conditions and shall be used for field sampling.
2.3 Readings from draft gauges shall be transmitted to indicators at the furnace
at grade. A separate indicator shall be provided for the draft gauge
connection below the convection section. Other points may be manifolded
into one common indicator.
2.4 The block valves in the steam lines for emergency coil injection and box
i

Furnaces
purge are to be located 50 feet minimum from the furnace and on the upwind
side of the furnace. Purge steam lines shall enter the furnace box through
the floor and shall be oriented to avoid steam impingement on the furnace
tubes.
2.5 For multipass furnaces, in all liquid or vaporizing services, each pass shall
have a flow controller with signals to the control house.
2.6 For all furnaces, pilot gas shall be natural gas, independent of the burner fuel
supply system.
2.7 All furnaces larger than 100 MBtu/hr (heat release) shall have their bridge-
wall and stack temperatures and bridgewall draft readings brought to the
control house.
2.8 Stacks (including vent stacks from unfired equipment) shall not be fabricated
from bolted sections unless approved by PDVSA.
2.9 The fire box radiant section shall be seal welded from the inside.

Safety Facilities
SECTION N° VIII
SAFETY FACILITIES
Centro de Refinación Paraguaná VIII-1 PDVSA

Safety Facilities
SAFETY FACILITIES
Safety facilities and equipment known to be required shall be shown in each

individual design specification. The Contractor is responsible for reviewing the design to
ensure that the facilities meet all required codes, and that adequate facilities are provided
to prevent fires, explosions and accidents. This section presents general design guides to
be used in the design of all safety facilities.
1. The safety facilities (pressure relief valves, flare, flare blowdown and seal drums,
etc) are to be designed to handle the largest load resulting from any possible single
contingency (i.e., non-remote). Contingencies, including fire, are considered as
unrelated if there is no process, mechanical or electrical interrelationship between
them. However, when analyzing any single contingency (such as cooling water
failure), all directly related effects resulting from that contingency should be conside-
red.
For non-related double contingencies (i.e., remote), the safety facilities shall be
designed such that the maximum pressure in any equipment item protected by the
safety facilities does not exceed 150% of its design pressure. This sets the basis for
the maximum superimposed pressure relief valve backpressures cited in this
section of the GII. In addition, the velocity in the flare seal drum, if applicable, shall
not exceed 230% of critical velocity during remote contingencies (versus 150%
during non-remote contingencies), the velocity in the flare blowdown drum, if
applicable, shall not exceed 175% of critical velocity (versus 100% for non-remote
contingencies), and the depth of the flare seal drum water seal leg, if applicable,
shall be at least equal to 110% of the maximum pressure in the flare seal drum
during remote contingencies (versus 175% of the maximum non-remote
contingency flare seal drum pressure). Critical velocity is defined as:
Vc = 0.157 (pl - pv)0.5

pv
3
Where: ρl= Liquid density, lb/ft .
3
ρv= Vapor density, lb/ft .
2. All unfired pressure vessels subject to overpressure either by fire or operating failure
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Safety Facilities
must be protected by pressure relieving devices that will prevent the pressure from
rising more than permitted by the ASME Unfired Pressure Vessel Code Section VIII
unless:
° The vessel is under 2 feet 0 inches diameter and is constructed of pipe, and
the pressure relief valve is required for fire only.
° The vessel normally contains no liquid and a pressure relief valve would be
required for fire only.
3. In designing for fire contingency, the plot areas affected as part of a single fire
contingency depend on accessibility and spacing. A group of equipment is to be
considered a single fire risk area if it is separated from another area by a clear
spacing of at least 20 feet, on all sides, to permit firefighting attack into all parts of
the area. The maximum plot area to be considered a single fire contingency is 5000
square feet.
4. The capacity of pressure relief valves on vessels must be sufficient to release the
vapor generated during a fire contingency, as well as any other contingency. API-
RP-520, as amended by this document, should be used as the basis for calculating
the vapor rate generated during a fire. It should be noted that unless the insulation
and insulation support is known to withstand direct flame and fire water
impingement, as specified in BP3-2-4, no credit can be taken for it. The wetted
surface used to calculate heat
absorption for a practical fire situation is normally taken to be the total wetted
surface within 25 feet of grade. "Grade" usually refers to ground level, but any other
level at which a major fire could be sustained, such as a solid grating platform,
should also be considered. In the case of vessels containing a variable level of
liquid, the high liquid level is considered. Specific interpretations to be used for
various vessels are as follows:
A. Horizontal Drums

Safety Facilities
° Less than half full (to HLL) - The wetted vessel surface up to high
liquid level is used, regardless of distance above grade. This applies
to all types of grating, solid or open.
° More than half full (to HLL) - The total wetted vessel surface within 25
feet of "grade" ("Grade" means actual grade or a solid grating platform
beneath the drum), or up to the vessel equator, whichever is greater,
is used. If open-type grating is used and the vessel is more than 25
feet above grade, the total wetted vessel surface up to the equator
shall be used.
B. Vertical Drums - The wetted vessel surface within 25 feet of "grade" ("Grade"
means actual grade or a solid grating platform beneath the drum), based on
high liquid level, is used. If the entire vessel is 25 feet or more above
"grade", and open-type grating is used, then only the surface of the bottom
head need be included.
C. Fractionators and Other Towers - An equivalent "tower dumped" level is

calculated by adding the liquid holdup on the trays to the liquid in the tower
bottom (at high liquid level). The surface that is wetted by this equivalent
level and which is within 25 feet of "grade" ("Grade" means actual grade or a
solid grating platform beneath the tower) is used. If the bottom tangent line is
greater than 25 feet above grade and open-type grating is used, then only
the wetted surface of the bottom head need be considered.
D. Heat Exchangers, Air Fins and Piping - These items of equipment are
normally not considered for establishing the wetted surface of exposed
vessels in a fire risk area. However, there may be special situations, such as
congestion and substandard spacing, or an unusually large piece of
equipment, such as a reboiler with liquid holdup of about 1,000 gallons or
more, which warrant their inclusion.
In these cases, the total wetted area exposed to fire (or in the case of airfin
exchangers, the total surface area) should be used.
E. Storage Spheres and Spheroides - The total surface area within 25 feet of
grade, or up to the elevation of the centerline, whichever is greater, should
be used.
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Safety Facilities
The heat absorbed by the liquid in a vessel during fire exposure is calculated by the
equation Q= C1 F A0.82 where Q is in Btu/hr, F is the environmental factor (1.0 for
bare vessel) and A is the wetted surface in Ft2. C1 equals 21,000 for typical onsite
units in which good drainage exist. C1 equals 34,500 for facilities that lack good
drainage (e.g., typical offsite facilities, such as diked areas around tanks which
increases the level of fire involvement).
For insulation that meets the requirements of BP3-2-4 and for gunite/concrete, the F
factor is as follows:
Thickness, inches F
Gunite/Concrete 1.5 0.33
Insulation 0.25 0.25

0.50 0.125
1.00 0.075
> 1.00 0.075
If a vessel contains liquid, its pressure relief valve and associated piping, as well as
the flare collection system, may have to be sized for two-phase vapor/liquid flow
during fire exposure. The following procedure shall be used to determine if two-
phase vapor/liquid flow can occur during fire exposure for either horizontal and
vertical drums.
4.1 Vessels Smaller than 10 Feet in Diameter
° If the vessel is provided with an independent high level alarm set to

prevent liquid overfilling above 85% full (by volume), after accounting
for thermal expansion, then the pressure relief valve is to be designed
for all-vapor flow. Thermal expansion of the liquid shall reflect the
increase in liquid volume when the liquid is expanded from its coldest
storage temperature to the bubble point temperature corresponding to
the pressure relief valve set pressure.
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Safety Facilities
° If the maximum expanded liquid volume is greater than 85% of vessel

volume, then the pressure relief valve and its associated piping must
be designed for two-phase vapor/liquid flow.
° If two.phase vapor/liquid flow is predicted and if the pressure relief

valve discharges to a closed system, the closed system must be
designed to accommodate a minimum of 10% of the vessel volume.
4.2 Vessels 10 Feet or Greater in Diameter
° If the vessel is provided with an independent high level alarm set to

prevent liquid overfilling above 95% full (by volume), after accounting
for thermal expansion, then the pressure relief valve is to be designed
for all-vapor flow. Thermal expansion of the liquid shall reflect the
increase in liquid volume when the liquid is expanded from its coldest
storage temperature to the bubble point temperature corresponding to
the pressure relief valve set pressure.
° If the maximum expanded liquid volume is greater than 95% of the

vessel volume, then the pressure relief valve and its associated piping
must be designed for two-phase vapor/liquid flow.
° If two phase vapor/liquid flow is predicted and if the pressure relief

valve discharges to a closed system, the closed system must be
designed to accommodate a minimum of 10% of the vessel volume.
For vertical vessels, the maximum usable volume shall exclude the volume of the
top head. If two-phase vapor/liquid flow is predicted to occur, the Contractor shall
contact the owner for the procedure to be used for sizing the pressure relief valve
and its associated piping.
5. Routing of pressure relief valve discharges to the atmosphere or to a closed

system is determined in accordance with the following criteria:
A. Discharge to a closed system is required for pressure relief valves in the

following categories:
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Safety Facilities
° Pressure relief valves handling materials which are liquid or partially

liquid at the valve inlet. An exception to this is made for certain offsite
thermal expansion relief valves as described below.
° Pressure relief valves normally in vapor service, but which under any
single contingency may discharge flammable, corrosive or hazardous
liquids.
° Pressure relief valves located in the vapor space of partially liquid-
filled vessels when all of the following are not provided:
a. The vessel has an independent high level alarm.
b. The vessel vapor space above the independent high level

alarm is a 30 minute (or larger) holdup based on the design
liquid inlet rate and stoppage of liquid outflow. An exception,
however, may be closed loop refrigeration systems where
limited inventory precludes overfilling.
° Pressure relief valves handling toxic or corrosive vapors which

condense at ambient conditions.
° Pressure relief valves in toxic vapor service where discharge to the

atmosphere would result in the maximum calculated concentration at
the property line or at any working area (either at grade or an elevated
platform) exceeding the Threshold Limit Value (TLV). Refer also to
BP3-2-4. The Contractor shall obtain required meteorological data
from the owner.
° Release of flammable vapors which would result, after dilution with

air, in a fuel-air mixture with a concentration above 50% of the Lower
Explosive Limit (LEL) at grade or any platform or equipment.
° Releases of flammable vapors which, if discharged to the

atmosphere, would in the event of inadvertent ignition, result in radiant
heat densities in excess of the permissible exposure level for per-
sonnel. This maximum level is defined as 6,000 Btu/h ft2 at ground
level.
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Safety Facilities
An additional requirement applies to light gases, such as hydrogen,

methane, ethane and ethylene and to vapors above 600°F since
these materials have a higher probability of ignition than other typical
hydrocarbons. For these streams, automatic instrumentation should
be provided to effectively reduce the Pressure Relief Valve release so
as not to exceed 3,000 Btu/h ft2 heat density at ground level. This
requirement would have no effect on the sizing of pressure relief val-
ves, but would only reduce the probability of reaching the maximum
design release. However, should the instrumentation fail to operate
properly, the maximum heat density should still not exceed 6,000
Btu/h ft2.
In calculating maximum ground level radiant heat densities, maximum

wind speed at the pressure relief valve discharge riser elevation shall
be used. This wind speed is calculated as follows:
U at riser elevation –
ft/sec = 22.0 ( H )0.14
33
where H= Elevation of the pressure relief valve discharge riser

above grade, feet.
° Pressure relief valves discharging vapors which do not fall into the
above categories but which would be significant contributors to at-
mospheric pollution. Such releases should not normally be used to
size the closed system but should be tied in up to the limit of its
capacity. The order or preference for tying in to the closed system is
(1) malodorous vapors, (2) unsaturated hydrocarbons, (3) saturated
hydrocarbons.
B. Pressure relief valves can be discharged to the atmosphere only if all of the
following conditions are satisfied:
° The fluid handled is only vapor at the valve inlet.
° Pressure relief valves in partially liquid-filled vessels if all of the

following are provided:
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Safety Facilities
a. The vessel has an independent high level alarm.
b. The vessel vapor space above the independent high level

alarm is equivalent to a 30 minutes hold up based on the
design liquid inlet rate and stoppage of liquid outflow.
c. Discharge to a closed system is not otherwise required.
d. Local regulations regarding atmospheric releases are complied

with.
Outlet piping for pressure relief valves that discharge to the atmosphere should be
designed in accordance with the following:
a. The requirements of BP 3-2-4 under the heading "Discharge to

Atmosphere" covering discharge risers for pressure relief valves,
including bracing and supports, elevation, snuffing steam connections
and drainage, must be satisfied.
b. The built-up backpressure limitations defined in BP 3-2-4 and in this

document must be met.
c. Pressure relief valve leakage or release to the atmosphere may be

ignited by lightning, autoignition, or an electrostatic discharge of the
release.
The following should be provided as applicable:
1. Leakage:
To enable the operator to extinguish a fire from a leaking

pressure relief valve, a snuffing steam connection should be
provided in the following cases:
- All pressure relief valves in hydrogen or methane

service.
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Safety Facilities
- Pressure relief valves in hydrocarbon streams above

their autoignition temperature, typically 600 ºF.
2. Release:
To minimize the probability of an electrostatic discharge during

release, all pressure relief valve risers in hydrogen or methane
service should be provided with a torroidal ring.
6. Pressure Relief Valve Piping
a) The Contractor shall ensure that the pressure drop and back pressure
requirements of BP-3-2-4 and this document are met. Contractor's pressure
drop, back pressure, and other pressure relief valve calculations shall be
submitted to the Owner for review.
b) The inlet line to a pressure relief valve must be at least the size of the
pressure relief safety valve inlet. When multiple pressure relief valves are
manifolded, the cross sectional area of the manifold piping must be equal to
or greater than the sum of all the inlet areas of valves open to the manifold.
c) Pressure relief valve inlet line size must be checked independently of sizing
the pressure relief valve. The maximum allowable frictional pressure drop
between the vessel and the pressure relief valve inlet shall be 3 percent of
valve set pressure in psig units and shall consider only friction losses,
including contraction and expansion losses. Effect of liquid acceleration on
static head is excluded. This 3% limit applies to conventional, pilot operated,
and balanced bellows valves. Equipment with a design pressure of 50 psig
or less shall be referred to the owner if the 3% criteria is impractical to
achieve.
d) For pressure relief valves discharging to the atmosphere, the flow in

discharge piping shall be subsonic and the exit velocity shall be
approximately 75 percent of sonic to limit noise problems and to avoid
choked flow. If the discharge piping has to be enlarged to meet this, the
length of the expanded section shall be a minimum of ten times the nominal
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Safety Facilities
diameter of the large pipe.
e) Vapor relief valves discharging hydrocarbons to the atmosphere must

discharge at least ten feet above the highest structure within fifty feet
provided the heat radiation limits mentioned in Paragraph 5 are met. In
addition, the riser tip must be at least as high as any part of the vessel or its
overhead piping to avoid direct, discharge impingement and should
discharge vertically upward.
f) Pressure relief valve discharge risers in flammable service should be

designed such that exit velocities are at least 100 ft/sec under all foreseeable
contingencies (except fire) which could cause the valve to release.
g) Pressure relief valves discharging toxic vapors to atmosphere shall be

provided with risers at sufficient height and location so that the toxic
vapors in any area where personnel may be present are below the specified
limits for workplace concentrations.
h) Discharge piping from an individual relief valve should not be smaller than
the valve outlet.
i) The maximum allowable velocity in safety valve laterals and headers

discharging to the closed system shall also be approximately 50 percent of
sonic (75% of sonic for systems that one normally idle, such as flare
headers).
j) The backpressure limitation quoted in BP3-2-4 shall be observed.
7. Pressure relief valve discharge piping shall be designed such that the following
backpressure limits are not exceeded:
Allowable BP, % of Set Pressure
Conventional Bellows
BUBP SIBP TBP BUBP SIBPa TBPb

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Safety Facilities
Non-Fire, Single Risk 10 25 --- ---- 75 50
Fire in a Given Fire 21 25 --- ---- 75 50

Risk Area.
a) For a bellows PRV, the indicated SIBP is for a remote

contingency (i.e., this PRV is not discharging, other PRV's are
discharging, maximum overpressure = 1.5 times design
pressure in case this PRV discharges).
b) TBP for a bellows PRV refers to non-remote BUBP + SIBP.
In the above table:
BUBP: Built-up backpressure.
This applies when the pressure relief valve is discharging, and is

equal to the total frictional pressure drop from the valve discharge to
the point of final disposition (atmosphere, atmosphere via a flare
system, or another piece of equipment).
SIBP: Superimposed backpressure.
This applies when the pressure relief valve is not discharging. If the
valve discharges to a closed flare system, this is the maximum
pressure in the flare system considering all contingencies during
which this valve does not discharge.
TBP: total backpressure = BUBP + SIBP(for bellows, the 50% maximum TBP
equals BUBP + SIBP).
The set pressure in the above table is in units of psig.
The SIBP limits are based on not exceeding 150% of the equipment's design
pressure in the event a non-blowing valve discharges as a result of a non-related
(i.e, double) contingency.

