Overall - Design Basis (Digboi) - Process

00 ALL CS 24.12.07 TSM 26.12.07 SMK 26.12.
07 IFC ssued for Comments

Rev. Sheet Name Date Name Date Name Date Status Remark, kind of revision
Prepared, revised Checked Approved
Designation Basis document
DG
UNIT NO. 34, 35, 36 & 37
-
Project Name
MSQ UPGRADATION - IOCL DIGBOI
Project No.
10169B
Document No.
D 10169B 90 4LI 1001
Sheet / of
1/6
Revision
00
EDP dent. No. 190729521.doc Derived from GFA 0373E B!"#$ %&'( GFA 0373)*
ssue 04 ,30.10.1998 ssue: Rev. 02 , 21.05.2002 Sheet 1 of 36
PART - PROCESS PACKAGE
SECTON A - ENGNEERNG DESGN BASS
S)CTION + IIA
)NGIN))RING D)SIGN BASIS - PROC)SS
.
T",!- &% C&#.-#./
000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000
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4 U.*!*.*-/ S2-1*%*1".*&#/
5 )74*2(-#. D-/*6# B"/*/
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11 L*#- N4(,-'*#6 "#3 I3-#.*%*1".*&# S9/.-(
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13 A#"!9/*/ 2&*#. #4(,-'*#6
14 P'-//4'- '-!*-% ;"!;- #4(,-'*#6
15 S"%-.9 R-1&((-#3".*&#/
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Project Name
Project No.
10169B
Document No.
D10169B904LI1001
Sheet / of
/6
Revision
00
EDP dent. No. 190729521.doc Derived from GFA 0373E Blank form
ssue 04 ,30.10.1998 ssue: Rev. 02 , 21.05.200 Sheet 2 of 36
I#3-= &% R-!-;"#. D&14(-#./
No. Title Summary of Revisions
Project Name
Project No. Document No.
D10169B904LI1001
Sheet / of
3/6
Revision
00
EDP dent. No. 190729521.doc Derived from GFA 0373E
ssue 04 ,30.10.1998 ssue: Rev. , Sheet 3 of 36
1.0 I#.'&341.*&#
P!-"/- 1&#/4!. .8- 3-/*6# *#%&'(".*&# 2'&;*3-3 ,9 .8- P'&1-// L*1-#/&', M/S A=-#/
<*.8 *#.*(".*&# .& IOCL.
1.1 ndian Oil Corporation Limited (OCL), the owner, intend to Engineer, Construct, Commission and Operate
MS QUALTY UPGRADATON (MSQU) Project at its Digboi Refinery in the state of Assam. Lurgi
ndia Company Pvt. Ltd. has been retained by OCL to provide services for Project Management
Consultancy (PMC) and Front End Engineering Design (FEED)
The following process facilities are covered under the FEED package:
The following units are part of the MS Quality Upgradation Project planned in OCL AOD Digboi
Refinery, ndia.
T8- N"28.8" S2!*..-' 4#*. 034 >NSU?,
T8- R-%&'(".- S2!*..-' 4#*. 035 >RSU?,
T8- N-< @DT 4#*. 036
T8- I/&(-'*A".*&# 4#*. 037
.
The objective of .8- N"28.8" S2!*..-' >4#*. 034? is to split the blend of feed composed by straight
run naphtha (SRN), coker naphtha (CN), DHDT naphtha (DHDTN) and Guwahati naphtha (GRN)
into a light Naphtha feeding the New SOM- HDT unit (unit 036) and a heavy naphtha feeding an
existing HDT/reforming unit.
The objective of .8- R-%&'(".- S2!*..-' >4#*. 035? is to split the feed from the existing reforming
unit into a light reformate feeding the stripper of New HDT unit (unit 036) and a heavy reformate
send to MS pool.
The objective of .8- N-< ISOM-@DT 4#*. >4#*. 036? is to treat light naphtha from unit 034 in order
to produce a sulfur free and stabilized naphtha (including the light reformate feed from unit 035),
containing less than 0.5 wt ppm sulfurand less than 0.1 wt ppm nitrogen, and 0.1ppm(max)
Oxygen to feed the somerization unit (unit 037).
The objective of .8- I/&(-'*A".*&# 4#*. >4#*. 037? is to increase the RON of the hydrotreated light
naphtha cut.
The somerization unit capacity is 46.76 Mt/year and the stream factor is 8000 h/yr.
The unit turndown rate is 50 % of the design capacity while making on-specification products.
