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D:\ss\AOGC-036-PR-DSC-001-B0-New.doc
CLIENT: CONSULTANT:
Prepared B.SH
Checked B.GH
Approved M.N
D:\ss\AOGC-036-PR-DSC-001-B0-New.doc
CLIENT: CONSULTANT:
TABLE OF CONTENTS
Page
1.0 INTRODUCTION ................................................................................................................ 4
1.1 Terms and Definitions.................................................................................................. 4
2.0 GENERAL .......................................................................................................................... 5
2.1 Meteorological /Environmental Data ............................................................................ 5
2.2 Units Of Measure ........................................................................................................ 5
3.0 PROCESS DESIGN CRITERIA.......................................................................................... 6
3.1 Design Standard and Codes ....................................................................................... 6
3.2 Symbol& Legend ......................................................................................................... 7
3.3 Piping .......................................................................................................................... 7
3.3.1 General Design and Hydraulics ............................................................................ 7
3.3.2 Two-phase Flow Regions ..................................................................................... 7
3.3.3 Two-Phase Flow Unit Loss ................................................................................... 9
3.3.4 Valves and Fittings............................................................................................. 13
3.3.5 Line Sizing .......................................................................................................... 14
3.3.6 Line Sizing Criteria ............................................................................................. 14
3.3.7 Liquid Line Sizing Criteria ................................................................................... 16
3.3.8 Vapors/Gases Line Sizing Criteria...................................................................... 18
3.3.9 Liquid Vapor Mixed Phase ................................................................................. 18
3.3.10 Pipeline Hydraulics ............................................................................................. 19
3.4 Design Over Sizing Factor ......................................................................................... 20
3.4.1 Pump Sizing ........................................................................................................ 20
3.4.2 Line sizing .......................................................................................................... 21
3.5 Design Pressure & Temperature of Pressure Vessel ................................................ 21
3.5.1 Design Pressure ................................................................................................. 21
3.5.2 Pressure Conditions ........................................................................................... 21
3.5.3 Design Temperature ........................................................................................... 22
3.5.4 Temperature Conditions ..................................................................................... 22
4.0 PUMP CALCULATION ..................................................................................................... 23
5.0 RELIEF SYSTEM DESIGN CRITERIA ............................................................................. 25
6.0 NOZZLE, MAN WAY AND CONNECTION ON PRESSURE VESSELS .......................... 26
6.1 Vent, Drain And Steam Out Connection .................................................................... 26
6.2 Man Way ................................................................................................................... 27
6.3 Vessel Nozzles .......................................................................................................... 28
7.0 CONTROL VALVE SIZING CRITERIA ............................................................................. 28
7.1 Control Valve Manifold .............................................................................................. 29
7.2 Selection of Valves .................................................................................................... 33
7.3 Battery Limit Block Valves ......................................................................................... 34
7.4 Pressure Thermal Relief System Design Criteria ...................................................... 34
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CLIENT: CONSULTANT:
1.0 INTRODUCTION
Arvandan Oil and Gas company intends to construct an 8" N.B. buried flowline
from Sohrab WH1 to South Azadegan North Cluster.
Sohrab Field is located at North of Azadegan Field, and 115 Km North West of
Ahwaz right along the international border with Iraq.
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CLIENT: CONSULTANT:
2.0 GENERAL
As a general rule, the SI metric system of units shall be used and particularly:
Mass kg
Length m & mm except the pipes diameter for which inches are
allowed
Flow rates
- Mass kg/h
- Vapour kg/h
Normal conditions
Heat rate MW
Viscosity (kinematic) cp
Vapour flow rate = MMSCFD Million Standard cubic feet per day
(at 15C & 1.013 bara).
Temperature = C
In design of this plant all of the IPS standard relevant to process design such
as following must be completed.
Units E-GN-100
Basic Design Package & Recommended Practice for Feasibility Studies E-PR-
150
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3.3 Piping
This section provides the Process Engineer with methods for sizing process
piping and calculating pressure drops in straight pipes and associated fittings.
It also provides some useful design data for pipes and fittings required for
sizing purposes.
The two-phase flow patterns are shown in Table 3-1 first column. The
selection of one of these flow patterns is made using Fig. 3-1. The borders of
the various flow pattern regions in Fig. 3-1 are shown as lines. In reality these
boarders are rather broad transition zone.
Baker parameters
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"By" depends on the vapor phase flow rate, on vapor and liquid densities, and
on the pipe size. The practical significance of the later variable is that by
changing pipe diameters, the type of flow might also be changed, which is in
turn, also changes friction losses in pipe.
Note:
As Equation above shows "Bx" depends on the mass-flow ratio and the
physical properties of the liquid and vapor phase. Once calculated, it does
not change with alternative pipe diameters. The position of the Bx line in Fig.