Safety Facilities
For pressure relief valves discharging to a closed flare system, the normal pressure
in the flare system shall be assumed to be zero. The maximum superimposed
backpressure is a function of location in the flare system, and shall be provided to
the Contractor by the Owner. As an approximation, the maximum superimposed
backpressure on any pressure relief valve discharging to a closed flare system is
approximately 20 psig.
8. The following considerations shall be taken into account in the design of heat
exchange equipment to cover the possibility of tube leaks or tube rupture:
° The entire low pressure system must be checked for mechanical adequacy
relative to overpressure in the case of a split tube.
° If the design pressure of the entire low pressure side is more than two-thirds
that of the high pressure side, no further consideration of a tube split is
necessary.
° If the design pressure of the entire low pressure side is less than two-thirds
that of the high pressure side, the system must be examined to determine
the need and size of pressure relief valves for a split tube contingency per
BP3-2-4.
° In determining the flow into the low pressure side resulting from a tube split,
the following shall be considered:
- Flow from the high pressure to low pressure side occurs through two
fully open tube ends.
- In determining if the low pressure side can be over-pressured, the

differential pressure driving force shall be the difference between the
normal operating pressure of the high pressure side and 150 percent
of the design pressure of the low pressure side (or critical pressure
drop, whichever is smaller).
- To determine the amount of flow relieving capacity required, the

differential pressure driving force shall be the difference between the
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Safety Facilities
normal operating pressure of the high pressure side and 110 percent
of the design pressure of the low pressure side (or critical pressure
drop, whichever is smaller). The relief valve is set at the low pressure
side design pressure and 10 percent accumulation is allowed.
Normal process flow into the low pressure side is assumed to stop.
The effect of flashing as liquid flows from the high pressure side to the
low pressure side, vaporization of any liquid in the low pressure side
due to contact with high temperature fluid, and loss of normal process
flow into the low pressure side must be taken into account.
° Where a control valve is present in the low pressure system piping downs-
tream of the exchanger, it shall not be considered to fail simultaneously with
the tube split. However, if process control would cause the valve to shut as a
result of conditions developed in the low pressure system resulting from the
split, the valve must be considered to shut. If the process control would
cause the valve to open or remain in a stationary position, the valve opening
shall be considered that existing under minimum normal flow conditions
through the valve.
° When the high pressure and low pressure fluids are at different temperature
levels, the effect of vaporization due to heating of the cooler fluid must be
considered.
° Piping or vessel material on the low pressure side may not be suitable for
cold temperatures resulting from a tube split. If a brittle fracture is possible in
the low pressure system as a result of a tube split, this condition shall be
referred to the Owner for further review.
° In addition to evaluating the effect of a split tube, internal tube sheet or

tube leakage can occur, often unknowingly, under normal operation.
Where the single action of closing a valve on the low pressure side of
the exchanger exceeding 1.5 times its design pressure as result of an
internal leak, the low pressure side of the exchanger should be
uprated; or a pressure relief valve sized for leakage through a 0.25
inch hole or a minimum size pressure relief valve should be installed.
9. When a vessel or exchanger is one of a series interconnected by piping without

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Safety Facilities
block valves, and if the piping is of adequate size to handle vapor or liquid displaced
by design vapor generation in the equipment and is not subject to plugging, then the
system may be considered as one unit when calculating the required relief valve
relieving capacity.
When a car-sealed-open (CSO) block valve is located in the interconnecting piping

between vessels or exchangers, the system may be considered as one unit.
However, a CSO valve should not be employed in a system where the single contin-
gency of inadvertent closing of the CSO block valve would directly result in the
overpressure of any equipment above 150 percent of its design pressure.
In the case of block valves installed on the cooling water outlet line of an exchanger,
the block valves shall be CSO if a free path is required for the condition of a split
tube.
10. Pressure relief valve types have been specified as Consolidated valves, which are
the preferred type conventional pressure relief valve. The Owner will specify
preferred vendor(s) of pilot operated pressure relief valves. An integrally reinforced
bleeder shall be provided between the pressure relief valve and the upstream
pressure relief valve block valve. A valve bleeder shall also be provided between
the pressure relief valve and any downstream pressure relief valve block valve for
pressure relief valve outlets routed to process equipment (not the flare system).
11. All pressure relief valves shall be located for easy accessibility for maintenance
including manual unbolting and shall have "in place" mechanical equipment
handling per BP4-2-1.
12. Contractor shall determine the need for and design the required "thermal relief"
pressure relief valves, caution signs, small open bypass valves, liquid drainage
facilities, etc., per BP3-2-4 for heat exchangers and long piping sections. All
designs must be reviewed by the Owner. In addition to the requirements of BP3-2-
4, the following shall apply:
° Leakage through a check valve or control valve is not sufficient to compensa-

te for thermal expansion in long line segments.
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Safety Facilities
° Onsite "thermal relief" pressure relief valves shall discharge to a closed

system. If the liquid is below its flash point, the "thermal relief" pressure relief
valve may discharge to the ground if it is offsite, but should not cause hou-
sekeeping or personnel hazard problems. The Contractor shall investigate
and evaluate techniques for recovery of discharges from offsite valves.
° Each "thermal relief" pressure relief valve shall be provided with an inlet CSO
block valve and an oulet CSO valve if the discharge is to a closed system.
Depressurizers 3/4" drain valves are required between the block valves and
the relief valves.
Depressurizers ¾" drain valves are required between the block valves and
the pressure relief valves.
13. The provision of valves, manually or remotely operated from a safe location, and
installed at strategic points throughout the equipment, is required to permit the
affected section to be isolated from other sections of the plant, so that the inventory
of fuel feeding a fire or emergency is limited to a small area or group of vessels.
These emergency isolation valves shall be provided in accordance with the
following guidelines. Valves required for equipment isolation are referred to as Type
A, B, C and D. Requirements for these valves are given in BP3-7-4, BP3-12-1,
BP15-9-2. Valve actuators should preferably be located upwind of equipment
protected.
Actuator buttons for type D valves should be located at least 25 feet from the fire
risk zone, preferably upwind. The same applies to type C emergency isolation
valves. Note that for a vessel feeding a pump, the push button must be at least 25
feet from the pump, the most likely source of fire. In addition, the emergency
isolation valve should be visible from the push button.
13.1 Compressors
° Isolation valves are required in the suction and discharge of any

compressor over 200 HP handling flammable or severely toxic
materials. For compressors with interstage equipment containing
more than 1000 gallons of flammable liquid at normal levels which
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Safety Facilities
can not be pumped out in ten minutes or less, isolation valves are
required in the interstage suction and discharge lines.
° For compressors meeting the above criteria having multiple suctions

or discharges to different pressure stages, isolation valves are
required in all suction and discharge lines normally open.
° Type D valves are to be provided unless otherwise noted in the

individual specification. For over 1,000 HP, the type D valves should
be located at least least 25 feet from the compressor, if piping layout
permits.
13.2 Pumps
° When the inventory in a pump suction vessel meets any of the criteria
listed below, a Type B, C or D valve is required, according to size and
location. Inventory is to the top of working level range; piping holdup
is neglected. In the case of towers, inventory is calculated at the top
of the working level range, with the addition of tray and reboiler holdup
if they are draining into the tower.
- Light ends over 2000 gallons (Light ends are defined as

pentane and lighter hydrocarbons, and unstabilized naphthas
with a Reid vapor pressure of 15 psia or greater).
- Hydrocarbon liquid above autoignition point or over 600°F,

over 2000 gallons inventory.
- Hydrocarbon liquid over 4000 gallons inventory.
° The "25 feet from equipment protected" in BP3-7-4, Paragraph 4.8

means 25 feet from the pump.
° If an emergency isolation valve is installed in a pump suction line
(single pump or common suction line to 2 or more pumps), the
isolation valve and all piping components between it and the pump(s)
must have a pressure rating at normal operating temperature not less
than 3/4 of the pressure that will exist downstream of the pump(s)
when the isolation valve is closed. The pressure in this situation is not
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Safety Facilities
necessarily the pump discharge pressure. This pressure is usually

the pressure in the vapor space of the first downstream vessel.
Should a charge of flange rating be required in a pump suction
system because of this requirement, it must occur at the upstream
side of the isolation valve.
13.3 Vessels
° Vessels containing light ends, heavier than light ends above its flash
point, or severely toxic liquids require isolation valves as follows:
- Liquid inventory over 1000 but less than 10,000 gallons

requires a Type A valve in each 2 inch or smaller line
connected below the top of the working level range.
- Liquid inventory over 10,000 gallons requires a Type A valve in

each line connected below the top of the working level range
regardless of size.
- Connections between the isolation valve and the vessel are

not permitted.
° For large high risk inventories a Type D valve is required in each

normally open line connected below the normal liquid level if all of the
following conditions apply:
- The vessel contains light ends or heavier than light ends above
its flash point.
- The vessel contains over 10,000 gallons to top of working level

range.
- Special factors which increase the potential for damage in the
event of fire, e.g., poor fire-fighting access, substandard
spacing or congested layout or stacking.
° In some suction lines from vessels to pumps, emergency isolation

may be required for both the pump and the vessel, if they both satisfy
the appropriate criteria. In such cases, duplicate isolation valves are
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Safety Facilities
not required. If an EBV is required for the vessel, connections to the

line between the isolation valve and the vessel should be avoided.
The button operator should be located 25' away from the equipment
to be protected and from the pump.
13.4 Reboilers
Tower reboilers are considered integral with their towers for isolation
purposes, contents to be included with tower inventory, and emergency
isolation valves are not required between tower and reboiler.
13.5 Furnaces
° Means must be provided to stop the flow of flammable process fluids

to furnace coils. An accessible manually operated block valve 50 feet
from the furnace is required in each stream feeding a furnace. Block
valves at feed pumps or compressors, or at feed control valves, which
meet the above requirement, are acceptable.
° Means of emergency isolation in the outlet of a furnace handling

flammable materials is also desirable where backflow would have a
major effect on a tube failure fire. This must be balanced against
problems of coking and inadvertent closure of isolation devices. High
pressure, volatile liquids and large inventory in downstream
equipment all favor furnace outlet isolation. Isolation is not normally
provided unless coil outlet pressure exceeds 200 psig. When
isolation is required a check valve of the swing-check (with not
external actuation or dampening mechanism) type is the normal
method for systems operating below 1000 psig coil outlet pressure.
No additional overpressure protection is required as a result of the
inclusion of this check valve.
° All fuel streams to furnaces, including pilot gas, should be provided

with accessible, manually operated block valves, located at least 50
feet from the furnace at grade. A battery limit valve or other
emergency block valve in the line may be considered to meet the fuel
shutdown requirement, provided that its closure would not create
other hazards or conflict with other actions that might be necessary
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during a plant emergency. Such manual isolation valves are in

addtion to the tight shutoff valves provided for the furnace emergency
shutdown system.
13.6 Battery Limits
° Except for relief valve headers, emergency isolation is required in

every line entering or leaving battery limits if the line is normally
pressurized (battery limits valves for relief valve headers and for lines
which do not require emergency isolation shall be provided on the
basis of requirements for turnaround isolation).
° Battery limits isolation valves should be grouped into one or more

manifolds provided with line identification. A single valve at battery
limits may serve for both emergency and turnaround isolation.
° Isolation valves must be specified Type B or C according to size and

meet BP3-7-4 requirements with the following exceptions:
- There is no limitation on elevation.

- For 14 inch and larger, Type C valves are to be considered for
flammable or severely toxic services. Contractor shall develop
recommendations for these valves, if not specified in individual
design specifications, and review with the Owner.
Requirements for other emergency facilities (including valves) which may be

needed for the remote shutdown of onsite equipment or critical streams and for the
depressurizing, removal or displacement of flammable material inventory of process
units shall be covered in the individual design specifications.
14. Emergency valves used in vapor blowdown (depressuring) service or for remote
shutdown of critical streams shall be tight shutoff type control valves. This is an
exception to BP15-9-2, Paragraph 5.2. Valves shall meet other requirements
applicable to Type D emergency valves given in BP3-7-4.
15. Requirements for type C and D emergency block valves.

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Safety Facilities
Emergency block valves which are fireproofed shall have additional requirements
per BP15-9-2 Paragraph 5.1 as follows:
° Deactivate control power fuse and motor protection by installing equipment

jumpers at the terminal blocks.
° Motor starter to be remote mounted, i.e., not at valve.
° Motor to have Class H insulation.
° Emergency valves which close on emergency should be seated by a limit

switch and the closing torque switch set at its highest setting to protect the
valve from mechanical damage if the limit switch does not open.
° Emergency block valves that open should be adjusted in the conventional
manner.
16. The vent line from a balanced bellows valve shall be routed as follows:
a. Low Concentration or Non-Toxic Vapors: To atmosphere, directed away

from equipment.
b. Potentially High Toxic Concentration Vapors: 1" vent line to atmosphere, 10

feet above and outside the limits of the platform, with a 1/4" drain hole at the
bottom of the vent riser.
c. Low Toxic Concentration Liquids: 3/4" line discharging to an open funnel,

with a 1" drain line routed to a sealed sewer connection.
d. Potentially High Toxic Concentration Liquids: 3/4" line to 4" diameter
disengaging pot; vapor from the pot to atmosphere via a 1" riser, terminating
10 feet above and outside the limits of the walkway; liquid from the pot to a
sealed sewer connection via a 1" line.
In all cases, the 3/4" bellows vent line should be supported such that the first
support is no more than 4 feet away from the pressure relief valve. In addition, the
3/4 vent line should be supported on a handrail. Both supports should be loose-fit.
Follow RP520 and BP 3-2-4. In addtion, the bellows vent for all cases shall be
i

Safety Facilities
provided with a 3/4" CSO valve followed by a 3/4" plugged stub for testing and
cleaning. The takeoff for the vent line shall be downstream of this CSO valve and
shall also be provided with a 3/4" CSO valve.
17. All pressure relief valves and car-sealed valves shall be painted yellow. Bellows
type pressure relief valves shall be painted yellow with a red band.
18. Control valves indicated to have a specified maximum valve Cv, thereby ensuring
adequacy of safety facilities, shall be painted yellow and provided with a sign in
spanish warning against replacement with a valve having a Cv greater than the
specified maximum.
When a control valve failure affects the pressure relief valve sizing, e.g wide open
failure position of a control valve admitting fluid (liquid or vapor /gas) from a high
pressure source into a lower pressure system, the pressure relief valve should be
designed in accordance with the following, whichever is controlling:
a.- Normal Contingency.
- Control valve 100% open.

- Bypass 50% open.
- Control valve flow based on maximum trim that fits into the
Control valve body.
- Flow through bypass = 50% at max. flow the Control valve.
- P1 at highest normal pressure.
- P2= (1.1) (P).
Where: P= Downstream design set pressure.
P1= Upstream pressure.
P2= Downstream pressure.
b.- Remote Contingency.
- Control valve 100% open.

- Bypass 100% open.
- Control valve flow based on maximum trim that fits into the
Control valve body.
- Flow through bypass based on actual size of the bypass valve.
i

Safety Facilities
- P1= highest normal pressure.

- P2= 150% of downstream design pressure= 1.5 (P).
In both cases, credit can be taken for vapor being relieved through the
normal channels (if the control scheme does not bottle-up the
equipment) as well as through the pressure relief valve.
c.- During startup, Control valve 100% open, bypass fully closed, only
source of vapor relief is the PR valve (assume downstream exit not
available).
For new designs the maximum Cv of the bypass valve should be

equal to the max. specified Cv of control valve.
19. Sample outlets for toxic gases (e.g. H2S) and non-viscous, volatile, toxic liquids
(e.g., sour water) should be designed to accommodate sample bombs in a closed
loop. Sample outlets for viscous, non-volatile toxic liquids (e.g., high boiling
aromatics) should be drawn from a closed loop and located near a funnel. The
funnel should have a screen to support a sample container with the funnel outlet
connected to a drain. However, sample outlets for viscous liquids containing a
fraction of volatile, toxic materials (such as H2S and benzene) should be located in a
closed housing box with local ventilation exhausted to a safe location (closed
system or an atmospheric location as determined by dispersion calculations). A
funnel (with a screen to support a sample container) connected to a drain should
also be located in the box. Sample outlets for toxic solids (such as coke) should be
located in a closed box. The connection of the funnel outlet into the drain should
prevent skin contact and prevent any flow onto the slab.
20. Sour gas monitoring systems will be required in areas where gas and/or liquid
streams are handled, containing H2S in sufficiently high concentrations so that any
liquid or gas release may cause hazardous situations.
21. All locations where off the road traffic can damage equipment or piping shall be
protected by a handrail.