The power requirement for the new facilities will be met from the existing system. Power will be
distributed to proposed new units through a new substation including a new transformer to feed the
new substation complete with facilities like ventilation, fire detection / protection etc. t includes all
cabling from switchgear (for LT panel to new units) and HT feeder (for HT drives in new units)
The scope also includes all SBL utilities distribution for above mentioned units including flare,
drains / sewers and blow down system.
Licensor's design for the above mentioned Units and PMC's design of the SBL Utility distribution
(including flare, drains / sewers and blowdown) and FEED blend station forms part of the FEED
Package of the project.
The design basis presented here intends to provide the detail engineering contractor with the
technical information required to complete the engineering design specifications of the project
units in a uniform and consistent manner.
1.2 Engineering Design Basis (EDB) for all facilities, containing technical information agreed between OCL
and Licensor, and OCL and PMC shall be binding on the process design and engineering of units,
utility systems and offsite facilities.
Project Name
D10169B904LI1001
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Revision
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1.3 This document constitutes common Engineering Design Basis defining overall project requirements for
making the units compatible and ensuring uniform design practices for the total project. t also
provides certain minimum requirements specified and used by Licensor.
1.4 This EDB constitutes the guidelines to be followed during detailed engineering design, procurement and
construction of the facilities in this project. LSTK Contractor shall employ and incorporate their best
engineering practices and experience to ensure smooth and safe commissioning of the plant
including start-up and shutdown/normal operation and emergency handling.
1.5 The design basis in Process Data Book Book 1 Volume 1/1, which is part of Process Package from
Licensor, shall also be considered an integral part of this EDB. n case of any discrepancy between
Process Data Book Book 1 Volume 1/1 and this EDB, LSTK contractor shall report the same to
PMC/OCL in writing for necessary clarification.
.0 P'&5-1. D-/1'*2.*&#
.1 P'&5-1. T*.!- T& B- U/-3 F&' A!! D&14(-#.".*&#
Project Name : MS Quality Upgradation
Owner : ndian Oil Corporation Limited
Location : Digboi Refinery, Assam
. U#*. N4(,-'/
The Unit numbers are as follows:
S'. N&. F"1*!*.9 U#*. N4(,-'
1 Naphtha Splitter 034
2 Reformate Splitter 035
3 New HDT unit 036
4 somerization unit 037
.3 U#*. D-/1'*2.*&#
.3.1 U#*. 034
N"28.8" S2!*..-'
Feed Capacity :

S."*68. R4#
N"28.8" D@DT N"28.8" C&$-' N"28.8" G4<"8".* N"28.8"
Weight rate
in kg/h 12 575 1 000 1 425 1 250
The purpose of the NSU >4#*. 034? is to split the naphtha feed composed by SRN, CN, DHDTN and
GRN into:
- a light naphtha feeding the SOM-HDT to somerization unit.
- a heavy naphtha feeding the existing HDT/CRU reforming unit.
.3. U#*. 035
Project Name
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Revision
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R-%&'(".- S2!*..-'
Capacity: 10208 kg/h
The purpose of the RSU >4#*. 035? is to split reformate feed from the existing HDT/CRU reforming
unit into:
- a light reformate sent to HDT stripper.
- a heavy reformate sent to MS pool.
.3.3 U#*. 036
@DT U#*.
Feed Capacity:
LIG@T NAP@T@A LIG@T R)FORMAT)
Weight rate in kg/h 5 069 843
The purpose of the @DT >4#*. 036? is to produce a clean desulfurized naphtha cut to be
processed in the somerization (unit 037) after removal of all impurities which are currently
poisons for catalysts (sulfur, nitrogen, water, halogens, diolefins, olefins, arsenic, mercury and
other metals).
.3.4 U#*. 037
I/&(-'*A".*&# U#*.
Feed Capacity: 5845 kg/h
I/&(-'*A".*&# >4#*. 037? is the conversion of low octane straight chain compounds to their higher
octane branched isomers. The light hydrodesulphurized naphtha feed is dried and passed over an
activated chloride catalyst in the presence of once through hydrogen (also dried). The
isomerization reactor temperatures are kept low in the range 120-160C taking advantage of the
higher equilibrium concentration of isomers at lower temperatures and minimizing hydrocracking.
The reaction requires a very low partial pressure of hydrogen enabling once through hydrogen to
be used.
A deisohexanizer tower is included in the flow scheme to recycle the low octane C6
n-paraffins and methyl pentanes back to the reactor circuit to obtain a high octane product.
