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1. INTRODUCTION

The purpose of this document is to define the rules which have to be followed to
prepare a Basic Process Package, or to specify any individual piece of
equipment in the absence of specific requirements on the subject from the Client
in the Contract.

When such requirements exist, they have to be followed and the present
document should be modified accordingly.

In case of licensed units, the rules of the Process Licensor will be followed as
much as possible for equipment to be added, in order to have a consistent
design.
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2. DESIGN PRESSURE

2.1. Design pressure at individual equipment

Except for special reasons (for example desalter, storage silos), the following
design criteria will be applied defining PD according to PSM :

PD : minimum mechanical design pressure

PSM : maximum continuous operating pressure

PSM (bar g) PD (bar g)

<0 Full vacuum (1) and 2.5

or 3.9 bar g according
to para. 2.3 herebelow
0-10 PSM + 1 (2) (3)
10-35 PSM x 1.1
35-70 PSM + 3.5
> 70 PSM x 1.05

Notes :

(1) Full vacuum design conditions will be applied to equipment that fulfill one of the following conditions :

Normally operates under vacuum

Is subject to vacuum during start-up, shut-down or regeneration
Normally operates full of liquid and can be blocked in and cooled down
Can undergo vacuum through the loss of heat input (to be studied case by case. Vacuum
prevention systems are also acceptable).

Partial vacuum design conditions are normally not considered, except for the following cases :

When the subatmospheric pressure is determined by the vapor pressure of the vessel contents.
Then consider the vapor pressure associated with the minimum ambient temperature.
When the thickness of equipment is determined by external pressure calculation instead of
internal pressure. Then it has to be considered case by case.

(2) With a minimum of 3.9 bar g or 2.5 bar g according to paragraph 2.3 herebelow.
Not applicable for thin wall equipment such as vessels open to atmosphere, storage tanks, storage
silos...
Full of liquid can be the governing case.

(3) For equipment in equilibrium with flare the design pressure is the flare design pressure.
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2.2. Design pressure profile for columns and reactors

The same design pressure will be selected for the top of a fractionator column
and associated condenser, reflux drum and interconnecting piping.

The design pressure at the bottom of a fractionation column will be determined

as follows :

PDB = PDT + ∆ P1

Where :
PDB : Design pressure at the bottom (vapor phase)
PDT : Design pressure at the top
∆ P1 : Column pressure drop

The liquid flowing density and the maximum liquid height will be indicated on the
Process Data Sheet.

2.3. Minimum set pressure of safety valves

3.9 bar g for a safety valve discharging to flare (1)

2.5 bar g for a safety valve discharging to atmosphere.

Note

(1) For distillation columns, 3.9 bar g is the design pressure at the bottom of the column (vapor phase),
the set pressure will be determined accordingly but not lower than 3.5 bar g.

2.4. Design pressure at the discharge of a centrifugal pump

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2.4.1. As a general rule the design pressure will be the maximum of the values
calculated by the two following formulas :

?max × [ max
PDD = PSM +
10.2
?C × [ max
PDD = PDA +
10.2

Where :

PDD : Design pressure at the discharge of the pump (bar g)

PDA : Design pressure at the suction of the pump (bar g)

PSM : Maximum operating pressure at the suction of the pump (bar g)

Hmax : Maximum differential head of the pump, generally at no flow condition (m)

HC : Rated differential head (m)

dmax : Maximum flowing specific gravity.

2.4.2. In fact, at the time of the development of the Basic Process Package, the
maximum differential head of the centrifugal pump is not available, as the
selection of the pump is not yet done.

The design pressure at the discharge of the pump will be set as follows :

1. 2 × ?C × [ max
PDD = PDA +
10.2

PDA : Safety valve set pressure for the suction vessel (bar g)
+ Pressure drop through the vessel (bar), if any
d
+ Maximum static head at pump suction (m) x max
10.2

At the detail engineering stage, it will be checked, after pump selection, that the
design pressure calculated by the hereabove formula is in accordance with the
criteria of paragraph 2.4.1.
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2.4.3. In case of two pumps in series, the maximum differential head will be the
sum of the maximum differential head of each pump if there is no pressure relief
valve between the pumps

2.5. Design pressure for complex systems

For systems such as reaction loops protected by one safety valve, the design
pressure of equipment on which this pressure safety valve is located is
calculated as per paragraph 2.1.

For any piece of equipment in the loop, the design pressure will be PD + ∆ P, ∆ P
being the maximum pressure drop in operation between this item and
equipment protected by the safety valve.