Electrical Desing Criteria
SECTION IX
ELECTRICAL DESIGN CRITERIA
Centro de Refinación Paraguaná IX-1 PDVSA

ELECTRICAL DESIGN CRITERIA

1. SCOPE
1.1 This section covers certain the general criteria as a guide for electrical
designs within the PDVSA Amuay Refinery located in Judibana, Estado
Falcón, Venezuela.
2. STANDARDS, CODES AND REFERENCES
2.1 The equipment and material to be furnished and the work to be done shall
conform to the following codes and standards.
- Engineering Design Manual (Volume 4-Electrical)

- National Electrical Code 1990 Edition (NEC), (ANSI C1), (NFPA
#70).
- National Electrical Safety Code 1990 Edition (NESC) (ANSI C2).
- Lightning Protection Code (ANSI C5.1) (NFPA #78).
- Exxon Basic Practices, last revision as referenced. In event of
a conflict between Exxon BP’s standards and the present
recommended guidelines, the most favorable criteria will prevail
over final decision.
- PDVSA’s specifications and typical Amuay installations
- American National Standards Institute, Inc. (ANSI).
- National Electrical Manufacturers Association (NEMA).
- Institute of Electrical and Electronics Engineers (IEEE).
- Insulated Cable Engineers Association (ICEA).
- Federal Aviation Agency's (FAA) Advisory Circular 70/7460-1g
Obstruction Marking and Lighting.
- Illumination Engineering Society (IES).
- Underwriters Laboratories listings (UL).
- American Petroleum Institute (API).
- American Society for Testing and Materials (ASTM).
- National Fire Protection Association (NFPA).
- Covenin.
- API 546
- API 541
3. DESIGN CONSIDERATIONS
i

Electrical detailed engineering performed by consultant is under his complete

responsability including electrical equipment derivated from its designs.
3.1 The electrical system shall be designed for reliable service, safety to
personnel and equipment, ease of maintenance and operation, minimum
power losses, mechanical protection of equipment, and the addition of future
loads.
3.2 Voltage insulation levels, equipment interrupting and continuous current

capacities, circuit protection, and mechanical strengths shall be selected and
coordinated in accordance with calculations and the recommendations of
IEEE, NEMA, ICEA, and ANSI to ensure that equipment and cable is
specified and purchased for the duty required.
3.3 System protective devices (relays, fuses, breaker trip units, etc.) shall be
selected and coordinated to ensure that the interrupter nearest the point of
fault (or high overcorrect) will open first and minimize equipment damage
and disturbances on the system. Similar criteria is applicable on selection of
ct’s, pt’s, etc.
3.4 All "Engineered Items" of electrical equipment shall be identified by owner's

tag numbers. These items include transformers, switchgear, motor control
centers, relay panel, lighting and power panels, and all other items requiring
special attention or selection.
3.5 All electrical equipment and material shall be new and supplied by approved
manufacturers. Equipment and materials shall be protected from damage
and the weather during transportation to site, site storage and construction.
3.6 Asbestos material shall not be used in fabrication or coating of any

component.
3.7 For cable installation in underground duct banks, cable derating will be based
on "ETAP" program or by using another similar computer program in lieu of
Paragraph 6.25 of Exxon Basic Practice BP16-2-1.

3.8 In event of up-grading some electrical equipment, same original

manufacturer shall be used, in order to guarantee entire and reliable match
between involved parts.
4. DRAWINGS
Standard format and symbols NEMA/IEEE shall be used for manufacturer's and
construction's drawings.
5. ENVIRONMENTAL CONDITION
See Section N° 1.
6. AREA CLASSIFICATION
6.1 Areas and/or process units shall be classified as to the type and degree of
hazard as defined by the National Electrical Code supplemented by the
recommendations in the American Petroleum Institute "Recommended
Practices" RP-500 and National Fire Protection Association Standard 70C
and others, where applicable.
6.2 Area classification drawings shall be produced in accordance with BP16-1-1,

last review, for areas and/or process units as required, and shall indicate the
limits, both horizontally and vertically, of classified areas. In situations where
a predominate portion of the plant is classified, Division 2 construction will be
employed throughout the plant if feasible.
6.3 Electrical equipment and materials for use in classified areas shall be
certified by an approved testing authority for the specific classifications.
7. SYSTEM CONFIGURATION AND DISTRIBUTION

7.1 System Design

Power System Design shall be in accordance with BP16-2-1.
7.1.1 Process Area
For process areas, secondary selective substations with automatic

transfer shall be provided. Secondary selective substations shall
have two buses, each supplied by a normally-closed incoming line
circuit breaker and connected together by a normally-open bus tie
circuit breaker. Transfer scheme shall be as described in BP16-2-
2.
7.1.2 Non-Process Area
For non-process area, a single-ended substation could be provided.

However, depending upon the specific reliability required, primary
selective substation could be supplied.
7.1.3 Captive Transformer
A captive transformer feeding a single large motor shall be fed from

two independent sources. The captive transformer shall be
provided with a manually operated, key interlocked, primary transfer
switch near the transformer.
7.1.4 General Objective
The auxiliary power distribution system shall be designed to provide

reliable electrical power during all modes of plant operation,
including all shutdown conditions.
7.1.5 Voltage Regulation
The system shall have a steady state voltage regulation of +/- 5%.
7.1.6 System Calculation

Calculations for system short-circuit studies, protective relays

coordination, system voltage dips during motor start, sequential
reacceleration and steady state voltage regulations shall be
performed using company's approved software programs. These
studies shall be done as needed by the consultant and always
under direct PDVSA technical supervision. The switchgear buses
and motor control centers fault duties and large motor starting
conditions shall be carefully considered in the selection of the
transformer sizes and transformer impedances.
7.1.7 Automatic Motor Reacceleration
Automatic motor reacceleration shall be provided for motors as

requested by process engineering and safety considerations.
Reaccelerations shall be based on fixed time steps, unless a
different directive is specified by the owner, for a specific project.
These steps shall be verified with appropriate computer
simulations. Sucessfull reacceleration shall be verified for the worst
expected condition of the system (minimum short circuit level at the
specific machine bus).
7.2 Voltage Levels
7.2.1 Plant System Nominal Voltages:
Distribution Voltages - 13.8 kV

Power Systems Voltages - 4160 V, 2400 V and 480 V.
7.2.2 Transformer BIL Levels

Nominal System Distribution Power

Voltage (kV RMS) BIL (kV) BIL (kV)
0.6 30 45
5.0 60 75
15.0 95 110
(For resistance grounded neutral, neutral BIL must equal phase

BIL.)
7.3 System Phasing
To maintain a consistent phasing throughout the entire electrical system,

connections between transformers, switchgear and cables shall be made as
follows for a 3-phase, 3-wire system:
SWITCHGEAR
TRANSFORMER BREAKER TERM CABLE
TERMINAL OR BUS BAR PHASE
H1 A A or 1
H2 B B or 2
H3 C C or 3
X1 A A or 1
X2 B B or 2
X3 C C or 3
XO Connect to grounding system (as seen from low-voltage side).
° Switchgear and motor control assembly phasing shall be A-B-C

when facing the front of the assembly, as follows:
a. Bus bars - left-to-right, front-to-rear and top-to-bottom.

b. Breaker and starter terminals - left-to-right.
7.4 Switchgear

7.4.1 4160 volt, 2400 volt and 480 volt switchgear line-up shall be as
defined on 7.1.1. The 480 V switchgear line-up shall provide power
circuit breakers for the large motors. Line-ups of 2400 volt and 480
V motor controllers (MCC's) are also fed from its respective
switchgears through Bus Ducts. 480 V power circuit breakers will
be used to protect 480V MCC. The design of switchgears will
comply with BP16-2-1.
° Motors 151 HP and larger shall be fed at 2400 volts.

° Motors 150 HP and smaller shall be fed at 480 volts.
° 13.8 KV Bus Machine line-up shall be defined as a front-dead
switchgear connected to a generator or utility source and
feeding down stream substations.
° Motors compressed between 101 HP and 150 HP will be
considered large motors at 480V.
7.4.2 Motor protection when supplied from a power circuit breaker shall
include a thermal relay (49) besides overcurrent and ground fault
relays. Microprocessor based relays for motor protection are
acceptable, provided that they are fed from a 125 VDC battery
source or 120 VAC UPS systems.
7.4.3 Motor control circuit and control relays shall be designed to meet
reacceleration requirements described in 7.9 125 VDC shall be
used for trip and close circuits.
7.5 In-Plant Distribution

Substation Design.
a. Main circuit breakers at 13.8 kV feeder entrance shall be provided

inside of new substations buildings. A single breaker for each feeder
is required. The 13.8 kV breaker will provide primary protection for
medium and low voltage plant substations. These main breakers
receives power cables from up-stream power plant.

b. Underfrequency relays, four step, solid state type, GE SSF or similar,

will be provided in each electrical substation for load shedding.
c. Electric loads to be shed shall be defined by Amuay Refinery.
d. The primary distribution to the Process Plant Substations, and the

offsite substation shall be at 13.8 kV. The process substations shall be
double ended and will consist of 2 transformers, medium voltage
switchgear at 2400 volt motor controllers.
e. The 480 volt substations shall consist of 13800-480 volt power

transformers and motor control centers or switchracks located within, or
adjacent to the process units. Units substations shall be designed
according to BASIC PRACTICES.
f. Breakers in the substation will have facilities for Power Manegement

System (remote) y local control.
g. The transformer yard shall be weather protected (roof and fading

are required). Elevated substations with open and ventilated basement
for conduit and bus ducts entrances are required. Unit substation shall
be provided with air conditioning and gas and fumes detection and
alarm. Outside air entrance shall be automatically blocked if gas and/or
fumes detection exceeds preselect values. An alarm to the control
room shall signal this situation. See complementary paragraph on point
26, page 9-33.
h. In the transformer yard the traditional design related to the use of rigid
steel galvanized conduit for underground service it is now being
replaced by an approved concrete e channel with metalic cover.
7.6 Neutral Grounding
Neutrals of wye connected systems are grounded as follows:

Winding Voltage Grounding Type

2400 V, 4160 V and 13800 V Low Resistance (Grounding

Resistors),
placed next to transformer on
concrete
base.
480 V and below Solid.
Grounding resistors shall be selected according to PDVSA ELECTRICAL

ENGINEERING DESIGN GUIDE, Section II, paragraph B.4.
7.7 Motors
7.8.1 Motor and motor enclosure shall conform to PDVSA Sp- 46-11.
7.8.2 In general, motors shall conform to the following:
Horsepower Voltage Phase HZ Enclosure
Below ½ 115 1 60 Explosion-

proof/ TENV
½ through 150 460 3 60 TEFC
151 through 2000 2300 3 60 TEFC
Above 2000 4160 3 60 TEFC
7.8.3 The type of motor enclosure shall be selected to conform to the

classification of the area in which the motor is to be installed.
7.8.4 Motors 75 horsepower and above shall be equipped with 120V

space heaters. The space heater shall be controlled by an auxiliary
contact of motor starters, and shall be automatically deenergized
when the motor is running and automatically energized when the

motor is not running. The auxiliary contact shall remain closed or

be automatically bypassed when the starting device is in the test or
withdrawn position. Power for the motor space heater will be
supplied from an external source supplied by Purchaser.
7.8.5 Each 2300 and 4000 volt motor shall have sufficient space in its
main junction box for stress cone termination of the incoming power
cables
7.8.6 Synchronous motors 1000 horsepower and above, and induction

motors 1500 horsepower and above shall have three window type
current transformers supplied by the motor manufacturer and
mounted in the main junction box for "self-balance primary current
method" differential protection.
7.8.7 Motors 1000 horsepower and above shall have surge capacitors
and lightning arresters supplied by the motor manufacturer and
mounted in the main junction box.
7.8.8 Motors 2.4 kV shall have two resistance temperature detectors

(RTD) per phase in the stator windings. Leads for these devices
shall be brought into a junction box separate from the main junction
box. A common junction box may be used for the motor space
heater leads and RTD leads. The RTDs shall be used for
temperature indication. RTD leads associated to motor
temperature protection shall be run to solid state relay located at
respective feeding motor controller in the substation.
7.8.9 Motors rated for 4 kV and higher voltage shall be provided with a
coupling sensor in order to monitor stator insulation for partial
discharges. Sensors shall be mounted and connected in the power
terminal box. Terminal box size will be adecuate. External
connector for data acquisition shall be also provided. IRS
technology for partial discharges shall be used and confirmed by
the owner.

7.9 Medium Voltage and Low Voltage MCCS
a. When reacceleration required, time relays and motor protection relays

shall be carefully selected and motor control circuit conductor shall be
designed to assure that the motor will reaccelerate sucessfully
(contactor will close and remain closed) even through voltage drops of
60% of the nominal system voltage. 120 VAC is the preferred control
voltage for low voltage MCCS.
b. Auxiliary relays must be installed in separate panels within the

substation.
c. Vaccum circuit breakers shall be used for medium voltage motors

above 2000 HP. Solid state relays shall be used for motor protection.
Ground Sensor relays are required (in addition to motor protection) for
protection of motor feeder cables.
d. The schematic diagram of fused medium voltage motor controller shall

indicate simultaneously interruption on M and MR coils. A flush
mounted disconnect switch shall be installed to be operated as owner
required.
e. Fused contactors shall be used for medium voltage motors below 2000
HP to 151 HP. Ground Sensor relays are required in addition to motor
protection for protection of motor feed cables. Solid state relays shall
be used for motor protection as well.
f. Low voltage 480V switchgear breakers used for motor control shall be a
electrically operated air circuit breakers type. Fused switches in 480
volt switchgear are not acceptable. Solid state overcurrent protective
devices acceptable.
g. Low voltage combination motor starters shall be used for low voltage
motors up to 100 HP rated 460 V. Ground sensor 50 GS relay are
required in addition to motor protection as protection of motor feed

cables on 25 HP motor and larger. Switchgear breakers shall be used

as motor starters for motors between 101 HP and 150 HP rated at
460V.
8. OPERATING DESIGN CRITERIA
8.1 Voltage Regulation
8.1.1 The following guidelines further supplements the BPs 16-2-1

paragraph 6.26 through 6.3.2.
a. Connections between power transformers and secondary

switchgear will be short lengths of bus duct with zero voltage
drops. Segregated bus ducts are not permitted.
b. Connections between lighting transformers and panelboards

will be short lengths of cable with zero voltage drop.
c. Transformer regulation shall not be considered for normal

operating conditions since transformer tap changers will be set
to obtain a specified bus voltage level under normal load
conditions.
8.1.2 During Starting of Motors
In all cases involving motor starting, the voltage at the motor

terminals must be sufficient to ensure proper breakaway and
acceleration of the motor.
In general, the allowable voltage drop through the system to the

source buses during single large motor starting shall not exceed:
a. On the bus supplying the primary distribution 1-2%

system (13.8 kV).

b. On the bus supplying the secondary distribution 10%

system (such as 4.16 kV or 2.4 kV).
c. On the a motor (4.16 kV, 15%

2.4 kV or 480 volt).
8.1.3 During Normal Operation
The allowable voltage drop in the cables, based on full load, shall
not exceed:
a. Primary distribution feeder cables 13.8 kV. (1%)
b. Power Transformer ( )
c. Secondary distribution feeder cables 4.16 kV, (2%)

2.4 kV or 480 volt.
d. Motor feeders and lighting transformer feeders. (2%)
e. Lighting circuits between the panelboard and the (2%)

most remote fixture or outlet
8.2 Load Criteria
The following guidelines shall be used as a basis for selecting transformer

capacities based on the Initial Design Load. Initial design load will be the
load calculated during the first stage of the detailed engineering.
8.2.1 Initial Design Load
a. The Initial Design Load shall consist of: The nameplate rating
of all normally operating motors; the nameplate rating of
motors designated as "future" on drawings and the mechanical

equipment list; and the lighting, air conditioning, heating and

miscellaneous loads.
b. Motors designated as "spare" (one of a pair in the same

service) shall not be included in the Initial Design Load when
they are connected to the buses of a double ended substation,
or to the same bus of a single ended substation.
c. "Spare" motors shall be included in the Initial Design Load

when the operating and "spare" motors are connected to
separate single ended substations with no interconnection
between the buses.
d. To convert motor horsepower to kVA use:
For 200 hp and below 1.0 x hp