.4 U#*. &# S.'-"( %"1.&'
The units are designed with on-stream hours per year at 8000 hours.
.5 U#*. T4'# 3&<# %"1.&'
The units are designed to operate with a turn down of 50% on flow rate.
3.0 M-.-&'&!&6*1"! 3"."
* Maximum temperature: 43
O
C
* Design maximum ambient temperature:
a) DBT for cooled exchanger design i.e not exceeded more than 5% of the time during four
warmest months of the year = 40
O
C
b) DBT and RH for air blowers and air compressor design = 40
O
C at 95% RH
c) WBT for Cooling Tower = 32
O
C
Project Name
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* Minimum temperature: 5
O
C
* Winterizing temperature: 4
O
C
* Design minimum temperature: 4
O
C
* Relative humidity- Average: 75%
- Maximum: 95%
* Dry bulb temperature: 40
O
C
* Barometric pressure - Average: 1013 mbar
A33*.*&#"!/ 3"."B
Average wind velocity 5 Km/hr
Maximum wind velocity 100 Km/hr
Earth quake factor S 1893 Zone V
Rainfall : Max recorded 80 mm in one hr
157.5 mm in 24 hr
Unit elevation 141.8 m above sea level
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4.0 U.*!*.*-/ S2-1*%*1".*&#/
4.1 Utilties conditions at unit battery limit are given below. The utilities pressure are as measured at the
respective headers in the piperack, adjacent to the MSQ Site. grade level.
S! P"'"(-.-' M*#*(4( N&'("! M"=*(4( M-18. D-/*6#
1 M)DIUM PR)SSUR) >MP? ST)AM
Pressure, kg/cmg 10 11 12 16.9
Temperature, C 250 260 300 345
2 LOC PR)SSUR) >LP? ST)AM
Pressure, kg/cmg 2.0 2.5 5.0 8.0
3 MP COND)NSAT)
Pressure, kg/cmg 6 - - 16.9
Temperature, C - - - 345
4 LP COND)NSAT)
Pressure, kg/cmg 6 - - 8.0
Temperature, C - - - 185
5 NITROG)N
Pressure, kg/cmg 3.0 5.0 6.0 12.0
Temperature, C Amb Amb Amb 65
6 COOLING CAT)R
Supply Pressure, Kg/cmg 2.7 3.0 5.0 7.0
Return Pressure, Kg/cmg 2.2 - - 7.0
Supply Temperature, C 33 33 33 100
Return Temperature, C - - 45 100
7 D)MIN)RALIS)D CAT)R
Pressure, Kg/cmg 4.5 5.0 5.5
Temperature, C Ambient Ambient Ambient
8 BOIL)R F))D CAT)R
Pressure, Kg/cmg 20 30 40 90
9 S)RDIC) CAT)R
Pressure, Kg/cmg - 1.8 -
Temperature, C 20 30
10 DRINEING CAT)R
Pressure, Kg/cmg 2.5 3.5 5.5
Temperature, C Amb Amb Amb
11 PLANT AIR
Pressure, Kg/cmg 6.0 7.0 8.0 10.0
12 INSTRUM)NT AIR
Pressure, kg/cmg 6.0 7.0 8.0 10.0
13 FU)L GAS
Pressure, kg/cmg 1.5 2.0 2.2 4.5
14 F'-/8 C"4/.*1 >S.'-#6.8 B 10 <.F?
Supply Pressure, kg/cmg - 8 - 14
Temperature, C - Amb - 75
Project Name
D10169B904LI1001
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15 @GDROG)N
Pressure, kg/cmg 19 23.5
Temperature, C 45 100
16
Pressure, kg/cmg
Temperature, C
17
4. )!-1.'*1"! P&<-'
Power for electric drives and lighting shall be:
6600 V 6%, 3 phase, 50Hz5% Resistance grounded for drives of 161 KW and above.
415, V 6%, 3 Phase, 50Hz5% for drives from 0.37 KW up to 160 KW, Neutral is solidly
earthed.
For motors up to 0.37 KW: 230 V 5%.
For instruments the voltage shall be 230 V 6%, 50Hz 3%, single phase AC, grounded.
UPS system for instrument & control shall be 230 V AC.
For lighting, the voltage shall be 230V 10%, 50Hz 3%, AC, single phase.
4.3 F4-!
Refinery Fuel Gas
Refinery Fuel Gas will be available from the refinery gas net work at the following battery limit
conditions:
Fuel gas Pressure Temperature
Minimum: 1.5 Kg/cmg Ambient
Normal: 2.0 Kg/cmg Ambient
Maximum: 2.2 Kg/cmg Ambient
Mechanical design: .5 Kg/cmg 100 !"