A pressure profile taking into account all operating conditions will be drawn.

Settling out pressure on compressor shut-down will not be considered for design
pressure determination of separator.

2.6. Tube rupture for heat exchangers

This concerns TEMA and multitubes heat exchangers.

The installation of safety valves for reason of tube rupture must be avoided as
much as possible for the following reasons :

Their sizing is not always easy

They can discharge liquid, or important quantity of water into hydrocarbon
flare system with possible liquid accumulation.

According to the paragraph 3.18.2 of API 521 (3rd edition, November 1990)
such a safety valve may be required if :

PD (low pressure side) < 2 (high pressure side).

3

The recommended practice consists in oversetting, if necessary, the design

pressure of low pressure side of heat exchanger :

In all cases up to the limit acceptable of the 150 lbs piping class.
After analysis, case by case, for higher pressures.
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This practice applies only to the heat exchanger itself and does not concern
relevant piping and valving.

According to the paragraph 3.18.6 of API 521 (3rd edition, November 1990),
double pipe type of heat exchangers are not concerned.

2.7. Steam containing equipment

As a general rule, full vacuum conditions should be added to design conditions

of a steam containing equipment under normal operation, since vacuum can
happen during cooling of such equipment, if it is not connected to atmosphere.

Steam out operation is not to be included in that rule.

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3. DESIGN TEMPERATURE

3.1. Equipment operating at temperature above 0°C

3.1.1. As a general rule the design temperature will be :

TD = TSM + 15°C

Where :

TD : Design temperature (°C)

TSM : Maximum continuous operating temperature (°C).

The accidental temperature which can occur in emergency situations such as

loss of utilities, valve closure, any abnormal operation... corresponding to a short
duration are not taken into account as long as the temperature increase does
not exceed codes limits (investigation has to be followed with specialists).

However equipment containing parts which can be damaged by abnormal high

temperature has to be designed for this temperature. It concerns column
internals, desalter internals, heat exchanger or air coolers tubes with polymer
coating... For this type of equipment, steam out delivery conditions have to be
reconsidered in order to remain below the maximum acceptable temperature.

Exceptional operating temperatures may have to be considered, the duration of

the corresponding operations exceeding a total of 100 hours per year. If there is
no change in operating pressure, the process design temperature will be the
maximum of the two values :

Either the maximum exceptional temperature

Or the maximum continuous operating temperature + 15°C.

If there is a significant change in operating pressure for this exceptional

operating conditions (for example reaction loops with in-situ catalyst
regeneration), an other set of design temperature and pressure has to be
specified corresponding to these operating conditions.
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3.1.2. Special cases

If for process reasons, the maximum operating temperature must not be

exceeded, this maximum possible operating temperature is used as design
temperature (ex catalytic reforming reactors).

For feed/effluent exchangers in reaction sections, the margin between

maximum operating and design temperature will be increased (to 25/30°C)
to take into account the temperature profile modification at low capacity.

For heat exchanger trains with by-pass of individual exchanger, the design
temperature (hot side) of the downstream exchanger will be the normal
operating temperature of the by-passed exchanger assuming that shells are
by-passed piece by piece.

3.1.3. Steam out

The steam out conditions (using LP steam) for vessels are as follows :

120°C
Atmospheric pressure.

This information is considered directly by Vessel Department and will not be

specified on SPP.

3.1.4. Emergency depressurizing

The exceptional temperature generated by depressurizing of equipment or

complete system will be indicated with the related residual pressure in order that
the pressure vessel designer can check the selection of material accordingly.

3.1.5. Vacuum conditions

A specific design temperature will be associated to specified vacuum design

pressure.

3.1.6. External minimum ambient temperature

This information is considered directly by Vessel Department and will not be

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3.2. Equipment operating at a temperature below 0°C

As a general rule the design temperature will be :

TD = TSM

Where :

TD : Design temperature (°C)

TSM : Minimum continuous operating temperature (°C) taking into account

minimum operating pressure and fluid composition range.

Notes :

(1) The "cold" design temperature for equipment operating at low temperature can be completed by an
exceptional "hot" temperature (related design pressure shall also be indicated).

(2) For depressurizing see paragraph 3.1.4.

3.3. Discontinuous processes

Conditions of P and T will be specified for each phase and must be considered
as simultaneous design conditions. Mixing of extreme conditions of pressure
and temperature shall not be considered.
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4. LIQUID HOLD-UP OR RESIDENCE TIME

The hold-up time is defined between Low Liquid Level (LLL) and High Liquid
Level (HLL).