For 250 hp and above 0.9 x hp
For synchronous motors (1.0 PF) 0.78 x hp
e. When synchronous motors with a leading power factor are

connected to a bus, the resulting leading kVAR shall be
considered when calculating the transformer kVA capacity.
8.2.2 Transformer Capacities
a. Ratings and sizing power transformers shall be in accordance

with BP'S and ANSI/IEEE STANDARDS.
b. Each transformer shall be sized such that its fan cooled rating
is equal to or grater than the product of the substation initial
design load in Kva, multiplied by a factor of 1.2.
c. During the find stage of the detailed engineering the design
load shall be calculated again and the transformer sizing shall

be checked.
8.3 Short Circuit Levels
a. Maximum available short circuit duties shall not exceed the interrupting
and short circuit (momentary) rating of standard metal clad switchgear
ANSI standards shall be applied. Transformer impedances are
selected to meet this requirement (besides of voltage drop
requirements).
b. Switchgear is not rated for maximum short circuit duty

occurring during momentary paralleling of buses during bus transfers.
8.4 Breakers Operating Philosophy
Switchgear-Bus Tie Breakers
• 480V, bus tie air breakers shall be normally open and shall have
auto transfer scheme.
• 2.4 kV and 4.16 kV bus tie vacuum breakers shall be normally open
and shall have auto transfer schemes.
Switchgear-Low and Medium Voltage Tie and Incoming Breakers
Breakers control will be either handled from Power Management System

(PMS) remote control station or by the local breaker control switch, as
indicated on PDVSA Specifications. This mean, the substation transference
scheme shall have remote and local operation facility. One local four (4)
position selector switch shall be provided for performing the above
operations.
9. PROTECTIVE RELAYING

a. Amuay Refinery follows the protecting relays scheme indicated in Exxon BP16-
12-2 in its electrical substations. Electromechanical relays for 50/51 protection
has been replaced by solid state relays GE MDP type for 50/51/51G protection.
b. Amuay protective relaying criteria will be used for relaying coordination

studies.
c. Protective relays (microprocessor...) Will be accepted whenever it carry out the

Amuay Electrical Protection Schemes, particulary the automatic transfer of
substations and motor reacceleration requirements.
10. DC SYSTEMS
10.1 Types
a. DC systems shall be provided for switchgear protection and control

power. Instrument power supply includes: emergency protection
systems, such as fire and gas protection systems, process control
systems, shutdown systems.
b. Separate DC systems will be provided for emergency motor loads,

such as seal oil and lube oil systems. The systems consist of batteries
and charger, redundant bulk power supplies. 125 Vdc system for
electrical and process control (solenoids) application must be obtained
from different 125 Vdc source.
c. Instrument power supply shall be design according to BP-16-8-1.
d. VAC Power supply for IPS and UPS will be redundant: one
480VAC supply shall be provided from the 480V TAPC located in the
low voltage substation. The second 480V supply will be provided from
MCC located in the low voltage substation.
10.2 Location
a. DC systems for switchgear protection and control and emergency

motor loads are located at the substation (separate room). Other

systems are located in the control building. Where batteries are used
with the system, the batteries shall be located in the same building as
the system, but in a separate room.
10.3 Voltages
Systems voltages for the various systems are as follows:
a. Switchgear protection and control power - 125 Vdc.

b. Emergency protection systems - 125 Vdc.
c. Process control system - 125 Vdc, and/or 24 Vdc.
d. Shutdown systems - 125 Vdc, and/or 24 Vdc. Depending on specific
process area.
10.4 Batteries
The batteries shall be of lead-acid construction consisting of tubular-type

plates. The battery system that supplies station load, as stated in Section
10.1 of this document, shall have the capacity at the minimum design
temperature to supply the loads for 8 hours with the charger off.
10.5 Batteries Chargers
The battery chargers for station batteries shall be sized to recharge a fully
discharged battery to 95 percent full charge in not more than 8 hours while
supplying 100 percent of the rated load. Batteries and battery chargers are
further discussed in PDVSA Specification, "Station Battery and Battery
Charger".
10.6 DC Distributions
Complete coordination study is required for each DC system. Coordination

will include main power supply breaker in 480 VAC. Appropriate fuses and
breaker shall be selected to guarantee coordination

11. UNINTERRUPTIBLE POWER SYSTEM (UPS)
11.1 Types
UPS shall be provided when a continuous source of ac power is required for

critical loads. These loads include various types of process control systems
(Distributed Control System (DCS), Programmable Logic Controllers (PLCs),
Analog Controllers, computer systems, communication systems, fire and gas
control systems, and emergency lighting. UPS shall provide an
uninterrupted source of power for safe and orderly shutdown of equipment or
systems, safe and orderly evacuation of facilities, and safety related
monitoring and communications within the facility, in the event of loss of
power from the normal power source. UPS is also provided when a "clean"
(spike, surge, sag and noise free) source of power is required. Voltage dips
(sags) on the normal power source can cause control and computer systems
to shutdown or restart, causing loss of control and loss of data.
The UPS systems shall consist of the following components: rectifier, battery,
battery disconnect, inverter, automatic transfer switch, bypass transformer,
manual/-maintenance bypass switch, and power distribution panels.
11.2 Location
UPS power supply for the plant control system shall be located in the control
building. UPS modules are installed in separate room from the batteries.
11.3 UPS Output Criteria
a. Output voltage is automatically regulated within +/-2 percent of rated

voltage.
b. Output frequency is stable within +/- 0.1 percent of rated 60 Hertz
when the inverter is not synchronized to an external ac line.
c. Automatic transfer between UPS module and the regular alternate

power source is achieved with less than ¼ cycle power interruption on

a 60 Hertz basis.
d. Redundant UPS modules are sized to carry 100 percent of the total of
all loads on the system.
11.4 Batteries and Chargers
a. The batteries shall be of lead-acid construction consisting of Faure-type

plates. The battery system shall have the capacity at minimum design
temperature to supply the loads for 60 minutes.
b. Battery chargers for UPS system batteries are sized to recharge

fully discharged battery to a 95 percent charge in not more than 8
hours while supplying 100 percent rated UPS output load
11.5 Local and Remote Alarm
The UPS Systems shall be equipped with a local alarm panel and a form "C"
(DPDT) dry contact for the following critical alarms:
a. Load on Alternate Source.

b. System on Battery.
c. DC Bus Ground.
d. System Overtemperature.
e. Low or High DC Battery Voltage.
f. Loss of Inverter.
11.6 UPS Coordination Study
A complete coordination study is required for each UPS system.

Coordination shall include main power supply breaker in 480 VAC and
distribution in 480 VAC and 120 VAC. Appropriate fuses and breakers shall
be selected to guarantee coordination.
12. ELECTRICAL EQUIPMENT

12.1 Space Allocation
a. Minimum working clearances about electrical equipment shall be in

accordance with BP's and NEC Code requirements.
b. Extra space is reserved for operation and maintenance of all electrical

components in accordance with manufacturer's requirements.
c. Main 4.16 kV and 2.4 kV switchgear rooms are provided with a minimum
of 6 feet of spare room length for future addition of switchgear cubicles in
addition to required working clearance spaces.
d. Barrier walls between electrical equipment rooms have 3-hour fire rated
walls. This apply for busses machines within power supply building.
12.2 Switchgear
a. Switchgear shall consist of grouped assemblies of freestanding, vertical,

dead-front steel structures containing power buses, removable power
circuit breakers, necessary auxiliary control devices, instrument
transformers, relays, meters, and control and meter switches. As BP16-
12-12.
b. Switchgear assemblies for installation in switchrooms or buildings shall

be the indoor type NEMA 1. Space heaters shall be specified for
switchgears line-up and out door, indoor bus ducts.
b. Switchgear assemblies for installation outdoors shall have weatherproof,

bird-proof, rodent-proof, fully gasketed enclosures, adequately lighted
and ventilated and shall be provided with space heaters to prevent
internal condensation.
c. Each power circuit breaker shall be capable of safely interrupting the

maximum system short circuit current at which it may be subjected at the
applied voltage level.

d. In general, switchgear assemblies shall be connected to supply

transformers by bus duct. Bus duct shall be completely metal-enclosed,
weatherproof, nonventilated type.
12.3 Medium Voltage Switchgear
a. Switchgear rated 2.4 kV through 13.8 kV shall be metal-clad type with

insulated buses.
b. Circuit breakers shall be drawout vacuum type, electrically operated

and shall have the "stored energy" type operators.
c. For more detailed equipment see "General Specification for Medium

Voltage Switchgear".
d. 13.8 kV loop feed shall provide power to a maximum of (5) five

transformers per circuit breaker.
12.4 Low Voltage Switchgear
a. Switchgear rated 600 volts and below shall be metal-enclosed. All

buses shall be isolated (or insulated) such that bare bus bars are not
exposed when the door is opened or the rear panel is removed.
b. Circuit breakers shall be drawout type and manually or electrically

operated with "stored energy" type operators. Trip units for manually
operated breakers shall be the solid state type with selective
characteristics.
c. Manually operated breakers that are tripped by remote devices shall

have shunt trip coils.
d. Circuit breakers used as motor controllers shall be electrically

operated.

e. For more detailed equipment see "General Specification for Low

Voltage Switchgear".
12.5 Power Transformers
12.5.1 Substation power transformers shall be outdoor type, liquid-

immersed, 3 phase, delta-connected primary and wye-connected
secondary windings, and with four 2 ½ percent full-capacity taps,
two above and two below rated primary voltage. In some cases, a
higher impedance may be specified to limit short circuit currents to
within the standard ratings of manufactured equipment.
12.5.2 The neutral point of secondary windings rated 2400 volts through
34.5 kV shall be low resistance grounded. The neutral point of
secondary windings rated 600 volts and less shall be solidly
grounded.
12.5.3 In general, the power transformers shall have a no load air-filled

terminal chamber instead of customed primary interrupter switches
on the primary side and a flanged throat for bus duct connection on
the secondary side. The primary chamber will contain Bus Bars for
feeding cable connections.
The Stationary Bus Bars shall carry out the following requirements:
- Bus Ampacity rated as cables.

- Incoming and outcome cables facilities.
- Bus Links after incoming cables and before the power
transformer entrance derivation and of the outcome cables.
12.5.4 Transformer taps shall be set so that, under no-load conditions,

voltage on the secondary shall not exceed 105 percent of the rated
voltage.
12.5.5 Refer to section 8.2 for Transformer Initial Design Load guidelines.

12.5.6 For more detailed equipment, see "Liquid Immersed Power

Transformers Specification".
12.5.7 Transformer differential relays will be required for transformer sized

5 MVA and larger.
12.5.8 Liquid-filled power transformers shall be sealed tank type.
12.5.9 Transformer shall have shades, made of corrugated fiberglass

material or approved equal, above them.
12.6 Controller for Medium Voltage Motors
a. Controllers for medium voltage motors (2300 volts through 4000

volts) shall be NEMA Class E2, current limiting fuse, vacuum
contactor type. For motors beyond the ampere rating of this type of
controller, switchgear type vacuum circuit breakers shall be used.
b. Controllers shall be grouped in metal-enclosed, freestanding, dead-

front assemblies. Assemblies for indoor installation shall have
NEMA I gasketed enclosures. Assemblies for outdoor installation
shall have NEMA 3R dust-tight, rain-tight, sleet-proof and rodent-
proof enclosures.
c. Each controller shall be provided with three current transformers

one ground sensor, three overload relays, control power
transformer, necessary control accessories and additional
protective devices as required for the specific motor. Relays for
motor protection shall be solid state.
d. For more detailed equipment, see "General Specification for High

Voltage Controller for Motors and Feeders".

e. Each controller shall be provided with a surfaced off-remote

selector to simultaneously denergize MR and M Coils.
12.7 Controllers for Low Voltage Motors
- Spare capacity shall be 20 percent minimum.

- Ground fault relaying for motors 25 HP and larger shall be included
for low voltage motor control centers and turnaround power centers.
• Single Phase Motors Controllers
In general, controllers for 120 volt single phase motors shall be

manual motor starters except in special cases where magnetic
contactor type starters are required. Single phase motors, when
used, shall not be powered from a lighting panelboard.
• Three Phase Motor Controllers
a. Controllers for three phase low voltage motors shall be the

combination type consisting of a molded case air circuit breaker
(MCP) and a magnetic contactor. Minimum contactor size shall be
NEMA Size 1.
b. As minimum, each starter shall have three overload relays and a

120 volt secondary control power transformer with primary and
secondary fuses.
c. Motor controllers for indoor unclassified installations shall be
grouped, metal-enclosed, freestanding, dead front, NEMA 1 type
motor control centers with NEMA Type B wiring. All starters, NEMA
size 1 through size 4, shall be "plug-in" type.
d. Motor control center type assemblies for outdoor, unclassified

installation shall be essentially as Paragraph 12.7.C except with
NEMA 3R, rain-tight, sleet-proof and rodent-proof enclosures.
e. Motor controllers for installation in outdoor areas may be grouped

on switchracks. Each individual controller shall be enclosed in an

enclosure listed or approved for the area classification and when
applicable, sealed in accordance with the NEC.
f. Circuit breakers in combination starters shall have adjustable

magnetic instantaneous only type trip units.
g. Circuit breakers for feeders shall have thermal-magnetic type trip

units.
h. See,"General Specification for Low Voltage Motor Control Centers"

and "General Specification" for Low Voltage Prefabricated
Switchracks for more detail.
12.8 Turnaround Power Centers
Turnaround power centers (TAPC) will be metal-enclosed, freestanding,

dead-front assemblies. The following loads will be fed only from TAPC:
- Lighting panels.
- Welding outlets.
- Air conditioning equipment.
- Battery Changers.
- Space heaters.
In double ended substation, TAPC will be connected to both sides of the low
voltage switchgear and key-interlock will be provided to avoid simultaneous
closing of both sources.
13. CONTROL AND METERING
- Test switches shall be provided for all current and potential circuits for
equipment rated 5 kV and above.
- Multilin solid state relay shall be used to conform the power management
system (PMS) in substation. Fiber optic cable shall be used to communicate

the multilin relay with PMS console at control room.
14. GROUNDING SYSTEM
- A loop grounding system, with radial taps to equipment, shall be installed,

The loop shall be run continuous down both sides of the process unit.
- For buildings and groups of equipment located greater distances from the
main loop, supplemental Nº 4/0 AWG loop connected to the main loop shall
be utilized. Isolated equipment, remote from process area, shall be
grounded by using a local Nº 4/0 AWG ground loop attached to ground rods.
- Below grade grounding conductors shall be buried a minimum of 2'-0", and

shall be installed with slack between connections. Underground connections
shall be exothermic weld type. Exposed grounding connections shall be of
the mechanical type.
15. LIGHTNING PROTECTION
15.1 Tall or isolated structures shall be protected against lightning in accordance

with NFPA recommendations.
15.2 Down conductors from air terminals or lightning mast shall be provide with an
individual ground rod as well as a connection to the plant ground grid.
15.3 Structure Lightning Protection.

Dissipation Array System (DAS) shall be supplied for storage tanks
intended for flammable liquids. DAS is a patented product and design by
LEC (Lighting Eliminators & Consultant, Inc.). DAS design and material for
each tank shall be provided by LEC.
16. LIGHTING
16.1 Illumination Levels

Illumination levels shall be in accordance with BP 16-5-1 and 16-5-2. For

areas not covered by the referenced practices, refer to Table 3 of API-
RP540-74.
16.2 Fixtures and Circuits
In general lighting system will be designed to blend in with the existing

lighting system for the refinery and in compliance with BP16-5-1, Lighting.
The following will assist in fixture and circuit selection.
a. Mercury vapor fixtures shall be used for outdoor lighting and high-bay
lighting areas.
b. Fluorescent fixtures shall be used for general lighting in buildings.
c. Incandescent fixtures shall be used for stand-by lighting and gauge

glass illumination.
d. Floodlights shall be used to maximum extent possible for general area

lighting.
e. Floodlights, streetlights and high-bay lighting shall have ballasts rated

for 480 volts; all other fixtures shall be rated for 120 volts.
f. Outdoor lighting shall in general be photoelectric cell controlled. This

shall be accomplished by feeding the lighting circuits (through
panelboards and/or transformers as required) from lighting contactors
feed from the turnaround power centers.
g. Wall-pack emergency lights shall be provided in the control room,

substation buildings and other strategic locations.
h. When required, marine warning lights shall be provided in accordance

with the Code of Federal Regulations, Title 33, Part 67.

i. When required, obstruction warning lights shall be provided in accor-

dance with the Federal Aviation Agency's Advisory Circular 70/7460-
1G.
j. The 480 volt service to the lighting transformer/panelboard for exterior

lighting only shall be from a combination circuit breaker-magnetic
contactor located in a 480 V MCC (or switchrack). The contactor shall
be controlled by a photoelectric switch and a hand-off-auto switch.
17. CONDUIT AND CONDUIT FITTINGS
Design of underground and above ground conduit system shall comply with the
requirements of BP16-3-1, Wiring Method and Material Selection. The following
guidelines further supplements the BP's.
17.1 Underground Conduit
a. Underground conduit shall be rigid steel hot-dipped galvanized or