6-4-2/1 changes only if the liquid-vapor mixture proportion changes and, to a
much lesser extent, if the physical properties of the concurrently flowing liquid
and vapor changes. This can occur in long pipe lines where relatively high
friction losses reduce the pressure. Consequently, the vapor content of the
mixture in equilibrium increases with corresponding decrease in vapor density.
The Bx line will shift somewhat to the left.
The intersection of Bx and By on Fig. 3-1 determines the flow region for the
calculated liquid- vapor proportion and physical properties of the liquid and
vapor. With increasing vapor content, the intersection point moves up and to
the left.
It is suggested that the designer calculate By first. If By 80,000 the flow will fall
in dispersed flow region for hydrocarbon liquids of normal viscosities, then, the
long multiplication of Bx does not have to be calculated. This can be expected
when the vapor content is 25 percent or more of the total mass flow rate.
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Fig. 3-1
However, the calculations of the unit losses for vapor-liquid mixtures are
based on the method of Messrs. Lockhart and Martinelli. Only the essential
necessary relationship are repeated here and used with the customary data of
practical process piping design. The general equation for calculating two-
phase flow unit losses is:
Calculate the pressure drop of the vapor phase, assuming that there is only
vapor flowing in the pipeline. It is assumed that the two-phase flow is
isothermal and turbulent in both liquid and vapor phases and that the pressure
loss is less than 10% of the absolute upstream pressure.
Correct the calculated P100 (vapor) with the correlations listed in Table below second
column.
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a = 4.8-0.0123 d
HORIZONTAL
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Where "a" includes the vapor-phase flow rate and the pipe cross section and
"b" is a constant, except for annular flow where in "a" and "b" only pipe
diameters appear as variants.
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Usually both phases fall in transitional turbulent zone, where the friction factor
varies with varying
Reynolds numbers, fL/fv increases with the increasing vapor content of liquid.
Reynolds number is calculated separately for the vapor and liquid-phase using
the same diameter, corresponding flow rates and viscosities.
Re = 353.7W/d.
A convenient form of Darcys equation for unit pressure loss calculations for
liquid or vapor as previously stated is:
Use the same diameter for liquid and vapor-phase and corresponding phase
flow rate, density and friction factor.
As with all line sizing procedures pipe sizes must be estimated first. After pipe
size selection, flow region coordinates can be calculated and the flow type
determined. After finding the vapor-phase unit loss and applicable two phase
flow correlation (in Table 3-1), two-phase flow Unit losses can be calculated by
mentioned Equations. can be also found through Fig. 3-1 or Table 3-1.
The over-all friction loss in the pipe between two points will be:
P =P100 (two-phase)(L/100)
The pressure drop resulting from friction is only one part of the total pressure
drop in a piping system. In addition to friction, other factors that cause
pressure drop are:
Before final line sizing, the system shall be evaluated with the objective of
resulting in a total cost effective design. This may include evaluation of
functional requirements, cost of equipment and piping, space requirements
and weight, energy costs, mechanical and process limitations, maintenance
cost etc.
The following design criteria are observed during engineering design and
material sizing/selection.
Considering the economics of the project, one of the following factors may be
used in selecting a line size:
Generally, the line shall be sized based on the friction loss. Velocity limit may
be used for checking, or making preliminary sizing. In some cases, the size is
determined by a maximum velocity limit:
Line sizing shall be based on the total available pressure drop, which will
ensure a minimum line diameter. Care shall be exercised to limit the velocity in
the pipes. The pressure drop limitations are shown on the next pages. These
values are somewhat arbitrary, which may be applied for continuous services
and may be exceeded for intermittent services, while problems of noise,
erosion, and water hammer shall be considered.
Limitations of velocity
The velocity limitation shall be used as the main factor for avoiding erosion,
liquid hammer, pressure surge, noise, vibration and reaction and or chocked
flow. In some cases, a minimum velocity is required. A compromise between
line size and pump power has to be taken.
Depending on the flow regime, the liquid in a two-phase flow system can be
accelerated to velocities approaching or exceeding the vapor velocity. In
some cases, these velocities are higher than what would be desirable for
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Each mixed phase flow line shall be handled as special case, taking the
following considerations into account:
Stable flow pattern shall be maintained for the two-phase flow line.
The flow pattern shall be checked for maximum turn down flow rates.
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CLIENT: CONSULTANT:
A minimum size of 2" should in general be used for all process, process
support and utility piping to ensure adequate mechanical integrity. Smaller
piping can be used, where protection and/or support is provided for the
following services:
Instrument air.
Chemical injection.
Sample connections.
Instrument connections.
Minimum size for the sewage and open drain header shall be 4" and sub-
headers 3".
For corrosive or erosive fluids in carbon steel pipe, the velocity will be
reduced to half.
When available pressure drop in the system dictates a lower friction loss
velocity as compared to the mentioned range, then such lower friction loss
/ velocity shall apply.