#uel $as %ualit& :
* GAS TYPE: FG TO HDT
* LHV : kcal/kg 11 756
* HHV : kcal/kg
* PRESS. @ B/L : kg/cm
2
g
1.5 min / 2 nor / 2.2
max
* TEMP. @ B/L : Min/Nor/Max. C 25 ( Nor )
* MOLECULAR
WEGHT:
18.50
COMPOSTON MOL %
HYDROGEN 23.43
CARBONDOXDE 0.01
ETHYLENE 3.24
ETHANE 14.98
HYDROGEN SULPHDE 0.10
OXYGEN 0.00
Project Name
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NTROGEN 0.53
METHANE 51.07
CARBONMONOXDE 0.52
C5=+ 2.97
PROPANE 0.72
PROPYLENE 0.00
SO-BUTANE 0.15
N-BUTANE 0.53
1-BUTENE 0.04
2-METHYLE PROPENE 0.03
T-2-BUTENE 0.00
C-2-BUTENE 0.00
1,3 BUTADENE 0.00
SO-PENTANE 0.73
N-PENTANE 0.95
TOTAL 100
Note : All new heaters will be fuel gas fired.
4.4 I#-'. G"/ >N?
Licensor's minimum quality requirements for Nitrogen is as follows (vol%) and same shall be made
available by OCL at unit battery limit
O2 5 ppm max.
CO 20 ppm max.
CO2 20 ppm max.
Other carbon compounds 5 ppm max.
Chlorine 1 ppm max.
Water 5 ppm max.
H2 20 ppm max.
N2 99.7 mini.
Noble gases Balance
N2 QUALTY (volume composition)
N2 99.9 vol % (normal)
O2 10ppm
CO 20ppm max (peak value) 10 ppm normal
CO2 20ppm max (peak value) 10 ppm normal
Chloride 1ppm max
Water 5ppm max
Project Name
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H2 20ppm max
Other carbon compound 5 ppm max
Noble Gas Remain

4.5 @93'&6-#
The quality of make-up hydrogen available at the battery limit is as follows
Component Mole %
Hydrogen 99.5
C1 0.5
H2S <10 (ppm mole)
HCl <0.5 (ppm mole)
CO < 5 (ppm mole)
COS Nil
CO+CO2 <20 (ppm mole)
Olefins Nil
H2O No free water
Maximum allowable contaminant levels in Hydrogen make-up :
Total sulfur 1.0 wt ppm max.
Total Nitrogen 1.0 wt ppm max.
Water 0.5 wt ppm max.
(1)
CO + CO2 10-20 wt ppm max.
Olefins 10 mol ppm max.
Chloride 5.0 wt ppm max.
H2 composition
Component vol % mpurities wt ppm
H2 (min) 99.5................................. Sulfur
..........................................
C1 (max) 0.5................................... H2O
..........................................
C2
........................................
CO + CO2 (max) 20......................................
C3
........................................
Olefins
..........................................
C4 +
........................................
HCl (max.) 1 ppm vol max,
...(0.5 to be considered for
chloride guard design)
(1) At the outlet of the hydrogen dryers in Unit 037
Note Hydrogen make-up to Unit 037 should be taken separately from Refinery header & also from
PSA outlet header.
4.6 A*' Q4"!*.9
Project Name
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S'.
N&.
P"'"(-.-' P!"#. A*' I#/.'4(-#. A*'
1 Dew point at atmospheric pressure - 40
o
C
2 Relative Humidity % Saturated
3 Oil Content, ppm Nil Nil
5.0 )74*2(-#. D-/*6# ,"/*/
5.1 C&!4(#/, D-//-!/ "#3 R-"1.&'/
"? D-/*6# P'-//4'-
Factors like pump shut-off conditions, pressure drops in recycle loop etc. should be considered
for fixing design pressure. Pump shut-off shall be calculated at 1.25 x rated differential
pressure + max. suction pressure.
Equipment which could have to bear the shut-off pressure of a pump in case of a valve closing
(either control valve or block valve) is designed for the following pressure:
Design pressure = Design pressure of the suction vessel + liquid height at vessel !! at pump
suction + "#$% of pump differential pressure&
When operating pressure is less than or equal to 100 kg/cmg, design pressure shall be equal
to normal operating pressure plus 10% (min. 2.0 kg/cm). When operating pressure is more
than 100 kg/cmg, design pressure shall be equal to normal operating pressure plus 5% (min
10 kg/cm).