PVC (two-inch minimum).
b. Riding steel galvanized conduit shall be used for all lateral runs
from nonmetallic conduit duct banks, bends 45° through 90°, and
risers.
c. Threads of metallic conduit and couplings shall be coated with an

approved compound before being joined.
d. Cable pulling calculations shall be made as required, to ensure that

the cable will not be damaged during installation.
e. All underground conduit shall be encased in a red concrete

envelope providing a minimum outside encasement of three inches
on all sides.
f. The top of the concrete envelope shall be a minimum of 18 inches

below finished grade and shall be colored red. The concrete

envelope shall be omitted within the confines of building
foundations.
g. Wherever the concrete encased conduit is subject to heavy traffic,

such as roadway crossings, it shall be structurally analyzed and
reinforced with steel reinforcing bars.
h. Conduit entering switchgear, motor control centers, and similar

equipment through a concrete floor shall terminate in couplings set
flush with the finished floor, nippled, with a ground bushing, and
sealed with a plastic sealing compound.
i. Where conduit rises above grade, the red encasing concrete shall
be extended a minimum of 6 inches above grade and be sloped for
water runoff.
j. Underground duct banks shall have at end of construction 30

percent minimum free spare conduits. Spare conduits shall
include the following:
• Stub-up for spare conduits shall be strategically distributed

next to the central piperack columns. All stub-ups must be
properly capped.
• Each spare conduit shall be provided with a polyethylene pull

rope.
k. Four (4) inches will be adopted as minimum diameter for 2.4 KV

motor feeders. Same criteria shall be used on motor spare
conduits.
l. Appropriate separators shall be used for pvc conduits

alignement in duct banks
17.2 Above Ground Conduit and Fittings

a. Above ground conduit shall be rigid steel, hot-dipped galvanized

except in wet, humid or corrosive atmospheres where aluminum,
PVC coated or plastic conduit may be better suited. Above ground
conduit shall be securely and adequately supported and grouped in
a selected portion of the pipeway. Conduit shall be supported in
accordance with the National Electrical Code, Article 346-12. Use
of aluminum for above ground conduit must be authorized by
owner.
b. Above ground conduit shall be 3/4 inch minimum.
c. Long radius elbows (factory bends) shall be used for 1 ½ inch

conduit and larger. Field bends shall be in accordance with the
National Electrical Code.
d. During construction, temporary openings in the conduits system

shall be plugged or capped to prevent entrance of moisture and
foreign matter.
e. Conduit between pipe supports and equipment may be supported

from piping (6 inch minimum clearance) except: uninsulated hot
lines (above 150°C, 12 inch minimum clearance); lines that vibrate;
lines requiring frequent maintenance.
f. Conduit fittings shall be selected in accordance with the National

Electrical Code:
g. For unclassified and Division 2 areas not requiring splices in wiring,

the following condulet shall be used:
1 inch and larger - Crouse-Hinds Form 8 or equal.
h. Where splices are required, boxes having sufficient volume to

comply with the National Electrical Code shall be used.

i. Expansion fittings shall be installed in long straight, horizontal and

vertical conduit runs. The maximum distance without an expansion
fitting shall be 150 feet for rigid steel conduit.
Location of the expansion fittings shall be shown on the electrical

conduit drawings.
j. Vented drains or drain seals shall be provided at the low point of

long, vertical or horizontal runs of conduit where condensate could
accumulate and in/outdoor areas where conduit enters boxes or
enclosures from above.
k. Connections to equipment subject to vibration or movement shall

be made with flexible metallic conduit. Liquid-tight flexible metal
conduit and approved fittings shall be used for outdoor equipment
in unclassified and Class I, Division 2 locations.
l. Conduit connections to heavy outdoor pendant lighting fixtures

subjected to vibration or movement shall be made with approved
flexible couplings.
m. Electrical metallic tubing (EMT) may be used in indoor locations

where the conduit will not be subject to severe physical damage
and where hazardous atmospheres do not exist, such as office
buildings, administration buildings, work houses, change houses,
and similar buildings.
n. Control stations installed in classified areas shall be the factory

sealed type.
o. Fiberglass ladder type cable trays and conduit with PVC coating
shall be used for coke handling areas.
18. MANHOLES AND VAULTS

18.1 Manholes - Above Grade
a. Manhole locations and configurations shall be engineered so that

cable will not be damaged when properly pulled.
b. In general, manholes shall be installed in or along roadways.

Installation of manholes in classified areas will not be permitted.
Only under forced conditions and upon PDVSA agreement
manholes in classifed areas would be accepted but, as described in
Section 18.2 of this document.
c. Manholes shall be provided with grated sumps, pulling irons,

ladders and cable racks. The access openings shall be extended
above grade to preclude the entrance of surface water. Conduit
between manholes shall slope toward the manholes for drainage
purposes.
d. Main power distribution cables in manholes shall be coated or

wrapped with an approved fireproofing material.
e. All cables and conduits in manholes shall be completely identified.
18.2 Manholes - Below Grade
In general, manholes within classified areas shall be avoided. However,

under forced situation and previous acceptance, below grade
handholes/manholes may be utilized in Class 1, Division 1 and Division 2
areas, they shall be filled with sand and besides meet the following criteria:
a. Be located near substation for cable pulling only.

b. Shall have removable covers and be water-tight.
c. Shall be partially elevated to prevent water penetration.
d. All conduits within manhole/handhole shall be sealed to prevent
sand from entering the conduit, and cables properly identified with
noncorrosive plastic markers.

19. POWER AND CONTROL WIRING
For low voltage power and control cables, 600 V and below, see PDVSA
Specifications.
19.1 Cables for Service Above 600 Volts
a. Cables for service above 600 volts shall be stranded conductor,

(copper up to 500 kcmil) with specified insulation ratings and an
overall cable jacket. The insulation shall be ethylene propylene
rubber (EPR), rated 90°C conductor temperature in wet or dry
location.
5 kV class cables shall be non-shielded and 15 kV class cables will
be shielded with insulation for isolated neutral.
b. The current carrying capacity and short circuit withstand of cables

shall be in accordance with applicable ICEA tables and
recommendations.
c. Power conductors shall be installed in a separate conduit from

control or instrument conductors.
19.2 Cables for Service 600 Volts and Below
a. Wire and cable for service 600 volts and below shall be stranded
copper conductor, with a 600 volt insulation. The insulation shall
be a heat resistant, thermoplastic rated 75°C copper temperature in
wet or dry locations for revamp of existing installations.
For new installations will be cable type XHHW or RHH-RHW as
defined PDVSA Specification "Wire and Cable 600 V Power and
Control". In high temperature locations, wire with suitable insulation
shall be used.
b. Minimum conductor sizes shall be Nº 12 AWG for general power

and lighting circuits and Nº 14 for control circuits.

Control wires associated with 460 volt motors shall be installed as

shown below:
c. Nº 12 AWG control wires in a common conduit with power when

motor leads are Nº2 AWG and less.
d. Nº 12 AWG control wires in a separate conduit when motor leads

are Nº 1 AWG and larger.
e. In general, wire and cables shall be sized in accordance with the

National Electrical Code.
f. Lighting branch circuit wires shall be color coded black, red, blue for
phases A, B and C respectively and white for the neutral.
g. Multiconductor control cables shall be color coded or numbered in

accordance with "ICEA S-61 -402, NEMA WX - 5, and Appendix I.
h. 480 V power feeders shall be multiconductor cable up to size 6

AWG, larger feeder shall be single conductor.
19.4 Cables for ground return.
a. For 13,8 KV feeders running in underground ducts, a ground

cable return will be provided by means of a single 4/0 AWG
copper conductor to be run in a dedicated 3” diameter pvc conduit.
Ground conductor shall be connected to ground rods in each
manhole.
b. No ground conductor is required for each 13.8 KV feeder.
c. For either 4.16 KV, 2.4 KV and .480 KV motor feeder, an isolated
ground return cable will be provided. Sizing and installation will be
according to Exxon Basic Practice, paragraph 7.9 to 7.14.
19.5 The manufacturer's recommendations shall be used for the minimum

bending radio of cables and wires.
19.6 Cable for installation in cable trays shall be approved for cable tray
installation.
19.7 Cables shall be identified with a heat shrinkable plastic sleeve or approved
equal at each end.
19.6 For cable derating studies, the theoretical brake horsepower loads shall be
used.
20. INSTRUMENTATION AND CONTROL SYSTEM WIRING
20.1 Materials
a. For all electronic multiconductor instrument and thermocouple

extension wire and cable, see PDVSA Amuay Specifications.
b. Enclosures of exposed equipment such as individually enclosed

motor controllers, lighting panels, and junction and terminal boxes
shall be cast iron or cast aluminum alloy (0.4 percent copper
maximum) where available. Sheet steel enclosures when used
shall be hot - dip galvanized, with a minimum thickness of 0.063
inch (1.6 mm) {Equivalent weight of coating approximately 2 oz/ft2
(610 g/m2) of sheet}.
c. Terminal strips for instrumentation wiring shall consist of 600 V,

medium duty, tubular clamp type, polypropylene terminal blocks
mounted on slide rail strips.
20.2 Installation
a. Wiring for field instrumentation shall be routed in conduit to field

junction- boxes. Wiring from the field junction boxes to the control
room shall be "home run" cables routed in conduit.

b. Home run cables are multiconductor, multi-pair, mult-triad or multi-

quad cables, as applicable for the wire types, between the field
junction boxes, satellite control room and control house.
c. Wire and cable types are based on the type of signal as listed
below:
• 4-20 mA: Twisted, shielded pair.

• RTDs (Millivolt): Twisted, shielded (triad {for 3 wire RTDs})
(quad {for 4 wire RTDs}).
• Thermocouples: Twisted, shielded pair (thermocouple
extension wire).
• Digital Signals: (Twisted, shielded, pair) (# 14 AWG individual
conductor).
• Control 24 Vdc and 120 Vac: #14 or #12 AWG individual
conductor as required.
d. Home run instrument cables shall contain 20 percent spare pairs,

riads, quads or conductors, as applicable. The spare conductors
shall be terminated and tagged "spare" at both ends.
e. Home run cables shall be tagged with the cable number at both
ends. Individual groups of conductors (pairs, triad and quads) shall
be tagged at both ends with the instrument number or wire number.
White, tubular, heat-shrinkable sleeve with black characters
permanently imprinted in the sleeve shall be used for tagging.
f. In general, shield drain wires for individual pairs, triads and quads
shall be terminated and grounded at only one end. The other end
shall be cut and taped. The individual shield drain wire shall be
grounded at the end of the loop from which power for the loop
originates. Individual shield drain wires for thermocouples shall be
grounded at the thermocouple head. Generally, all other individual
shield drain wires are grounded at the control room.
g. When individual shields are provided for the individual pairs, triads

and quads in the home run cable, the shield for the field wires shall
be connected to the corresponding shield in the home run cable at
the junction box. The overall shield for the home run cable shall be
cut and taped at the junction box and grounded at the control room.
h. All shields and drain wires shall be insulated from ground at the
junction box.
i. All conduits systems, cable tray systems, and signal separation

shall be in accordance with IEEE 518, which groups the signal
types in accordance with their susceptibility to noise and defines
signal separation on that basis.
21. COMMUNICATIONS
21.1 Provision for a dial type plant telephone system shall be made . Conduit with
a pull wire and space on pole lines shall be furnished, but all other material,
equipment and labor for the telephone system will be by others.
21.2 When requested an "intra-plant" communications system shall be furnished.

The system shall be a "page-intercom" type such as the GAI-TRONICS
system, consisting of handset and speakers, one paging channel and one or
more individual talk channels. Each handset and each speaker shall have its
own solid state amplifier.
This shall be in accordance with PDVSA Specification Intra-Plant
Communication System.
21.3 When requested a two-way radio communication system shall be furnished.
22. RECEPTACLES
22.1 480 V Power Receptacles
a. 480 V receptacles shall be 3-wire, 4-pole, 60 amperes, and

installed in convenient locations within 150 feet of process unit

structures or areas in which portable power units may be required.
Same requirement will be also applicable on vertical installation,
like towers, furnaces, etc.
b. All 480 V power receptacles shall be of the same size and rating.
The ground pole of each receptacle shall be solidly and
permanently connected to the plant grounding system through the
conduit or a separate ground wire.
c. A maximum of four (4) receptacles shall be connected to one

feeder. Feeder cable sizes shall be based on a demand factor of
0.6.
22.2 120 V Receptacles
a. 120 V receptacles shall be located throughout process units so that

equipment at grade can be reached with extension cords not over
50 feet in length. A receptacle shall be located on each platform
servicing a manhole on vessels and towers.
b. The ground pole of each receptacle shall be solidly and
permanently connected to the plant grounding system through the
conduit or separate ground wire.
c. Receptacles installed in classified areas shall be the factory sealed

type.
23. NAMEPLATES
Electrical equipment and device nameplates shall be in Spanish. A nameplate

schedule shall be prepared for PDVSA's approval.
24. FIELD CHECKOUT AND TESTING
Equipment and materials shall be inspected for shipping damage immediately after

receipt at jobsite. In general, checkout and testing of systems and equipment shall
be done.
25. ELECTRICAL TIE-INS
Procedures for Tie-Ins field connection shall be issued by contractor to PDVSA for
approval. The contractor to prepare a complete design and material procurement
for tie-ins, regardless of the works be made by them or PDVSA.
26. ELECTRICAL SUBSTATION
26.1 Elevated substation building will be required to house main electrical

equipment. An external shielded roofed area should be used to housepower
transformers. Two separate rooms in the substation shall be used to house
air conditioning and batteries for the IPS and/or ups systems. Air
conditioning of battery rooms is a basic requirement. Filtrater systems are
also necessary.
26.2 List of electrical equipment that shall be taken into account for the design of
an electrical substation.
a. Switchgear.
b. Bus Ducts.
c. Power Transformer.
d. MCC'S.
e. TAPC'S.
f. General Purpose Panels.
g. IPS (125 VDC).
h. Annunciator/Alarms.
i. Fire Detection and Alarm.
j. Auxiliary phone
k. Ground resistor
26.3 The following systems shall be covered in substation designs.

a. Lighting.
b. Grounding.

c. Air Conditioning.
d. Air filtration in Air Conditioning System.
e. H2S and Gases Detection.

f. Weld Receptacle and General use Receptacle.
g. Power Management System (PMS).
h. Load Shedding.
i. Transferred Trips.
j. Distributed Control System (DCS).
k. PLC'S for motor control
l. Relays Coordination (Complete).
m. 125 VDC
27.- ELECTRICAL INFORMATION TO BE FURNISHED BY PDVSA
a. Basic Criteria for Relay Coordination.

b. Recommended Manufacturer List.
c. PDVSA Electrical Specifications.
d. Amuay Refinery Electrical Data and Topology.
Nevertheless electrical data be furnished by PDVSA, the following subjects will be

the contractor reponsibility:
a. Analize impacts on operational continuity over both electrical and process

systems due to relays coordination criteria application, so that give alert to
PDVSA in case of abnormal situations.
b. The Protection Coordination Studies related to existing or brand new
installations and shall cover as minimum.
1) Motor Controller (MCC) and Main Breaker up-stream (SWGR).

2) Main Breakers 52 - 1,2 and breakers 52-24 (SWGR).
3) 13.8 kV feeders and 67V and 51S relays (tie between existing
syncronizing buses). Shall include: short circuit level, reaceleration
and maxim power transference through syncronizing buses
revision.

28.- ELECTRICAL INFORMATION TO BE FURNISHED BY CONTRACTOR AS

DETAILED ENGINEERING AS PART EPC AGREEMENT
Drawings:
a. Area Clasification.
b. One Lines/ Phasing Diagram/ Three Line Diagram/ Connection Diagram/
Interconnection Diagram/ Vendor Drawings.
c. Above Ground: Power, Control, Alarm and Signals.
d. Under Ground: Power, Control, Alarm and Signals.
e. Conduit/ Cable Schedules.
f. Substation-Equipment Arrangement.
g. Instrumentation.
h. Motor/ Transformer/ SWGR/ MCC/: ANSI/ IEEE Final Factory Test Report,
including all results and associated documentation.
i. Sistem (Associated to Drawings to be performed) Fire/ Lighting/ Ground/ H2S
Detection/ PMS/ Load Scheduling/ Transfered Trips/ Relays Setting
Tabulation/ Substation: Air Conditioning, electrical interfase/ Ground Grid.
j. The Consultant will also be responsible for updating the following materials:
k. General drawings and documents.
l. 13.8 kV Distributions System (Underground System) General Drawing.
m. 2.4 kV Distribution System (Serial Line).
n. Power supply and electrical distribution operation manuals.
o. Amuay Relay Setting Tabulations.

p. Soil Resistivity General Drawing.
29.- CALCULATION BY CONTRACTOR
Load study, sizing of tranformers, relay coordination (Upstream and Downstream of

the substation). Cable Derating, Voltage Drop, Cable Pulling, Lighting , IPS Sizing,
Grounding, and:
a) Short Circuit Level.

b) Load Flow.
c) Motor Reaceleration.