As a general rule hold-up times will be as follows :

SERVICE HOLD-UP TIME (minimum)

Surge 20 to 30 minutes

Reflux 5 minutes
or 2 minutes if product sent to storage
15 minutes if product feed to column

Product to storage 2 minutes if direct cooling

5 minutes if heat exchange with other
process streams

Feed to distillation column 15 minutes

(5 minutes for crude distillation)

Reboiling by heater 10 minutes on vapor phase

or 5 minutes on bottom product

Reboiling by kettle 5 to 10 seconds (hold-up time transferred

to the kettle).

The residence time corresponds to half of the hold-up time, the Normal Liquid
Level (NLL) being set at 50% of the HLL-LLL range.
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5. OVERSIZING

Oversizing percentages are defined with respect to normal flowrates as per

material balance (maximum or sizing case).

5.1. Heat exchangers / Air coolers

In general no oversizing will be considered except for special cases, for example
to take into account lower performance of upstream heat recovery systems.

5.2. Pumps

The minimum margin between the normal (maximum) flowrate and the rated
flowrate will be as follows :

Reflux pumps and pumparound pumps : 20%

Feed pumps : 5%
Boiler feed water pumps : See applicable codes
Other pumps, in general : 10%

Notes :

(1) When a permanent recirculation flow for mini flow protection is installed, extra flow must be added
to the net process flow.

(2) Normal and rated flowrates will be identical in such instances as :

Intermittent service, sump pumps....

When the pump has been over rated to allow a centrifugal type selection
Recirculation flows.

5.3. Compressors

The minimum margin between the normal and rated flowrate will be as follows :

Recycle compressors (centrifugal) in reaction loops : normally 0%

Other centrifugal compressors : normally 10%
Reciprocating compressors : 10 to 20%

5.4. Fired heaters

The minimum margin between normal and design duty is 10%. It can be
increased, for example to take into account lower performance of upstream heat
recovery systems.
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6. METALLURGICAL REQUIREMENTS

6.1. Corrosion allowance (mm) (1)

Carbon Steel and Stainless Steel or

low-alloy steel (2) high-alloy steel

Corrosion process service (3) (4) 3 mini (5)

Non corrosive process service 1,5 mini (6) 0

Water 3 mini 0

Steam 1,5 mini (6) 0

(1) The corrosion allowance applies for all pressure vessels. For piping, refer to piping classes.
For storage tanks (thin wall), normally no corrosion allowance need to be provided.

(2) Heat exchanger tubes will be in BWG 14 for 3/4" size and in BWG 12 for 1" size.

(3) Including amine systems, sulfur recovery units and crude distillation units.

(4) A 6 mm corrosion allowance will be provided on vessels in wet H2S services at ambient
temperature without protective coating.

(5) Corrosion allowance is to be calculated for equipment life of 10 years.

(6) These values should be considered as minimum requirement for process reason. It could be
increased to 3 mm in some particular cases, for example if TEMA R is selected for tubular
heat exchangers.
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6.2. Postweld heat treatment

For caustic soda service, a postweld treatment for stress relief will be specified
to avoid cracking when :

The line is steam traced, whatever its operating temperature

Operating temperature in °F is higher than :

170 - B

Where : B is "Baumé"
B = 145 - 145/specific gravity.

For example a solution of caustic soda at 20% wt corresponds to a specific

gravity of about 1.2. In this case :
B = 145 - 145/1.2 = 24

A postweld heat treatment is required if the operating temperature is above :

170 - 24 = 146°F (63°C).

For lean and rich amine service, a postweld treatment for stress relief will
also be specified.

6.3. Hydrogen and/or hydrogen sulfide service

The partial pressure of hydrogen and/or hydrogen sulfide (based on design

pressure as total pressure) will be indicated on the process specification of the
concerned equipment.

For wet H2S service carbon steel HIC resistant will be specified. Materials shall
also conform to the NACE HR 01.75 in its last revision.

6.4. Temperature limit for carbon steel in environment of hydrocarbons

containing sulfur compounds

As a general rule carbon steel will be used up to 280°C (normal operating

temperature).

For pressure vessels including fractionation columns, above a normal operating

temperature of 280°C carbon steel with 3 mm minimum cladding 11/13 Cr will
be used. Cladding should be considered as corrosion allowance.

