Attachment-3 GENERAL SPECIFICATIONS FOR LINESIZING DESIGN BASIS. 1.0 GENERAL INFORMATION.

These specifications cover guidelines for Line sizing for Process Plants and Offsite and Utilities. 2.0 Piping Engineering Hydraulics Liquid Hydraulics. Vapour Hydraulics. Mixed Phase Hydraulics. 2.01 LIQUID HYDRAULICS.

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Piping systems should be designed taking into consideration capital cost versus operating costs and with due allowance for noise erosion and corrosion limitations. The following tables are to be used as a guide for the sizing of pipe lines in liquid service. Line sizing should satisfy both the pressure drop and the velocity criteria. Recommended Velocity and Maximum D P for Carbon Steel Liquid Lines Liquid Lines in Process and Equipment Service Sr. No. 1. 2. 3. General recommendation Laminar Flow Turbulent Flow Liquid density 100 lb/ft3 1602 kg/cm3 50 lb/ft3 20 lb/ft3 4. 801 kg/cm3 320 kg/cm3 6-10 10-15 1.8-3.0 3.0-4.6 5-8 1.5-2.4 Type of Service Velocity ft/sec. 5-15 4-15 m/sec. 1.5-4.6 1.2-1.5 Maximum D P psi/100ft 4 kg/cm2/100m 0.92

Pump Suction Boiling Liquid Non-boiling liquids 2-6 4-8 0.6-1.8 1.2-2.4 0.5 1 0.115 0.23

5.

Pump Discharge 0 250 0 57 6-8 1.8-2.4 6 1.38

gpm 250-700 gpm >700 gpm 6. 7.

m3/hr 57-159 m3/hr >159m3/hr 10-15 4-6 1-4 3-4.6 1.2-1.8 0.3-1.2 2 0.6 0.15 0.46 0.14 0.035 8-10 2.4-3 4 0.92

Bottoms Outlet Reboiler Trapout

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Attachment-3 8. 9. 10. 11. 12. Liquid from Condensor Liquid to Chillers Refrigerant Lines Gravity Run LInes Liquid Feed to Towers 3-6 4-6 2-4 3-8 4-6 0.9-1.8 1.2-1.8 0.6-1.2 0.9-2.4 1.2-1.8 0.4 0.4 0.09 0.09 0.5-0.11

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WATER LINES Sr. No. 1. General Service Diameter, inches 1 2 4 6 8 10 12 16 20 and up 2. 3. 4. 5. 6. 7. Pump Suction and Drain Pump Discharge Boiler Feed Refinery Water Lines Cooling Water From Condensor 2-3 3-4.5 5-7 7-9 8-10 10-12 10-14 10-15 10-16 4-7 5-10 8-15 2-5 12-16 3-5 0.6-0.9 0.9-1.4 1.5-2.1 2.1-2.7 2.4-3.0 3.0-3.7 3.0-4.3 3.0-4.6 3.0-4.9 1.2-2.1 1.5-3.0 2.4-4.6 0.6-1.5 3.7-4.9 0.9-1.5 2.5 2 0.58 0.46 Type of Service Velocity ft/sec. 2-16 m/sec. 0.6-4.9 Maximum D P psi/100ft 2 kg/cm2/100m 0.46

RECOMMENDED VELOCITY AND MAXIMUM D P FOR CARBON STEEL VAPOR LINES VAPOR LINES IN PROCESS AND EQUIPMENT SERVICE Sr. No. Type of Service Velocity ft/sec. m/sec. Maximum D P psi/100ft kg/cm2/ 100m 1. General Recommendation Pressure Level

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Attachment-3 psig P > 500 kg/cm2 P > 35.1 2.0 1.5 0.6 0.3 0.15 0.1 0.5 0.46 0.35 0.14 0.069 0.034 0.023 0.12

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200<P<=500 14.1<P<=35.1 150<P<=200 10.5<P<=14.1 50 <P<=150 0 < P <=50 3.5 <P<=10.5 0< P <=3.5

Subatmospheric 2. Gas Lines within Battery Limits 3. 4. Compressor Piping Suction Compressor Piping discharge 5. 6. 7. Refrigerant Suction Lines Refrigerant Discharge Lines Tower Overhead Pressure (P > 150 psia) 40-50 12-15 15-35 35-60 4.6-11 11-18

0.5 1.0

0.12 0.23

0.2-0.5

0.0460.12

Atmospheric Vacuum (P < 10 psia)

60-100 125-200

18-30 38-61 0.05-0.1 0.0120.02

STEAM LINES Sr. No. Type of Service Velocity ft/sec. m/sec. Maximum D P psi/100ft kg/cm2/ 100m 1. General Recommendation Maximum : Saturated Superheated Steam Pressure : psig 0 - 50 50 - 150 150 - 300 >300 kg/cm2 3.5 3.5 - 10.5 10.5 - 21 >21 200 250 61 76