The a, b and c studies will be developed by contractor with his own resources using
PDVSA-Amuay computer program. The Consultant shall be familiar with Magnet
Program (Available Operation Manuals). For remainder calculations other
programs may be used.
30.- SHOP INSPECTION-PDVSA WITNESS TEST PARTICIPATION
a. Switchgears/ Bus Duct.

b. Power Transformer.
c. MCC's/ TAPC's.
d. UPS/IPS.
e. Special electrical equipment.
PDVSA also wants in relation to these equipments participate on RFQ'S and vendor
drawings revision.
31. CATHODIC PROTECTION IN PROCESS PLANT.
Cathodic Protection System (CPS) it is seldom used in Amuay Refinery process

plants. However, the detailed engineering sponsor shall submit to Amuay Refinery
for approval those areas under the consultant consideration for CPS, before
initiating related designs.

Miscellaneous
SECTION N° X
MISCELLANEOUS
Centro de Refinación Paraguaná X-1 PDVSA

Miscellaneous
MISCELLANEOUS
Page N°
Hot Service Insulation Requirements X-2
Thermal Expansion During Steam-Out X-2
Paint and Protective Coatings X-2
Selection of Materials X-2
Design Temperature and Design Pressure X-3
Fireproofing X-4
Machinery X-4
Gasketing X-4
Piping X-5
Ladders and Platforms X-14

Miscellaneous
HOT SERVICE INSULATION REQUIREMENTS
This information is a supplement to the requirements of SP-80-1 covering hot

service insulation and applies to piping, vessels, exchangers, and equipment other
than storage tanks.
Pipe insulation excluding acoustical.
Pipe insulation for operating temperature up to 650ºF shall be according to these

characteristics: performed mineral wool pipe cover, nominal density of 11 lbs./cu.ft.,
with
organic binder, reference: Sonoterma 1300, or other product with similar
characteristics
whose laboratory test shall be sent to the owner for consideration and approval.
Pipe insulation for operating temperature above 650ºF to 1200ºF shall be according
to
these characteristics:
Option 1: Performed covering of calcium silicate, nominal density 15 lbs./cu ft. ,
Marsville “Thermo-12”, Owens Corning “Kailo 10”Pabco, “Super
Caltemp”.
Option 2: Performed covering of expanded perlite, water proof, reference

“Good Temp 1500”.
THERMAL EXPANSION DURING STEAM-OUT
For equipment (towers, drums, exchangers, etc.) which have design temperatures
less than 300°F but which would be steamed-out during startup or shutdown
operations, provisions shall be made for thermal expansion at 300°F. Product
rundown lines will not be steamed out. Steam-out is required during start up for the
following services: steam, instruments air and nitrogen.

Miscellaneous
PAINT AND PROTECTIVE COATINGS
Amuay specification AS004 (latest rev.) will be used.

For pumps use the follow:
a. Surface preparation according to SSPC-SP-5 and primer of inorganic zinc with
2.5-3.0 mils thick.
b. Final coating to be applied in situ according to Amuay Specification AS004.
SELECTION OF MATERIALS
All new materials selected will be reviewed by the owner, otherwise follow SP-50-5.
“Piping Material Specification”, last issued.
DESIGN TEMPERATURE AND DESIGN PRESSURE
The following general rules shall be used for establishing equipment design
temperatures and design pressures.
Design Temperature
1. Below 60°F, the minimum design temperature shall be equal to the lowest
temperature reached during upset, startup, or normal operations.
2. For operations up to 650°F, the maximum design temperature is usually set

50°F higher than the operating temperature. However, where the addition of
the 50°F increment becomes costly because of code or material
requirements, only an increment large enough to cover operating flexibility
shall be added to the operating temperature.
3. Above 650°F for carbon steel and above 850°F for alloys, the temperature
increment added to operating temperature to set design temperature shall be
minimized. Only if variations in operating temperature are expected or if
operating flexibility with respect to temperature is important shall any

Miscellaneous
temperature increment be added to operating temperature.
4. Towers operating over a wide temperature range from top to bottom may
have graded design temperatures for the purpose of reducing flange ratings
in the top. Usually the tower is divided into sections at the points of
significant temperature changes such as pump around and feed trays.
Design Pressure
1. As a general rule, design pressure shall be the maximum operating pressure,

normal operating pressure plus 10 percent, or normal operating pressure
plus 30 psi, whichever is greater.
2. Design pressure of equipment downstream of pumps and not protected by a

safety valve is the greater of either:
° Normal pump suction pressure plus 120 percent of normal pump

differential (see Paragraph 1.6 on Section 3).
° Maximum pump suction pressure plus normal pump differential

pressure.
In certain cases it may be necessary to design for maximum pump suction

plus 120 percent of normal pump differential pressure, such as control valve
failure on fractionator top pump around return line.
3. For vessels operating under vacuum, maximum and minimum design
pressure shall not be less than 15 psig, and full vacuum respectively.
Vessels operating with hydrocarbons or steam that could draw a vacuum
shall be designed for full vacuum.
4. Reboilers and auxiliary equipment on low pressure towers shall have a

design pressure equal to the sum of the tower design pressure plus the static
head of liquid in the tower when operating at the high or emergency liquid
level in the tower.

Miscellaneous
5. In general, design pressure of exchangers and coolers shall be set by Items

1, 2, 3 or 4 of this section. However, when the low pressure side of an
exchanger can be subjected to the high pressure side in the event of tube
rupture, the requirements of Paragraph 8, Section 8 must be met.
FIREPROOFING
Fireproofing is not to be provided inside the skirt of vessels on solid concrete

foundations.
Fireproofing will be concrete and in accordance with Manual de Ingeniería de
Riesgos. PDVSA.,(MIR. last edition).
MACHINERY
Oil mist lubrication shall be provided for all onsite general purpose type equipment
such as centrifugal pumps, fans, gears and steam turbines which have non
pressure oil feed type bearing lubrication. Oil mist lubrication of offsites centrifugal
pumps and their drivers shall be considered where a number of pumps are centrally
located, the required utilities are available, and the system installation can be
justified.
Oil mist systems shall be designed for dry sump lubrication ("pure mist"). However,
equipment and oil mist systems shall be designed and supplied for initial operation
of the systems on "purge mist". Purge mist installations method shall be per the
original Figure 2 of BP3-3-12, last revision. Future conversion to dry sump
lubrication ("pure mist") shall be by the Owner. Grease lubricated antifriction
bearing type electric motors shall be designed for future conversion to dry sump
lubrication ("pure mist") by the Owner.

Miscellaneous
GASKETING
Cardboard gaskets shall not be used for any service or for hydrotest.
Where compressed asbestos is permitted or approved by the owner use only
compressed asbestos gasket with "NBR" binder anti-stick agent and minimum
tensile strength across the grain of 4000 psi. Klingerit Universal and Mamusa MM-
4078 are preferred. The perimeter of the gasket must be painted orange,
PIPING
1. Flexibility Analysis
1.1 Tower overhead lines are to be designed for the tower design
temperature. Temperatures lower than the design temperature may
be more limiting with respect to flexibility analysis.
1.2 Normal operating temperatures or minimum operating temperatures

must be considered where they are more severe with respect to
system flexibility requirements.
1.3 Piping circuits which can be alternately hot or cold must be analyzed
for the worst condition. For example:
° Multiple feed points.
° Water drawoffs.
° Parallel exchangers or other equipment which can be

maintained while the unit is operating.
° Flexibility analysis must allow for steam out with 145 psig
steam.
1.4 Flexibility must consider loss of cooling on a single contingency basis.

Miscellaneous
Do not design for total loss of parallel coolers.
2. General
2.1 Design piping to minimize liquid traps. Install drains vertically

downward with no bends, and provide a 6 inch minimum clearance
below the drain (12 inch minimum for drains which could plug with
catalyst or coke).
2.2 Tower drawoff and reboiler feed/drawoff lines shall drop at least 5 feet
vertically from horizontal drawoff nozzles before a diameter reduction
and/or any horizontal run. For vertical reboiler drawoff nozzles, such
as tower bottoms nozzle for feeding a kettle reboiler, the drawoff line
shall drop at least 5 feet vertically below the tower normal liquid level
before a diameter reduction and/or any horizontal run.
2.3 Block valves and bypasses are not to be provided around heat
exchangers, coolers, and condensers except where required for
control or for services where frequency of cleaning or tube leakage is
known to be greater than frequency of plant shutdown and economic
justification exists.
2.4 Where connections between equipment and closed system (safety
valve header, fuel gas header, etc) are 2 inches or less and are all
welded lines, one pair of flanges shall be provided at the proper
location to permit installation of a blind during startup or shutdown
operation in accordance with BP3-7-4, Paragraph 3.7, last issue.
2.5 Only in critical heat loss service e.g. aeration steam, provide
insulation on flanges for all steam services and on flanges and valve
bodies for all steam valves 6 inch and larger, otherwise is not
required.
2.6 The following water side valves must be provided on all sea water
coolers and condensers:
a. Block valves (preferably butterfly type) are required on both

Miscellaneous
inlet and outlet water lines. In addition, provide a 3/4 inch

bleeder between the two block valves and provide a thermal
expansion caution sign in accordance with BP3-2-4, last issue.
b. Blackflushing manifolds are required where specified. Manifold

design to be the same for all exchangers to simplify operation.
c. Do not install low point drains on salt water piping.
2.7 Cast iron valves shall not be used in any refinery service except salt
water.
2.8 Carbon steel piping shall be sized in accordance with the guidelines
given on Table 1, Page 10-10.
2.9 Flange ratings as specified on the design flow plans are based on
ANSI B 16.5. The contractor shall ensure compliance with ANSI
B16.5 and B16.34 last edition.
Reductions in the flange ratings specified on the design flow plans

require approval of the owner.
2.10 Lines sizes of 1¼, 2½, 5, 14 and 18 inches and 400 lbs. flange rating
are not to be used unless approved by the owner. This is applicable to
piping and equipment connections of any type. Unions are only to be
used in potable water, instrument air or another services where
threaded pipe is permit without seal welding. Unions can be used in
60 psi steam tracing service.
2.11 Lines for the following services shall be sized in accordance with the
maximum velocity guides given below:
a. Salt water cooling lines: Maximum velocity in main header or
branch lines may be 15 ft/sec.
b. Maximum velocity in sour water services; ft/sec:

Miscellaneous
C.S. S.S
° Sour water and HC 20 -
° Sour water above 250°F 5 10
° Sour water below 250°F 10 15
c. Maximum velocity in amine services, ft/sec:
° Lean amine above 200°F 20
° Lean amine below 200 °F none
° Rich amine 3-5
2.12 Gusset is required at valve branch connections < 2" on:
a. Hydrocarbon Service
b. Vibrating Service: 2 phase flow, all machinery and safety

valves.
c. Toxic Service: MEA, H2S, Sour Water, Caustic.
d. High Pressure Steam.
Gussets are not required on Integrally Reinforced extended body

valves (see drawings on BP3-18-1).
2.13 Block valves locations and branch take off locations shall be in
accordance with the guidelines given on Table 2, page 10-11.
Steam, instrument air and fuel gas connections shall be from the top
of the supply header or sub-header. All small piping connections < 2
inch shall be fabricated using a minimum length of pipe between the

Miscellaneous
takeoff point and valve and without the use of elbows between the
valve and takeoff point so that the outlet of the valve is within 9 inch of
the branch connection.
All instruments and connections to instruments, sublateral take off, etc

shall be from top of header or sub-header. Additional connection will
be evaluated at the end of each header/sub-header to permit
moisture removal.
2.14 All drain connections shall be provided with a block valve.
2.15 Slip on flanges shall be avoid. Use only with PDVSA approval and all
slip on flanges 4 inches or larger require 1/8" NPT hole before field
installation on any hydrocarbon service. A 15 psig air test must be
performed and recorded for slip on flanges.
2.16 Lines shall be identified at battery limit. Valve hand-wheels for Battery
Limit (BL) valves shall be directly accessible and positioned to be
within normal reach for operation. For elevated locations, platforms
with ladders for direct access from grade shall be provided.
Limitations governing the installation of EBV design type B or C on
Battery Limit Valves are given on PDVSA Manual de Ingenieria de
Riesgos. ( IR-P-01.Emergency Shutdown and Isolation ).
Provide a warm-up connection at battery limit valve for 600 and 145
psi steam lines.
2.17 Traps shall always be installed to assure self-draining. An upstream

Y-type strainer is required unless trap is furnished with an integral
strainer. Steam trap TLV and Spyrax Sarco are preferred.
Orientation of trap to be horizontal or vertical as recommended by
vendor.
2.18 Dead-ended extensions of piping shall be avoid in lieu of dummy pipe
supports.

Miscellaneous
Dummy pipe supports, where used, shall have sealed ends and be
provided with a low point drain hole.
2.19 The minimum orifice and control valve Flange Rating shall be class
300 ANSI.
2.20 Car seal open (CSO) valves shall be installed with the stem in a
horizontal to downward position. A seal or any other adequate device
shall be provided for these valves,
2.21 Nitrogen connectors at the utility stations shall be Bowes Quick lock
type or equivalent and must be approval by the owner.
2.22 Steam, instruments air, fuel gas, pilot gas piping are generally
cleaned by blowing all header terminations shall be designed with
flanges/blind flanges to permit cleaning. Terminations shall be
provided with drain valves.
Chemical cleaning is required for piping serving steam generating
equipment and rotating machinery.
2.23 Vent and drain lines from a balanced bellows safety valve shall be in
accordance with BP3-2-4 and RP520.
2.24 Hot tap tie-ins are not allowed in 600 psi steam and air instrument
lines.
Any hot tap and stopples connections shall be per “Manual de
Normas y Prevención de Accidentes de la Refinería de Amuay”.
2.25 Valves on orifice taps will be offset by using different size nipples.
2.26 Rotating equipment skids shall be directly drained to the open drain
system.
2.27 PWHT in seal welds is not required. PWHT requirements shall be in
accordance with ASME 31.3.

Miscellaneous
2.28 To weld on welding or on fittings is not recommended and requires

owner’s approval.
2.29 Any control valve bypass < 2 inches shall be flanged.
2.30 A typical piping arrangement for pressure indicators at the suction

and discharge lines for pumps shall be installed.
3. Piping in Wet H2S and Amine Service
3.1 The requirement for piping in Wet H2S Service is that all welds to be
stress relieved.
3.2 All piping in amine service including entrained amine shall be PWHT
at all service temperatures.

Miscellaneous
TABLE 1
DESIGN BASIS - "AVERAGE" CARBON STEEL LINES (1)

Average Maximum Maximum Total
Press. Drop Press. Drop Press. Drop
Line Type Psi/100 Ft. Psi/100 Ft. Psi (Approx.)
Pump Suction and 0.25 0.4 -

Gravity Rundown Lines
Pump Discharge 1.5 2.0 -
Lines (Except High Pressure)
High Pressure Pump 3.0 4.0 -
Discharge Lines (700 psig
and Higher)
Vapor Lines (Atm. & Press 0.2 0.5 0.5-1.0
Overhead Lines)
Gas Lines (Within 0.2 0.5 4-5
Battery Limits)
Gas Lines (Tie-in - - 5-10% of Available Pressure
Lines)
Compressor Suction 0.1 0.3 0.5-1.0
Lines
Compressor Dischar- 0.2 0.5 4-5
ge Lines
High Pressure Steam Lines 0.5 1.0 2
(Short)
High Pressure Steam Lines 0.1 0.4 5
(Long)
Exhaust Steam Lines (Short) 0.2 0.4 1
Exhaust Steam Lines (Long) 0.05 0.1 1.5-2.0
Water Lines (Short) 1 1.5 2
Water Lines (Long) 0.25 0.5 5
Liquid Transfer (2) - - 25
and Tie-in Lines (Long) 0.5 1.0
and Tie-in Lines (Short) 1 1.5 25
Notes
i

Miscellaneous
(1) An economic evaluation will be necessary to determine the optimum pressure drop of lines constructed of
other than carbon steel.
(2) For slurry lines, sized base on minimum and maximum velocity considerations.
Maximum Velocity 3.0 ft/sec (saltation)
Maximum Velocity 15.0 ft/sec (erosion)
(3) Short ≤300 feet
LADDERS AND PLATFORMS
1. Safety ladders, platforms, stairs, and railing shall comply with the requirements of
the U.S. Occupational Safety and Health Standards.
2. Ladders except for stacks shall be caged when the vertical length between the
ladder base and the platform it serves is more than 20 feet.
Ladders under 29 feet shall also be caged when the base of the ladder is above
grade and the ladder serves a platform more than 20 feet above grade. The cage
shall extend down to a point 7 to 8 feet from the ground or platform.
3. A second means of escape or auxiliary escape shall be provided for operating

platforms if they are over 10 feet above grade and have an area in excess of 200
square feet. Walkways shall be provide with an escape-way so arranged that there
are no dead ends in excess of 20 feet.
4. The access from a ladder to a platform shall be side step.