All steam handling / condensate vessels shall be designed for full vacuum conditions also.
All vessels / columns subject to internal pressure should be designed to withstand a minimum
external pressure of 0.175 kg/cm abs.
Minimum design pressure for equipment connected with flare header without NRV should be
3.5 kg/cmg.
The pressure in 034VV001, pressure has been kept at 1 Kg/cm2g for sufficient Pressure drop for
the CV. n such cases, the design informations provided by Axens to be followed.
Special consideration should be given (for vacuum design) to the design of vessel normally
subject to internal pressure and connected to a compressor suction or ejectors.
Full vacuum will be specified for isolable equipment containing fluid having a vapour pressure
lower than atmospheric pressure at ambient temperature.
For equipment subject to pressure and temperature swings, the magnitude and frequency of
these swings will be given on the specification sheet.
When several pieces of equipment are protected by the same relief valve, each piece of
equipment will be designed at least for the pressure imposed by the discharge conditions of
the relief valve in case of emergency.
For fractionation columns, the reference design pressure is taken as that at the bottom of the
column.
The equipment subjected to steam out shall be designed for full vacuum. Additionally, such
equipment shall be designed with maximum operating pressure or steam pressure which ever
is higher as operating pressure plus the standard over design.
Project Name
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b) D-/*6# .-(2-'".4'-
Design temperature for unfired pressure vessels and interconnecting piping will in general be
equal to maximum anticipated operating temperature plus 30C if vessel operates between
zero to 400C and 28C if vessel operates above 400C.
Conditions like steam-out (for handing out vessel to maintenance) will be considered while
specifying design temperature.
For vessels operating at ambient temperature, 65C will be used for mechanical design.
Note: When different metal temperatures can be predicted to occur for different zones of a
vessel during operation then different temperature should be indicated on the sketch and
different temp. should be taken into account for designing the vessel.
For feed / effluent exchangers of reaction section + 25 C 35 C to be added to max.
operating temperature to take into account the temperature profile modification at low
capacity.
For operating temperatures below 0C, design temperature to be minimum operating
temperature 5 C or minimum ambient temperature, whichever is lower.
The effect of autorefrigeration due to depressurisation to atmospheric pressure will be taken
into consideration (LPG systems for example).
1? L*74*3 R-/*3-#1- .*(-
Residence time is defined between low liquid level and high liquid level
Service Residence time
Reflux 10 minutes
n the NSU Reflux drum, Axens has specified 15 min residence time which is to be followed.
Column feed 15 20minutes on flow control
Or 10 minutes on cascade level / flow control
Reboiling by heater 10 minutes on feed to heater
'et(een )** and *** : max o+ the t(o +ollo(ing ,alues
- calculated on net bottom -roduct : 15 mn on +lo( control .or / mn on cascade le,el/+lo( control0
+or +urther -rocessing or 2 mn (ith discharge to storage.
- calculated on total +eed heater : 2 mn
Between LLL and TL (with a LSLL installed at minimum distance from LLL) : 8 mn on the equivalent flowrate
of the vapor generated in the fired heater.
Reboiling by thermosiphon 10 to 30 seconds
Product to storage 2-5 minutes
Product feeding another unit 15 minutes on flow control
Or 10 minutes on cascade level / flow control
Feed surge drum 30 minutes of diam < 1.2 m
20 minutes if 1.2 m < diam < 1.8 m
15 minutes if 1.8 m < diam
Project Name
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n the case of pumps ensuring several services such as reflux and liquid distillate to storage, the
residence time of the corresponding vessel will be whichever is greater from the above list.
3? D-//-!/ S2-1*%*1".*&#/
Vessels will be sized according to inside diameter and 2:1 elliptical heads or hemispherical
heads. Top cover flanged if D <= 900 mm
All connections will be flanged
24-inch manways are currently specified. Minimum inside diameter shall be 20 inches for
D>=900 mm. Larger size will be specified when required to accommodate internals.
n trayed columns, manways will be provided above the top tray, at the feed tray and below
the bottom tray. A manway will be provided at any tray with removable internals. Minimum
numbers of manway : 3
One manway every 6000 mm or 10 trays, whichever is less
For small vessels 6 HH to be provided.
Vessels, exception done for reactors, will be provided with vent and drain nozzles. Vent and
drain sizes will not be indicated, unless required for process reasons.
Separate steam-out connections will be specified.