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Attachment-3 2. High Pressure Steam Lines Short (L<600 ft) Long (L>600 ft) Short Leads 3. Exhaust Steam Lines (P > 1 atm) Leads to Exhaust Header 4. Feed Lines to Pumps and 12.5-15 Reciprocating Engines 5. Power House Equipment 100-170 30.5-52 3.8-4.6 1.5 0.346 1.0 0.5 2.5 0.5 0.23 0.165 0.577 0.165

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and Process Piping (Saturated at P >=25 psig) 6. Boiler and Turbine Leads 115-330 (Superheated to P >= 200 psig) LIQUID SERVICE SINGLE PHASE : TYPE SERVICE OF MAXIMUM FRICTION LOSS DP KG/CM2 / 100 MT. MAXIMUM VEL. M/SEC. REMARKS 35-100 3 0.69

1)

Pump Suction

Boiling liquid

0.1

< 1.0

Non liquid

Boiling

Flooded Non Flooded

0.2 0.2

< 1.8 < 1.8

Note :1

2)

Pump Discharge

0.3

< 3.0

3)

Gravity run Lines

0.1

0.9 - 2.4

4)

Water Lines

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Attachment-3

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Main header

0.2

< 3.0

Sub header

0.3

< 3.0

5)

Sea water Lines (Concretelined/ Unlined Pipes)

0.3

< 3.0

2.02 VAPOUR HYDRAULICS The following tables are to be used as a guide for the sizing of pipe lines in steam or vapour service. Line sizing should satisfy both the pressure drop and the velocity criteria. Consider economic factors when and where applicable. STEAM SERVICE : TYPE SERVICE OF MAXIMUM FRICTION LOSS DP KG/CM2 / 100 MT. MAXIMUM VEL. M/SEC. REMARKS

1)

Steam Lines

Saturated Superheated

61 76

HP steam >21 kg/cm2G

0.25

< 20.0

MP steam 10.5- 21 kg/cm2G

0.12

< 20.0

LP steam 3.5 - 10 kg/cm2 G

0.08

< 20.0

2)

Exhaust Steam

0.15

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Attachment-3

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VAPOUR SERVICE

TYPE OF SERVICE

MAXIMUM FRICTION LOSS DP KG/CM2 / 100 MT.

MAXIMUM VEL. M/SEC.

REMARKS

1)

General Recommendation

Pressure levels kg/cm2 G P> 35.1 14.1 < P < 35.1 10.5 < P < 14.1 3.5 < P < 10.5 0 < P < 3.5 Subatmospheric 0.25 0.25 0.14 0.08 0.03 0.02

2)

InstrumentAir/ Air lines

Plant

0.1

<15

3)

Compressor

Piping Suction Piping Discharge

0.12 0.23

4)

Tower Overhead

Pressure (P > 2.5 kg/cm2 G) Atmospheric 0.046 - 0.12 12 - 15 18 - 30

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Attachment-3 Vacuum 0.012 - 0.023 38 - 61

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4.03 MIXED PHASE HYDRAULICS The following basis shall be used as a guide for the sizing of pipe lines in mixed phase flow service. Line sizing should satisfy both the pressure drop and velocity criteria. Consider economic factors when and where applicable. Condensate Lines Velocity < Erosion Velocity DP/100m < 0.2 kg/cm2 G UNIT The units and measurements to be used shall be those given below MEASUREMENT UNIT

PRESSURE :(As guage) LOW PRESSURE : PRESSURE :(Draft or Vacuum)

Kg/cm2 mmH2O mmH2O

FLOW : - Liquids - Gas - Air - Steam - Solids m3/HR,l/HR Nm3/HR Nm3/HR Kg/HR Kg/HR

TEMPERATURE :

Deg.C

LEVEL :(Other than Tanks)

VOLUME :

m3

LEVEL : (Tanks)

mm,cm or m

SPECIFIC GRAVITY: -Water 1.0 at 4 Deg.C 12/7/02

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DENSITY :

Kg/m3

DIFFERENTIAL PRESSURE IN ORIFICE :

mmH2O or Millibar

LENGTH :

mm,cm or m

WEIGHT :

Kg, ton

MEASUREMENT

UNIT

ENERGY :

Kcal

POWER :

Kilo-Watt (KW)

CURRENT :

Ampere

VOLTAGE :

Volt

STRESS IN MATERIAL :

Kg/cm2 or Kg/mm2

THERMAL CONDUCTIVITY :

Kcal/m.Hr.oC

HEAT TRANSFER COEFFICIENT:

Kcal/ m2.Hr.oC

LATENT HEAT :

Kcal/Kg

SPECIFIC HEAT :

Kcal/Kg .oC

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Attachment-3

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IMPACT VOLUME :

Kg.m/cm2

SURFACE TENSION :

Dynes/cm

MOMENT :

Kg.m

AREA :

m2

TIME :

Sec,Min,Hr,Day

VELOCITY :

m/sec

SPEED :

RPM

FREQUENCY :

Hz

SOUND LEVEL :

db

CONVERSION UNITS The conversion factors to be used shall be those as given below QUANTITY TO CONVERT FROM METRIC UNIT CONV. FACTOR