Miscellaneous
SECTION N° XI
DRAWINGS AND OTHER PROJECT DOCUMENTS
Centro de Refinación Paraguaná XI-1 PDVSA

Miscellaneous
DRAWINGS AND OTHER PROJECT DOCUMENTS
SCOPE
This section gives requirements of minimum information, designations, symbols,

legends, abbreviations, and notes used on drawings or other project documents. The
requirements include those given in the following documents, listed in order of precedence
in cases of conflict.
1. This section of the G.I.I.
2. PDVSA Engineering Design Manual Volume 15 (PDVSA-L-TP 1.1, May 94)
Pages 11-1 through 11-26 of this section give requirements for abbreviations,
equipment, instrument and line numbering and certain flow diagrams guides.
Flow Diagram Legend.
- P&ID Instrument and Piping Symbol PDVSA's Drawing number: MT.1-7-03-

11/ MT.1-7-03-12.
- Equipment Symbols and Legend PDVSA's Drawing number GE-0-00-18-03,

page 3.
- Sample Flow Diagrams.

° Header Flow Diagrams (Utility Flow Diagram).
° P&ID Delayed Coking Fractionation Side.
° Interconnecting Flow Diagram. Delayed Coker.
FLOW PLAN ABBREVIATIONS
° Process streams
B/SD - Barrels (42 U.S. Gallons) per stream day at 60°F
GPM - U.S. gallons per minute at conditions
Lb/Hr - Pounds per hour
MSCF/SD - Million standard cubic feed per stream day at 1 atm,
60°F
BHP - Brake horsepower
Centro de Refinación Paraguanáy PDVSA

11-2
Miscellaneous
MW - Molecular weight
SGc - Specific gravity at conditions
Cp (Cs) - Viscosity in centipoises (centistokes) at conditions
∆P - Differential pressure in pounds per square inch
ACFM - Actual cubic feet per minute at conditions
SCFM - Standard cubic feed per minute at 1 atm, 60°F
° Utilities
BF - Boiler Feed Water

BF-250 - 250 psig Boiler Feed Water
BFW-850 - 850 psig Boiler Feed Water
CW - Cooling Water (salt) Supply
DW - Demineralized Water
ZW - Softened Water
AR - Recovered Sewer Water
PW - Potable Water
RW - Raw Water
HS - 600 psig Steam
XS - 400 psig Steam
MS - 145 psig Steam
LS-60 - 60 psig Steam
HC - 600 psig Steam Condensate
XC - 400 psig Steam Condensate
MC - 145 psig Steam Condensate
LC - 60 psig Steam Condensate
UC - Service Condensate
VC - 4.5" Hg Turbine Condensate
NG - 500 psig Natural Gas
FG - Refinery Fuel Gas
FX - Flexicoker Gas
Utilities
PG - Pilot Gas
N2 - Nitrogen
UA - Utility Air
IA - Instrument Air

11-3
Miscellaneous
PA - Process Air
° Safety
ATM - To atmosphere at safe location (per BP3-2-4)

LF - To Flare via header and blowdown
XF - To existing H2S flare via header and blowdown
CLDR - Closed drain header
° Waste Disposal
SB - To slop Collection System

CD - To Refinery Sewer
AW - To Sour Water Stripper
WC - To Clean Cooling Water Sewer (e.i, Cooling Water
Containing C5-)
WD - To Dirty Cooling Water Sewer (e.i, Cooling Water
Containing C6+)
SD - To Sanitary Sewer
° Valves
EBV - Emergency Block Valve - Type A, B, C, D, HBV and

RBV (BP3-7-4)
HBV - Hand operated Block Valve Type A o B
RBV - Remote operated Block Valve Type C o D (See B.P.3-
7-4)
RCV - Remote operated control valve
FC - Fail close
FO - Fail open
FC(S) - Fails stationary, spring closes
FO(S) - Fails stationary, spring opens
FCR - Fails closed, manual reset (local)
FOR - Fails open, manual reset (local)
FCRP - Fails closed, control house panel manual reset
FORP - Fails open, control house panel manual reset
Valves
FL - Fail last position
FS - Flashing service

11-4
Miscellaneous
TS - Tight Shutoff
CSO - Car Seal Open
CSC - Car Seal Close
° Materials
Note: Only for Process Flow Diagram, for Detail Engineering use piping material
specification SP-478150-50-3, last issue.
2-½ Ni - 2-½ Nickel Alloy Steel

3-½ Ni - 3-½ Nickel Alloy Steel
MON - Nickel-Copper Alloy, Model 400

I-600 - Ni-Cr-Fe Alloy, (Inconel 600)
I-625 - Ni-Cr-Fe Alloy, (Inconel 625)
I-800 - Fe-Ni-Cr Alloy, (Incoloy 800)
I-825 - Fe-Ni-Cr Alloy, Alloy, (Incoloy 825)
A-20 - Cr-Ni-Fe-Mo-Cu-Cb Alloy, (Carpenter 20 Cb-3)
H-B - Ni-Mo Alloy (Hastelloy B)
H-C - Ni-Cr-Fe Alloy (Hastelloy C-276)
REL - Refractory Lined (e.g., RELCS, REL 5 Cr)

CML - Cement Lined
HAL - Coal Tar Lined
CTEL - Coal Tar Epoxy Lined
GRPL - Glass Reinforced Plastic Lined
PPL - Polypropylene Lined
FCL - Fluorocarbon Lined
RUL - Rubber Lined
EPL - Epoxy Lined
GCS - Galvanized Carbon Steel
HDPE - High Density Polyethylene

PVC - Polyvinyl Chloride
RC - Reinforced Concrete
AB - Inhibited Aluminum Brass
70/30 - 70% Copper/30% Nickel Alloy
90/10 - 90% Copper/10% Nickel Alloy
Al - Aluminum
Cu - Copper

11-5
Miscellaneous
Materials
TI - Titanium
CI - Cast Iron
CS - Carbon Steel
1¼ Cr - 1¼% Cr - ½% Molybdenum Steel
5 Cr - 5% Cr - ½% Molybdenum Steel
9 Cr - 9% Cr - 1% Molybdenum Steel
410 - Type 410 Stainless Steel
304 - Type 304 Stainless Steel, 18-8
310 - Type 310 Stainless Steel, 25 Cr - 20 Ni
316 - Type 316 Stainless Steel, 18-8 Mo
321 - Type 321 Stainless Steel, 18-8 Ti
347 - Type 347 Stainless Steel, 18-8 Cb
KCS - Killed Carbon Steel
CS/Inconel Clad - Carbon steel - Inconel clad
1¼Cr 0.5 Mo/ - 1 ¼% Cr - ½% Molybdenum - Type 321 Stainless
Type 321SS Steel.
° Corrosion Allowance
1 - .05 inch corrosion allowance

X - Varies (extra strong/double extra strong)
Where no corrosion allowance is indicated for equipment other than heat

exchangers, pumps, and compressors refer to:
BP3-10-1 - Piping
BP5-1-1 - Pressure Vessels
BP5-2-1 - Vessel Internals
BP5-2-2 - Reactor internals
BP9-2-1 - Storage Spheres

11-6
Miscellaneous
NUMBERING OF EQUIPMENT, INSTRUMENTS AND LINES
Equipment will be numbered according to example shown below. Instruments and

lines will be numbered in accordance with the numbering system shown in ATTACHMENT
1 (see examples below). The following table shall be used to determine the area and unit
code, and the equipment and instrument series. The range for instrument series No. may
be extended if required.
Example
Area Area Unit Unit Equipment Instrument

Title Code Code Description Series N° Series N°
40 41 - Steam 4100-4199 100-199

Generation
- Boiler Feed
Water System
Utilities 40 46 - Steam and 4600-4699 600-699

Condensate
System
- Lube Oil
System
40 47 - Offsite Coke 4700-4799 700-799

Handling
Water 50 10 - Demineralized 1000-1099 001-099

Treatment Water System

11-1
Miscellaneous
1. Equipment and Instruments
° Example of Equipment Numbering
40 - P - 4101 A
+- Use to Identify multiple items
| | | | | of alike equipment in parallel
| | | +---------+ or series in the same service (A, | | |
B,C, etc)
| | |
| | +----------Equipment Series Number
| |
| +---------------Equipment Code (Note 1)
|
+--------------------Area Code
Note 1: For Equipment Codes see PDVSA's Drawings GE-0-00-18-03,

page 3-3.
° Example of Instrument Numbering (Flow meter of Steam Generation

Section)
41 - F 101 - RC
| | | |
|
| | | On
flow plans
| | | |
|
| | +--- Function (Note 2) F-
101
|
| +-------- Instrument series number
R
C
| +------------ Instrument type (Note 2)
+----------------- Unit code
Note 2: For function and instrument type symbols see PDVSA's Drawings

11-2
Miscellaneous
MT.1-7-03-11 and MT.1-7-03-12.
° Example of safety valve numbering (Safety Valve of Steam and Condensate

Section)
46 - P101 - SV
| | +---- Safety valve prefix letters
| +------------ Safety valve series numbers (3 or |
4 digits)
+-------------------- Unit code
2. Line numbering
° Line number will be prefixed with unit code
° Lines will normally change prefix numbers at area limits
° All process and utility headers in the main interconnecting pipeway will be
assigned line numbers keyed to the interconnecting pipeway unit number.
° Within each area, line numbers for utility headers will be prefixed with the
pipeway unit code.
° Utility branch lines within an area will be prefixed with the unit number and
numbered in series with the mechanical flow diagram they serve.
° Use line class index from piping material specification SP-478150-50-3

(detail engineering).
° Example of line numbering
6" - P 41 O34 - A A 4 G
| | | | | | | |
| | | | | | | |
| | | | | | | +---Open Modifier (Note 3)
| | | | | | +------Corrosion allowance (Note 3)
| | | | | |
| | | | | +---------Material of construction (Note 3)
| | | | |

11-3
Miscellaneous
| | | | +------------Rating (Note 3)
| | | |
| | | +-----------------Line Number (three digits)
| | |
| | +----------------------Unit Code (one or two
| | digits)
| +--------------------------Service (Note 3)
|
+-------------------------------Line Size
Note 3: For the appropriate symbols see PDVSA's Drawings MT.1-7-03-11 and
MT.1-7-03-12.
FLOW PLAN SYMBOLS
FLOW PLAN TIE-IN LABEL, XX YY ZZ Where:

(Process Spec)
XX = Refinery Block number
YY = Project Code
ZZ = Serial number
Example:
30-LF-01 XX = Refinery Block 30

YY = LF, LFAY Project Code
ZZ= 01
P&ID TIE-IN LABEL, XX YY NN Where:

(Detail Engineering)
XX = Project Code
YY = OL (Process Tie-in)
UL (Utility Tie-in)
NN = Serial Number
Example:
LF-OL-01 XX = LF, LFAY, Project Code

YY = OL, Process Tie-in
NN = 01, Tie-In number

11-4
Miscellaneous
ATTACHMENT 1
AREA AND UNIT IDENTIFICATION
EXISTING UNITS
Area Title Area Code Unit Code Unit Description

Flexicoker 10 21 Reaction Section and LFAY
10 22 Fractionation
10 23 Light Ends
10 61 Common to Area
Flexicracker 20 24 Reaction Section
20 25 Fractionation
20 26 Light Ends
20 62 Common to Area
Alky/Isomer 30 27 Alkylation and Isomerization
30 28 Amine Regeneration/Sour
Water/GLAY/ FMAY-3/SWAY-3/4
C4 Hidrogenation 25 23 HBAY
Delayed 90 67 Common to Area
Coker 90 91 Delayed Coking Section
90 92 Delayed Fractionator
90 93 Delayed Light Ends
90 94 Onsite Coke Handling
99 95 Offsite Coke Handling
HDS Complex 09 2 Hydrogen Unit 3, HYAY-3
09 3 Gas Oil
Hydrodesulfurization HDAY-3/4
09 5 Diesel Hydrodesulfurization
09 7 HDAY-2
09 8 Amine Regeneration FMAY - 1/2
09 9 Hydrogen Unit 1 & 2, HYAY-1/2
09 23 Sulfur Recovered Units, SUAY-
09 10 1/2/3
Sour Water Units, SWAY-1/2

11-5
Miscellaneous
Naphtha and Merox Units, NFAY-

3
Area Title Area Code Unit Code Unit Description
Utilities 40 64 Common to Area
40 40 Steam Generation
40 41 Steam Generation CFAY
Boiler Feed Water - CFAY
40 46 Steam and Condensate
System CFAY
40 47 Offsite Coke Handling
CFAY
40 06 Fuel System
Offsite 50 10 Demin Water
50 46 Steam Distribution
50 17 Sea Cooling Water
50 29 Flare Nº 4, Serial 297X
Flare Nº 5, Serial 298X
Oil Movements 55 95 Light Ends

55 96 Naphtha
55 97 Gas Oil
Future Units
Naphtha Fractionator 25 15 DPAY
/TAME 25 15 TMAY
Future 25 16
Unit block

11-6
Miscellaneous
ATTACHMENT 2
PREPARATION OF FLOW DIAGRAMS

This guide outlines the standards to be followed in the preparation of flow diagrams.
Deviations from these instructions may be permitted for the sake of specific
circumstances but such deviations should be approved by PDVSA.
1.- PREPARATION OF FLOW DIAGRAMS
1.1 Process Flow Diagram (PFD)
The process flow diagram shows the basic process philosophy. It transmits
process information for the design and specification of equipment and
development of the piping and instrument flow diagram. It serves as a guide
for operation of the plant. Process flow and operation are readily apparent
on a well-drawn diagram.
1.2 Utility Balance Diagram
The utility balance diagram describes a major utility system. It shows the
relationship between the usage by consumers, for more than one case (start-
up, peak usage, seasonal, etc.) if necessary, and the generation by
equipment or other sources.
It is advisable to make a utility balance diagram for each utility on separate

pages. Typically, utility balances are made for:
- Inert Gases
- Steam and Condensate
- Cooling Water
- Fuel Gas
- Waste Water Collection
- Chemical Products
1.3 Piping and Instrument Flow Diagram (P&ID)

11-7
Miscellaneous
The piping and instrument flow diagram serves as the basic document to
show the scope of work and provides the detailed plant design definition
required for the engineering and construction of the plant. It reflects all piping
needs based on hydraulic calculations performed and instrumentation
required for plant operation.
Three types of P&ID's are prepared, they are:
Process Mechanical Flow Diagrams P&ID's

Utility Mechanical Flow Diagrams UFD
Process and Utility Interconnecting P&ID's
2.- INFORMATION TO BE SHOWN ON PROCESS FLOW DIAGRAM. (PFD)
2.1 Information to be Shown
The process flow diagram is a schematic representation of the sequence of

processing steps and operating conditions. It shows:
a. The rate of flow of material, intermediate and recycle steams, finished

products and waste effluents. Flow quantities are broken down into
various components which are shown in tabular form as material
balance.
b. The physical size of vessels, capacity of pumps, and duty

requirements for heat exchangers and fired heaters.
c. The temperature, pressure, and the magnitude and direction of flow

for all streams.
d. Major instrumentation required for the control of the process.
e. Notes to aid in understanding the process or to call attention to

specific process requirements which are not obvious from the flow
diagram, but are essential for the proper design of the plant.
The PFD does not necessarily show all equipment. For example, parallel
units or spares are not normally shown. However, the presence of these
items is indicated by the equipment number.

11-8
Miscellaneous
2.2 General Presentation
a. Equipment is shown in elevation using standard symbols for pumps,

drivers, compressors and exchangers as illustrated in Drawing GE-0-
00-18-03, page 3. Other equipment such as heaters, towers,
reactors, dryers, etc., are represented diagrammatically to show the
process requirements.
b. Process & Design condition for piping can be located either on the
bottom of the drawing or on a separate sheet.
c. Paper size, format type "D" 560 mm (22 in) x 880 mm (34½ in) is
preferred.
Note: For more details see PDVSA L-TP 1.1, May, 94.
3. INFORMATION TO BE SHOWN ON PIPING AND INSTRUMENT FLOW

DIAGRAMS (P&ID's)
The information to be shown on Piping and Instrument Flow Diagrams is

listed below:
- Equipment
a. All equipment such as furnace, columns, exchangers, drums, etc.,

with item number, including multiple units and installed spare
equipment with the same level of detail shown for main items.
b. Package equipment, identified by outlining with a package equipment

boundary line.
c. Title of equipment.
d. Mechanical design pressures and temperatures (see Table N° 1).
e. Main Equipment dimensions for items such as columns and drums

(diameter and tangent to tangent distance, see Table N° 1).