For heat exchangers, same as for pressure vessels, except for tube bundles for
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7. FOULING FACTORS (FOR CLIENT COMMENTS IF ANY)

a. Crude Distillation h.m2.°C/kcal m2.°C/W

Crude before desalter 0.0006 0.00050

Crude after desalter 0.0008 0.00070
Atmospheric overhead vapors 0.0004 0.00035
Naphtha 0.0004 0.00035
Kerosene (+ pumparound) 0.0004 0.00035
Light gas oil (+ pumparound) 0.0004 0.00035
Heavy gas oil (+ pumparound) 0.0005 0.00043
Vacuum gas oil (+ pumparound) 0.0005 0.00043
Light vacuum distillate (+ P.A) 0.0006 0.00050
Heavy vacuum distillate (+ P.A) 0.0008 0.00086
Atmospheric residue 0.0010 0.00086
Vacuum overhead vapors 0.0004 0.00035
Vacuum residue 0.0020 0.00172

b. Licensed units by Licensor by Licensor

c. Utilities

Cooling water 0.0004 0.00035

Cooling water with Sakaphen coating 0.0002 0.00017
Raw water 0.0003 0.00026
Chilled water 0.0002 0.00017
Saturated steam/LP condensates 0.0002 0.00017
BFW/Demineralized water 0.0002 0.00017
Superheated steam 0.0001 0.00009
Air, Nitrogen 0.0001 0.00009
Hot oil 0.0003 0.00026
Atmospheric air for air coolers 0.0004 0.00017
Tempered water 0.0002 0.00017
Desalter water 0.0004 0.00035
Stripped water 0.0004 0.00035
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8. SIZE OF NOZZLES

8.1. Minimum connection size will be

3/4" for welded connections

2" for flanged connections.

8.2. Nozzle sizes

1.25", 2.5", 3.5", 5", 7", 9", 22" and 26" shall be avoided.

8.3. Minimum size of manholes is 18" (DN 450)

Recommended size is 20" (DN 500)
Maximum size is 24" (DN 600)

Drums will be provided with one manhole and a 6" ventilation nozzle on the
opposite side.

In trayed columns, manholes will be provided at the top, below the bottom tray,
at the feed tray, at any other tray at which removable internals are located, and
at intermediate points so that the maximum spacing of manholes does not
exceed 15 trays. The normal tray spacing with manhole in the internal will be
900 mm. A minimum of 760 mm can be used for large diameter columns.

8.4. Preferred size of handholes is 8" (minimum 6")

They will be installed on vessel with diameter lower than 800 mm (one or two
handholes).

8.5. Vent, drain and utility connections for vessels shall be sized as follows
(smallest size of connections to be selected).

Volume of the vessel Vent Drain Utility connection

(m3) diameter diameter (steam out) diameter
V < 75 2" 2" 2"
75 < V < 220 3" 3" 2"
220 < V < 420 4" 4" 3"
V > 420 6" 4" 4"

Vent and utility connections are located on vessel while drain pipe is connected
to the bottom line, itself connected to the vessel lowest point.
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9. DIAMETER OF VESSELS

As a general rule, inside diameter will be specified on process data sheets.

If the required diameter for a vessel is lower than 800 mm, a note will be
added specifying that a pipe element is acceptable.

For vessels less than 900 mm I.D, flanged heads may be specified.
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10. LEVEL POSITIONS

The lower level control will be at a minimum of 300 mm from the bottom tangent
line.

Unless otherwise specified by Process Licensor, the following alarm and cut-off
setting will be used :

HLCO from 1 to 2 minutes residence time between HLCO and HLL (*)
HLL at 10% of the level controller range
HLA at 90% " " " " "
NLL at 50% " " " " "
LLA at 10% " " " " "
LLL at 0%
LLCO from 1 to 2 minutes residence time between LLL and LLCO (*)

The trip connections will be independent from other instrument connections.

(*) Mini : 200 mm

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11. ELEVATION OF EQUIPMENT

As a general rule, and unless otherwise specified by Licensor, for a vessel

containing a product at its boiling temperature, a minimum elevation of 5000 mm
will be specified when a bottom pump is provided.

If not, and if no other process constraint is involved, it will be indicated "mini for
piping" in place of elevation.
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12. INSULATION AND TRACING

Thermal insulation for hot or cold services is required for :

Heat or cold conservation of equipment and piping.

Personnel protection of equipment for operating temperatures above 70°C.
Temperature control to avoid condensation, solidification or a too high
viscosity.
Winterization of equipment.
Steam or electrical tracing.

Fire resistant insulation with a galvanized steel cladding can be specified case
by case in order to reduce the relief load to the flare system in case of fire.
However the normal engineering practice remains not to take any credit for
insulation. If fire resistant insulation is foreseen, this will be clearly specified on
SPP of the vessel(s) and relevant PSV.
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13. SPECIFIC REQUIREMENTS FOR HEAT EXCHANGERS

TEMA R will be generally used for all shell and tubes and hairpin type heat
exchangers.