Length Safety Distance Stress , Pressure Specific heat Surface Tension Latent Heat Flow rate

inch feet psig Btu/Lb F N/m Btu/lb lb/hr

mm m Kg/cm2 K. cal/Kg C dynes/cm Kcal/Kg Kg/Hr

25.4 0.3 .0703 1.000 1000 .556 .454

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Attachment-3 Power Btu/hr K. cal/hr .252

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6.0 EQUIPMENT DESIGN CONSIDERATIONS 6.01 DESIGN PRESSURE GENERAL Equipment which are liquid filled and can be blocked into a pump discharge pressure shall be designed to withstand the pumps shut-in pressure. Pump shut-off pressure shall be defined as the maximum suction pressure plus shut-off delta P. Maximum suction pressure is the sum of maximum operating pressure and static head. After vendor information on pumps are received, the maximum shut-off pressures shall be checked in order to confirm that they do not exceed the equipment design pressure. PROCESS EQUIPMENT The design pressure for vessels,towers and heat exchanger shall be atleast 1 kg/cm2 or 10 % higher than the maximum expected operating pressure including hydraulic head or pump shut off pressure,whichever is greater UTILITY EQUIPMENT Use mechanical design pressure given in the utility conditions 6.02 DESIGN TEMPERATURE PROCESS EQUIPMENT The design temperature shall be 25 oC above the maximum expected operating temperature.When the operating temperature is 15 oC and below,the dessign temperature shall be the minimum expected operating temperature.Vessel part in contact with two fluids having different temperatures, shall be designed for the higher of the two. When the operating temperature are 15 oC or less, they shall be designed for the lower temperature of the two. UTILITY EQUIPMENT Use mechanical design temperature given in the utility conditions 6.03 FLARE KNOCK-OUT DRUM : They shall be designed in accordance a vertical drum shall be based on economic consideration,taking into header.When large liquid storage is desirednnad the vapour flow is economical.The drum sizing shall be based on the separation of liquid vapour. 6.04 VAPOUR LIQUID SEPARATOR Where carryover of entrained liquid mist 400 micron and smaller is not critical to process or process or operation of the equipment, use knock-out drum to separate the vapour and liquid phases. If removal of liquid mist particles within 400 to 60 micron in size is essential, use wire-mesh entrainment separators. If it is essential to remove particles of liquid mist smaller than 60 micron, other types of mist eleminators must be used. 6.05 SHELL AND TUBE HEAT EXCHANGERS The design pressure for the process side of exchangers is based on the set pressure of the relief valve. If the system relief valve is upstream, use the set pressure for the design pressure. If the relief valve is downstream, use the set pressure plus the pressure drop from the inlet of the exchanger to the vessel, calculated at the maximum possible flow rate. Use maximum pump shut-off pressure where applicable. The design temperature for the shell and the tube sides of heat exchangers shall be based on the inlet temperature for the hot side and the outlet temperature for the cold side. From this basis, the same conditions shall apply for pressure vessels as given in 6.01 above. For a utility side use the same design temperature given in the utility conditions. Fouling factors used in the design shall be in accordance with TEMA recommendations unless otherwise specified. The tube side shall be used for cooling water unless otherwise dictated by the process. The process side of exchangers pressure that can be blocked against centrifugal pump discahrge pressure shall be designed to withstand the pumps shut-off pressure.Pump shut-off pressure shall be defined as the maximum suction pressure plus shut-off delta P. Maximum suction pressure is the sum of maximum operating pressure and static head. After receiving vendors information on pumps, check all pumps to make sure that the maximum discharge conditions do not exceed downstream vessel design pressure. file://D:\WINNT\Profiles\jjsnl\Desktop\StandardsFS_files\linesz 12/7/02 with API-521.The choice of a horizontal or account the required slope of the flare high, a horizontal drum is often more droplets of 300 to 600 microns from the

Attachment-3 For a utility side use the same design pressure given in the utility conditions. 6.06 DESIGN OF TANKS The design of tanks shall be in accordance with API 620, 650 and latest addenda. 6.07 DESIGN OF PUMP CENTRIFUGAL PUMPS The differential head for pumps shall be the circulated head based on process flow design rate.

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Manufacturer is to specify minimum by-pass flow rate, if required, and if so, the amount of this flow is to be specified. The pump motor shall be designed to cover the entire pump curve for the impeller. RECIPROCATING PUMPS The design capacity and differential head for reciprocating pumps shall be determined on the same basis as for centrifugal pumps. 6.08 DESIGN OF COMPRESSORS CENTRIFUGAL COMPRESSORS The compressors rated capacity shall correspond with the process design conditions. Compressors must be capable of operating throughout the range from start of run to end of run conditions.
RECIPROCATING COMPRESSORS The compressors design capacity shall correspond to the process design conditions, with no negative tolerance permitted. The differential head shall be the calculated value based on the process design flow rate. LUBE OIL AND SEAL OIL SYSTEMS Main oil pumps shall be driven from the crank shaft and the auxiliary oil pumps shall be motor driven. The Oil reservoirs shall be sized to supply oil for a period of 5 min.,during a power failure or stoppage of tube or seal oil pump

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