11-9
Miscellaneous
f. Capacity and special features of equipments items must be as per

Table 1 attached.
g. Elevation of items with special conditions, such as: vessels

connected to pump sections, condensers and reboilers. To avoid
confusion, no elevation should be shown where it has stated only
minimum.
h. Operating level of liquid containing vessels that are provided with

instrumentation for its measurement and control.
i. The internal components of drums, columns and reactors necessary

to clarify the flow diagram, such as, for example: distributors, vortex
breakers, special nozzles, trays, entrainment separators, heating or
cooling coils, fixed beds, etc.
j. Size of equipment nozzles if differents than line size.
k. Manholes and handholes on vessels are not shown.
l. Equipment support, ladders and like must not be indicated.
m. Equipment items that have not been designed to stand maximum

pressure differentials (such as the case with exchangers, when one
side is at operating pressure and the other is being vented).
n. Equipment items that need notice boards to avoid dangerous

conditions, such as, for example, liquid thermal expansion within a
heat exchanger.
- Piping and Valves
Minimum information required:
° Process lines, indicating direction of flow, size, line number, material

specification and type of insulation.
° Valves, including valve type (valves with special specifications must

be indicated and described).

11-10
Miscellaneous
° Changes in line diameter.
° Flanges with a rating higher than that of the piping (detail

engineering).
° Drains, vents and purges required for operating reasons and the type
of sump where they discharge.
° Utility piping serving the equipment items, such as fuel gas and steam
to furnaces; steam to turbines and reboilers/reheaters; cooling water
to exchangers and pumps.
° Block valves used for pre-heating or for pressure equalizing.
° Liquid seals existing in some lines for operating reasons.
° Type of fluid being handled by pipelines, as well as their origin and

destination (these must be shown at the point where lines enter or
leave the P&ID, indicating the P&ID and section where they come
from or the P&ID where they go).
° CSO or CSC seals for block valves.
° Lubrication systems for pumps and compressors bearings and seals

(detail engineering).
° Bleeder valves between double blocking valves and between

upstreams block valve and control valves.
° Drain valves between relief valves and block valves with CSO in the
inlet and discharge lines of these.
° The drain and venting valves in the suction and discharge of

centrifugal pumps.
° When discharging to atmosphere, it must be indicated whether vapors

are toxic or flammable as well as minimum discharge height.

11-11
Miscellaneous
° Chemical cleaning connections for equipment items, such as salt

water exchangers.
° Lines to purge or snuffing safety valves discharge lines with steam or

gas.
° Valves designated as block valves and which require stellites seats,

as well as Venturi valves, must be indicated (detail engineering).
° Equipments items utility connection valves must be shown in the

Utility Flow Diagrams (UFD's).
° Pump preheating lines, when required.
° Fire protection systems of motors must not be shown in the P&ID's.
° Spectacle blinds, single blinds and spacers, whenever required for

operating reasons. Spectacle blinds for critical services at the battery
limits (i.e. hot HC, toxic gas, high pressure gas) are required.
° Blocks valves at the battery limits.
° Check valves drilled to allow for heating of a pump must be indicated

with a note.
° Valves to be used to block or shut down a piece of equipment in case

of emergency, or to be used to depressurize or to quickly lower its
liquid level in case of emergency, must be clearly indicated.
° Special piping components, for example: expansion joints, hoses,

temporary or permanent strainers, special blinds and removable
spools.
° Steam or electric tracing (it is not necessary to indicate thermal

insulation).
° Special conditions for construction of some lines, such as symmetry,

slopes and non-pockets.
° Sampling connections, including their identification number.

11-12
Miscellaneous
° Spec. breaks; that is, points where line specifications change.
° Vents on bellow-type bonnets of safety valves.
° Fluids that contain dangerous chemical components and which

therefore should not be vented or drained to atmosphere.
° Steam traps for process purpose are shown with a note indicating the
destination of the condensate return.
- Instruments and Control
° Instruments function, symbols and identification shall be:
a) For new units in accordance with ISA-S-5.1 to 5.5.
b) For revamp or new installations in existing units in accordance

with PDVSA drawings.
- CR 1-7-08-001 and CR 1-7-08-002.

- MT 1-7-03-11 and MT 1-7-03-012.
Note:
PDVSA will provide more information and guides for each

case.
° Action of control valves upon air failure, as well as type if piston

operated versus diaphragm, and special conditions (i.e. flashing
service).
° Control valves manifolds with their hand-wheel or bypass valves and
drains must be shown.
° Control valve sizes are shown adjacent to the valve identification

balloon. Reducers upstream and downstream are not shown. Size
and type of upstream and downstream block valves and bypass
valves are shown.

11-13
Miscellaneous
° Instruments or indicators must be readable from grade or from a

nearby platform.
° Instruments with their representation symbols and appropriate tag

numbers. Control loops must be represented with all their elements
so as to describe its structure and operation. Thus, intermediate
elements such as primary elements, transmitters, relays, indicators,
switches must be drawn.
° Instruments valves when required for process reasons or to clarify the

function of the instruments; for example, level indicator drains and
valves around analyzers (it is not necessary to indicate the size of
such valves).
° Instruments that require liquid seals or that need to be purged or

flushed with air, oil or gas.
° Emergency shutdown systems and interlocking functions.
° The set points for alarms and emergency switches (pressure, flow,
level, temperature, etc.).
° Type, material, length and fabrication of thermocouples and

thermowells (detail engineering).
° Safety valves and thermal relief valves with size, set pressure and
inlet and discharge lines.
° Internal diameter of restrictions orifices (detail engineering).
° Location, type and inlet/outlet lines for analyzers, as well as systems

for transportation/conditioning and recovery of analyzer samples.
° Computer or data logger connection points.
° Interconnecting pneumatic and electrical representation.
The general guidelines for laying out the equipment and piping on Process

11-14
Miscellaneous
Piping and Instrumentations Flow Diagrams are listed below.
° Paper format Type "D" - 560 mm (22 in) x 880 mm (34½ in) is
preferred.
° Equipment Distribution.
a) The upper right hand side space of the diagram will be

reserved for notes. Notes must start from the top downwards.
b) Equipment items should be arranged so that enough space is

left for piping and instrumentation. It must be ensured also that
the drawing layout is well balanced.
c) Process representation will be, whenever possible, from left to

right.
d) Columns, reactors, drums and furnaces, located at grade, will

be drawn in the middle section of the paper, all at the same
level.
e) Pumps and compressors will be located at the lower end of the

drawing, all at the same level.
f) Other equipment items will be represented, whenever possible,

as per their function. Thus, overhead condensers will normally
be located over the reflux drum. Reboilers will be located
beside the column, etc. However, condensers at grade level
will have to be drawn below the reflux drum.
g) When the physical location of the equipment items is not of

particular importance, they can be distributed following the
process logical sequence, simplifying, as possible, the route of
the lines.
h) Columns, drums and tanks within a P&ID must keep,

whenever possible, their relative size relationship.
i) Groups of interconnected pieces of equipment which are part

of a vendor package will be enclosed within a segmented line

11-15
Miscellaneous
box. This line will define the battery limits of the system and
the tie- in points for piping and instrumentation.
j) All vendor package components will be drawn with all their

piping and instrumentation.
k) All equipment names, tag numbers and other information

required will be located at the top of the drawing, directly above
their corresponding item.
l) Whenever equipment internals are needed to be shown, they

will be drawn with clear and continuous lines. Layers of solid
materials contained within reactors and vessels will be
indicated by two horizontal lines and two crossed dashed
diagonal lines. The relative height of these "boxes" must
resemble the actual layers.
° Lines.
a) Process lines will enter and leave the drawing at the right or
left side.
b) Venting and relief lines will leave from the top section of the
drawing.
c) Utility lines, such as water, steam and nitrogen will enter or

leave the drawing adjacent to the equipment item that they
serve.
d) All lines will be identified with a thick arrow, whenever entering

or leaving the drawing. The number of the drawing where the
line continues will be shown within this arrow. Also, the line
number and the equipment number from which it comes or
where it goes will be shown on both sided of the line.
e) All process and utility lines will be drawn with the least possible
changes in direction. Whenever the line drawn changes
direction, the direction of flow will be indicated with a heavy
triangular arrow.

11-16
Miscellaneous
f) Line numbers will appear every time that there is difficulty to

identify a line from the others, but should appear at least once
per line.
g) Main process lines will be of a heaver line weight (#3) than the
secondary process, utility, drain lines and lines to and from
relief valves. Main process equipment will be of a heavier line
weight (#2) than spare equipment. Control valve bypasses will
be shown using the light weight line (#1), similar to secondary
process lines.
h) The symbol used for line reducer shall be use whenever a

change of line diameter is not obvious, or in order to show a
change of line size at any particular location, because of
process requirements.
i) Instrumentations lines will be broken every time they cross a

process line.
j) Equipment drain lines will be drawn as short as possible to the

sump showing the system to which it belongs.

11-17
Miscellaneous
4. INFORMATION TO BE SHOWN ON UTILITY OR INTERCONNECTING FLOW

DIAGRAMS
The minimum information to be contained in the Utility Piping and

Instruments Flow Diagrams is listed below:
a) Headers and branches of the utility systems serving each plant, for
example water (utility water, cooling water , raw water and potable
water), steam and condensate, relief system, instrument and utility air,
nitrogen and fuel gas. The representation of this systems should
reflect close relationship with the actual location of the equipment
items being served (Plot Plan).
b) Size, number, material specification, type of insulation and flow

direction of each line, as well as the equipment item number where it
has destination or where it originates.
c) The utility stations, correctly located with a consecutive number in a

box. Valving for the utility stations will be shown as note detail typical.
d) Valves, including type (special specification valves must be indicated

and described).
e) Changes in pipe diameters (by means of reducers).
f) Flanges with rating higher than pipe.
g) Drains, bleeders and vents required by operating and process

reasons.
h) Steam or electric tracing (there is not need to show thermal

insulation).
i) Special conditions of construction for some lines such as slopes and

non-pockets.
j) Points of specification breaks in the lines.

11-18
Miscellaneous
k) CSO or CSC seals in block valves.
l) Instrumentation with representation symbols and appropriate

identification numbers (though the instrumentation that usually
appears in utility P&ID is rather little.
m) Spectacle blinds, single blind and spacers when is required for

operating reasons.
n) Drinking water fountains, safety showers and eyes showers.
o) Breathing air stations, safety monitors alarms and horn are shown on
the fire protection drawings "in plot plant fashion".
° The general guidelines given on section 3.2 applies for the Utility
Systems Piping and Instrumentation Flow Diagrams.
° Process and Utility Interconnecting Piping and Instrument Flow

Diagrams are similar to other types of P&ID's except, that it
schematically presents the actual distribution of process or utility
service in "plot plan fashion".
° Use format type "D" - 560 mm (22 in) x 880 mm (34½ in).

11-19
Miscellaneous
ATTACHMENT 2
TABLE 1
Information to be included on P&ID Flow Diagrams.
EQUIPMENT PRIMARY IDENTIFICATION DETAILS REQUIRED

Vessels 1. Size (overall dimensions). 1. Elevation of bottom tangent
2. Design temperature and line above grade.
pressure. 2. Vessels internals:
3. Insulation. a. Type and number of trays
4. Trim. in towers.
b. Type of internals in drums.
3. Thickness of thermal
insulation.
Heat 1. Surface area. 1. For condensers and
Exchangers 2. Duty. reboilers,
3. Design temperature and show elevation above grade.
pressure.
4. Insulation.
Furnaces 1. Heat fired.
2. Heat absorbed.
3. Coil outlet temperature.
4. Design temperature and
pressure (tubes).
Boilers 1. Steam capacity.
2. Design pressure.
3. Superheater outlet
temperature.
Cooling Towers 1. Waterside throughput.
2. Operating inlet and outlet
water temperatures.

11-20
Miscellaneous
EQUIPMENT PRIMARY IDENTIFICATION DETAILS REQUIRED

Tankage 1. Size (diameter & height). 1. Surface area of any heaters.
2. Net capacity. 2. Number and type of agitators
3. Type (floating roof, cone or other mixing devices.
roof, etc.).
4. Design pressure and
temperature.
5. Material.
6. Insulation.
Pumps 1. Rated capacity. 1. Warm up (or cool down).
2. Pressure differential or Head 2. Cooling water piping
in feed. arrangement.
3. Actual shutoff pressure. 3. Flushing piping arrangement.
4. Type of driver (graphically). 4. Casing vent and drain piping.
5. Specify gravity at conditions. 5. Indicate drilled check valves
6. Insulation. and temporary strainers.
Steam 1. Steam inlet and discharge 1. Warm-up piping
Turbines temperature and pressure. 2. Washing facilities
2. Horsepower. 3. Strainers, traps and drains.
3. Material.
Compressors 1. Horsepower. 1. Flushing and drain facilities.
2. ACFM at inlet conditions. 2. Lube and seal oil facilities.
3. Discharge pressure and 3. Strainers.
temperature.
4. Head (feet).
5. Material
Instrumentation 1. Type (symbol). 1. All primary instruments and
2. Local or board mounted auxiliary components.
(symbol). 2. Block valve and bypass
3. Computer Input (symbol). piping.
4. Set Point.
Control Valves 1. Size (body x port). 1. Block valve and bypass
2. Valve position with actuating piping.
medium failure (symbol).
3. Flashing service.
4. Heat Tracing.

11-21
Miscellaneous
EQUIPMENT PRIMARY IDENTIFICATION DETAILS REQUIRED (1)
Pressure Relief 1. Size. 1. Inlet and discharge piping

2. Set pressure. including drains and vents.
2. Snuffing steam to discharge.
3. Interlocks.
4. Car sealed valves.
5. Bellows bonnet vents.
Piping 1. Line size and rating. 1. Bleeds associated with valves
2. Line number. or between double block
3. Line material classifications. valves.
4. Valve size if other than line 2. Chemical cleaning and
size. flushing connections; sample
5. Each drawing shall include: connections (indicate any
a. Description of process or heaters or coolers).
utility media entering and 3. Temporary strainers and
leaving (symbol). safety shields.
b. Flow rate of process media 4. Utility stations and safety
entering and leaving. showers.
c. Continuation references to 5. Locations of Figure-8,
subsequent drawings. hammer
or other permanent blinds.
6. Line slope.
7. Car sealed valves.
8. Identification of valves for
emergency isolation or
shutdown services.
(1) Heat tracing insulation and other provisions and process protection against ambient
temperatures shall be indicated for all facilities to be treated.

11-22

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COMPLEJO REFINADOR PARAGUANA

This specification contains technical information

GENERAL INSTRUCTIONS AND INFORMATION

1 Characteristics of Utilities and Meteorological Data 1-1

These General Instructions and Information apply to the preparation of the

Centro de Refinación Paraguaná PDVSA

Centro de Refinación Paraguaná PDVSA

I.1 GENERAL REQUIREMENTS

I.2 DESIGN REQUIREMENTS

I.3 UNIT PERFORMANCE

Centro de Refinación Paraguaná PDVSA

startup, shutdown and emergency conditions.

I.4 OTHER REQUIREMENTS

° Built-in handling facilities shall be provided in accordance with BP4-2-1.

° Utility stations shall be provided through the process block where

° Eye wash and emergency showers shall be provided at 50 feet or closer to

Centro de Refinación Paraguaná PDVSA

° Facilities must be designed to achieve a high service factor, a high degree of

° In rotating equipment selection, the contractor shall be on the side of

° A high degree of standardization of components and parts is to be achieved.

I.6 ECONOMIC BASIS FOR SELECTION OF EQUIPMENT AND DESIGN

For these alternatives, incremental investment may be added provided annual

Minimum Return = Yearly Operating Savings (1) x 100

Centro de Refinación Paraguaná PDVSA

Item Incremental cost of utility (3)

Year 2001-2005 2006-2016

Water - (RAW) 1.5 " $/1000 gals

Fuel - Natural gas 1.25 " $/1000 SCF

Electrical Power - 0.0547 " $/KWH

Hydrogen (from CHP) 1.13 “ K$/MSCF

Air - 0.014 " $/NM3

Nitrogen 0.135 “ $/NM3

Efluentes 8.407 “ $/M3

1. Operating savings are before taxes and depreciation.

2. Incremental investment shall include both utilities and process equipment

3. Incremental cost (Variable).

4. Based on 1.2 $/MMBTU.

Centro de Refinación Paraguaná PDVSA

5. Incremental cost to be supplied by PDVSA Service Center Project.

I.7 ENVIRONMENTAL REQUIREMENTS

Centro de Refinación Paraguaná PDVSA

AND METEOROLOGICAL DESIGN CONDITIONS

Centro de Refinación Paraguaná PDVSA

AND METEOROLOGICAL DESIGN CONDITIONS

1.1 Water Systems Process Mechanical

° Cooling Water (CW) (Sea Water)

Return, Cooler Outlet Temperature, °F 120 170

Cooling Towers (two pass HDS system)

Return (Cooler outlet) Temperature, °F 120 170

Centro de Refinación Paraguaná PDVSA

Return (Cooler outlet) Temperature, °F 120 (max) 170

° Raw Water (RW)

Centro de Refinación Paraguaná PDVSA

° Boiler Feedwater (BW)

High Pressure BW BK-11

High Pressure BW BK-29

850 psig BW BK-29

Centro de Refinación Paraguaná PDVSA

° Demineralized Water (DW)

Temperature, °F 250 300

° Recovered Sewer Water (AR)

° Recovered Industrial Water (IR)