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Notes:
(1) 3.0 m/s maximum (2 m/s average) at storage tank inlet or in loading.
(2) Vendor and/or Licenser requirements could supersede maximum velocity values upon Company
approval.
(3) Special considerations can be applied for copper-nickel or glass reinforced plastic piping upon
Client approval.
(4) Velocities below 0.91 m/s should not be used for cooling water service to avoid solids deposition.
(5) For amine service velocity should not exceed 1 m/s to avoid corrosion/erosion.
(6) For lines containing mixtures of hydrocarbon and water, velocity should be limited to 1 m/s to
avoid generation of static charge.
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Where:
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C = Empirical constant
Note:
1) Different values of C may be used where specific application studies have shown
them to be appropriate.
For liquid lines the normal average flow velocities should be selected between
1 and 2 m/s. Operations above 4 m/s should be avoided and lines containing a
separate water phase.
For gas lines, the normal average flow velocities should be selected between
5 to 10 m/s. In special cases, continuous operations up to 20 m/s. Velocities
lower than 5 m/s may have to be used for fluids containing solid particles
where maximum velocity will be dictated by the occurrence of erosion.
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Where
T = Flowing temperature, K
Where a mixture of gas and liquid is being transported, the erosional should
be used as maximum velocity.
If sand or other erosive solids are expected to be present, the fluid velocity
should be reduced and/or special materials selected to avoid or reduce
erosion.
However in two-phase lines (especially for long lines with elevation changes)
the velocity shall be selected to have a suitable flow regime with minimum
pressure drop across the lines.
Conditions Description
10% on maximum normal flow rate Centrifugal pumps
20% on maximum normal flow rate Chemical injection
15% on maximum normal flow rate Reciprocating & Rotary pumps
For pump design capacity and head the following equation shall be used:
Design capacity = (max. normal flow rate) x (design over sizing factor)
Design head = Pump head at maximum normal flow rate.
Fluid characteristics always quote at pumping temperature i.e. normal
suction temperature.
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CLIENT: CONSULTANT:
For an estimate, 30% of normal flow is used for pump minimum flow. For
existing pumps minimum flow shall be obtained from vendor data sheets
The design pressure is the value used in determining the minimum permissible
thickness or physical characteristics of the different parts of the vessel or
equipment as follows:
TABLE 3-5
Design pressure applies at the top of vessels, i.e. above any liquid level.
Mechanical thickness calculations take in consideration a maximum liquid
density and a maximum liquid level as well as the design pressure.
Pressure vessels should normally have a design pressure of not less than
3.5 barg, especially when fitted with relief valves relieving to flare systems.
Lower design pressures can result in increased sizing of the flare system
to limit acceptable backpressures. However, consideration may be given
to increasing the design pressure if this can significantly reduce, or
eliminate, relief loads.
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TABLE 3-6
The startup. Shut down, upset, or any other condition shall be considered
to determine the minimum operating temperature.
Over capacity is defined as the percentage difference between the normal and
rated flows. Normal and rated flows will be set by the process section and will
be indicated on the pump head calculation sheet.
Design margins as set out as table below are to be applied when setting pump
design capacities.
Suction Calculation
This calculation yields the system pressure available at the pump centerline of
horizontal pumps or at the centerline of the suction inlet nozzle for vertical
shaft pumps. It involves the summation of the feed vessels normal operating
pressure and the static head less the pressure drop in the suction piping
resulting from friction, inlet-exit, and other losses.
The static head for vertical vessels is calculated from the bottom tangent line
while for horizontal vessels, the bottom invert line is used. Usually no credit is
taken for the head contributed by liquid operating levels in a vessel.
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The minimum available NPSH is the difference between the pump suction
pressure and the fluids vapor pressure at the flow conditions. For NPSHA,
normally, a minimum of 610 mm differential head shall be provided over NPSH
requirement of pumps.
In reporting the vapor pressure, use the notation Bubble Point Fluid for
boiling point liquids instead of numerical values.
c) Foaming fluids.
In the special case of boiler feed water pumps, a margin of 2.0 m (6.6 feet) is
to be used.
Shut off pressure shall be calculated as maximum suction pressure plus 120
% of differential pressure. The shutoff pressure of a typical centrifugal pump is
approximately equal to the sum of the maximum suction pressure and 120%
of the net differential pressure generated by the pump, based on the
maximum anticipated fluid density. Other pumps with steep H-Q curves such
as turbine, multistage and mixed flow pumps, however, will have higher shutoff
pressures. The process engineer specifying these types of pumps shall
consult with the Rotating Equipment Group to determine this value since it
may influence the design pressure of downstream equipment.
The maximum discharge pressure sets the design pressure of a pump casing.