The maximum allowable shell diameter is .....".

The maximum allowable tubes length is .....".

Fixed tube sheet exchangers are acceptable for non fouling service on the shell
side. In this case, Licensor and/or Contractor should define all exceptional
operating conditions (start-up, shutdown,...) to check the necessity to provide an
expansion bellow on the shell.

U tubes can be used on service with fouling factor equal or lower than :

0,0002 hm².°C / kcal

0,00017 m².°C / W.

For water coolers, the sizing of by-pass on water side will be 3/4" for water pipes
up to 3", 1" for water pipes up to 8" and 1 ½" for water pipes more than 8".

The design air temperature to be considered for air coolers and air condensers
is ....°C for the maximum and ....°C for the minimum.

Air cooler is preferred to water cooler for cooling down to a process temperature
of ....°C.

If a trim water cooler is provided downstream of an air cooler, the preferred

break point is ....°C.

Induced draft is preferred (except for multiple purpose air coolers, several
sections stacked or when outlet temperature of fluid is above 85°C and air outlet
over 77°C).

50% of the fans equipped with auto-variable blade pitch control will be specified
when process control is required.
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14. LINE SIZING CRITERIA

14.1. Line sizing criteria for liquids

LINE MAXIMUM PRESSURE DROP

SERVICE SIZE VELOCITY Normal Max.
(m/s) (bar/km) (bar/km)

Pump suction, bubble point (1) < 2" 0.6 0.6 0,9
3"-10" 0.9 " "
12"-18" 1.20 " "
> 20" 1.5 " "

Pump suction, subcooled < 2" 0.9 2.3 3.5

3"- 6" 1.2 " "
8"-18" 1.5 " "
> 20" 1.8 " "

Pump discharge, P < 50 bar g 1.5 to 6 3.5 4.5

Pump discharge, P > 50 bar g 1.5 to 6 7.0 9.0

Gravity flow 0.6 0.25 0,45

Side-stream draw-off (2) < 2" 0.6 0.6 0.9

> 3" 0.9 " "

Amine, sour water, caustic soda 2.0

Cooling water 3.0 2.3 3.5

BFW 6.0 3.5 4.5

Notes :
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(1) Applicable to liquid to thermosiphon reboiler and liquid containing dissolved gas.
(2) Provide a vertical run of 3 meters minimum from nozzle, at nozzle size, before reducing the size of the line.

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14.2. Line sizing criteria for gases and steam

MAXIMUM MAXIMUM
SERVICE PRESSURE LINE SIZE VELOCITY rV2
(bar g) (m/s) (kg.m.S-2)

Gases; General (1) P < 20 60 6 000 (4)

20 < P < 50 50 7 500 (4)
50 < P < 80 40 10 000 (4)
P > 80 30 15 000

Vacuum distillation 90

Flare system (3) 50% Sonic

Compressor Suction (3)

Reciprocating (2) 3 000
Centrifugal (3) 6 000

Inlet of heat exchangers (3) 6 000

Steam, saturated (3) < 2" 10 15 000

3" - 8" 30 "
> 10" 40 "

Steam, superheated (1)(3) < 2" 15 "

3" - 8" 40 "
> 10" 60 "

Notes :

(1) The above indicated line sizing criteria are valid for continuous operation. In that case, the pressure drop in
bar/km shall be less than 5% of the static absolute pressure for long headers and 10% for short headers.
For intermittent operation, these limits may be overpassed on a case by case analysis. As far as steam let
down stations are concerned, for example, where sufficient pressure drop is available, the pressure drop limit
of 10% for short headers may be relaxed and the ρ V 2 limit of 15 000 may be increased up to 25 000.

(2) Allowable pressure drop between 0.2 and 0.7 bar/km

(3) Allowable pressure drop between 0.5 and 1.2 bar/km.

Special attention must be paid for pressure drop in long steam lines connected to steam turbines in offsites.
In addition, to these criterias flowing velocity for a noise point of view have to be considered.
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(4) Indicative value. Do not exceed 15 000.

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15. TRAY FLOODING

The recommended flooding factor for valve trays should be as follows :

0.82 for pressure columns and atmospheric column

0.77 for vacuum distillation column

0.65 to 0.75 for columns with diameter lower than 900 mm.

Higher flooding factors will be considered in special cases only for revamping.
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