This is the sum of the maximum suction pressure and maximum differential
pressure, which usually occurs at zero flow. In cases where the feed vessel is
protected by a safety relief valve, the maximum suction pressure will be equal
to the sum of the safety valve set pressure and the maximum static head.
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The safety relief valves shall be manufactured according to the ASME code
section VIII.
All pressure relief valves should be equipped with L/O blocked valves at
inlet & outlet as in above.
Double relief valve system shall be used for all equipment, which cannot
be removed from service without plant shut down.
For line sizing, the maximum capacity of the PSV shall be considered, even if
this figure exceeds the actual maximum flow rate set by process limitations.
P between the protected equipment and the PSV < 3% of PSV set
pressure (API RP 520 part II).
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Maximum velocity in a sub header is 0.7 Mach for short duration relieves only.
Maximum flowing velocity in the lines between of the PSV's to the first sub
header shall in general be less than 0.7 Mach. For the PSV's where the outlet
velocity is higher, a reducer shall be installed as close as possible to the PSV
to increase line size and hence limit the velocity to max 0.7 Mach downstream
at the reducer.
Flare stack diameter is generally sized on a velocity of up to 0.5 Mach for a
peak, short-term, infrequent flow, with 0.2 Mach maintained for the more
normal and possibly more frequent conditions for low-pressure flares.
However, sonic velocity operation may be appropriate for high-pressure flares.
The tip pressure drop is taken from vendor's information. For sonic type tip the
backpressure will be assumed 2 to 5 Barg depending on load, when there is
not any information.
All pressure vessels shall be provided with not operating valve vents
and drains discharging to atmosphere vents shall be located on top of vessel
and blinded or plugged.
Drain shall be blinded or plugged and preferably located on the low point of
the bottom outlet piping, outside the skirt. If there is no bottom line or said line
does not allow complete drainage of the vessels, the drain shall be connected
to a separate nozzle on the bottom head.
Size of vent, Drain and steam out nozzles on vessels shall select as per
following table:
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Table 6-1
A) Horizontal vessels
Larger than 1300mm ID Man way, on the side or on the top, 20" ID (1) Higher
size man way shall be provided if required to accommodate internals.
B) Vertical Vessels
C) Packed vessels
Each packed bed shall have a man way at above of bed and a man
way at bottom for withdrawal.
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The size of the nozzle on the vessels shall be equal to size of the
connecting pipe.
If the process has set a larger size than the pipe attached to it, then the
size shall remain larger as per process requirements.
If the process the set a smaller nozzle size than the pipe attached to it,
then the size shall be increased to the pipe size provided that the process
shall not be affected.
Auxiliary Nozzles
Blow down and pump out nozzles may or may not be provided depending on
the safety system used and the clients preference. When provided, they are
connected to the vessel in the same manner as the drain line.
Generally, the range of control valve opening should be between 10% for
minimum flow rate and 80% for maximum (design) flow rate. At the normal
flow rate valve opening percent should be 60%-70%.
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TABLE 7-1
Full line size block and bypass valves are required for the following:
Use downstream line size for block valve size when vaporization or volume
increase full line capacity.
Excessive noise.
Tag number
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Ration
Control valves shall be arranged in horizontal lines with the valve actuator
above the valve.
Where the line size is more than two sizes larger than the size of the control
valves, line size may be considered to sewage ahead of the manifold and then
the manifold shall be size as described before.
Control valves above 2" size shall have minimum ANSI rating of 300#.
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Exceptions
Full line size block and bypass valves are required for the following:
a) Vaporization or volume increase full line capacity use downstream line size
for block valve size. b) Gravity flow with small control valve differential.
c) Requirement for future expansion.
e) Excessive noise.
The following guide shall be used to select the type of valves for specific
application.
Gate valve may be used for on-off purpose especially for liquid lines when
throttling and tight shut-off is not required.
Check valve shall be used for unidirectional flow and when return of flow
shall be avoided.
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The type of ball valve shall be such that they provide metal to metal seating
upon the failure of the non-metallic parts during fire conditions (fire safe)
All pipes, which enter or exit from Battery Limit of unit shall be equipped with
Block Valve, Spectacle Blind, and vent and drain valves, which are installed
inside of Battery Limit.
Block valves for relief lines must be equipped with lock in open position.
In some cases which may back flow exists, a check valve shall be equipped in
up-stream of Block valve.
If a pressure relief header is being sized for fire condition, the fire area
shall be limited to 21m (70ft) in diameter within a single process unit.
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Flare line size above 24 inch in diameter shall be reviewed with project
lead engineer.
Double relief valve system should be used for all equipment, which cannot
be removed from service without plant shut down.
Each valve shall have 100% capacity, with inlet and outlet block valves
mechanically locked in open position. When relief system on the above
services consists of multiple relief valves, one additional relief valve with the
same capacity shall be installed, in order, to permit replacement of any of the
other valves.
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