Preferred diameters of columns and vessels : See attached table in the following page.
Where
possible minimum column diameter to be 1000 mm.
Please elaborate as in 037-CC-003 , dia is 300mm
Requirement of broad equipment specification:
Following are the constraints in transportation and handling of heavy equipment :
Maximum weight of equipment 400 MT
Maximum diameter including nozzles / projections 4.5 metre
Maximum length overall 25 metre
For DH & splitters, it will be acceptable to have more than 25 m
Please elaborate as except DH column, height of all the columns in DR MSQ is below 25m
For small diameter towers ( > 800), tower internals should be removable from one end and to
be cartridge type. Provide flanges where necessary along tower.
Size of vent and drain should be min 2
Project Name
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PR)F)RR)D DIAM)T)RS OF COLUMNS & D)SS)LS
O4./*3- D*"(-.-' >((?
300 2200
(350) (2300)
400 2400
500 2600
600 2800
700 3000
800 3200
900 (3400)
1000 3600
1100 (3800)
(1200) 4000
(1300) 4250
1400 4500
(1500) 4750
1600 5000
(1700)
1800
(1900)
2000
(2100)
NOTE: Second preference in brackets
Project Name
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-? T'"9/ & P"1$*#6/
Columns oversizing to correspond to 10% of normal flow rates.
T'"9/ B
Valve trays will normally be specified (stainless steel)
Valve tray columns will be specified with the following maximum flooding factors:
77 for vacuum towers
78 for other services
70 for column diameters under 900 mm
Licensor has already specified max flooding for all the columns which may be followed.
Operating range for the trays will be at least 50 to 110% of normal loads
Trays will be numbered from the bottom top
11-13 chromium alloy tray material to be specified with 1mm corrosion allowance
Anti Spin valves (on trays) to be provided. ( Please elaborate)
P"1$*#6 B
Column diameters are estimated using calculation methods provided by the major packing
manufacturers.
For random packing, provide hand hole at bottom of packing.
5. R-"1.&'/ S2-1*%*1 R-1&((-#3".*&#/
For low alloyed steels for Reactors
Specific recommendations for 1.25 Cr-0.5 Mo and 1.25Cr-0.5Mo with Clad or Overlay
"? G-#-'"! C&((-#./
The information given hereafter for "Base Metal Quality and "Welding results from Licensor's
experience in the field of high pressure units. Specific codes, as well as Client and Engineering
Contractor Standards may also influence the choice in materials and methods. Therefore, the
recommendations should be used as guidelines but the final decision is the responsibility of the
Detail Engineering Contractor.
The data given here should not in any case interfere with Manufacturer's know-how and their
quality standards.
,? S1&2-
These recommendations are to be applied to the equipment fabricated with 1.25 Cr-0.5 Mo low
alloyed steel and 1.25 Cr-0.5 Mo low alloyed steel weld overlaid or cladding with austenitic
stainless steel and built in accordance with the ASME code as applicable.
Design Code (As Reference)
ASME Section V, Div. 1 Pressure Vessels
ASME Section V, Div. 2 Pressure Vessels- Alternative rules
1? R-"1.&'/ M"#4%"1.4'*#6
*? B"/- M".-'*"! P!".-/
The plates to be used for the fabrication of the equipment shall comply with the basic
requirements of the grade SA 387 gr11 cl2 supplemented by following additional requirements:
Project Name
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S.--! M"$*#6 P'&1-///@-". T'-".(-#.
The steel plates shall be made by the electric furnace vacuum degassed steel process.
Heat treatments hold time shall be sufficient to obtain an uniform temperature throughout
the plate.
The tempering temperature shall be adapted so as to give the required mechanical
properties after post-weld heat treatment.
C8-(*1"! A#"!9/*/
The chemical analysis of the present steel grade shall be in conformity with ASTM requirements
with the recommended restrictions:
The expected level of impurities can be as follows:
Preferences
Ni 0.20% max
Cu 0.15% max
Si 0.44%-0.86% (product)
C 0.15% max
Al 0.030% max
V 0.010% max
P 0.007% max
S 0.005% max
Sn 0.010% max
As 0.012% max
Mn 0.35% - 0.73% (product)
Sb 0.004% max
N2 80 ppm max
O2 20 ppm max
H2 2 ppm max
Nb 0.01% max
Ti 0.01% max
P + Sn 0.012% max
n view of minimizing the risk of temper embrittlement, the "J factor shall not exceed 180.
This factor, which is determined by the following formula where the elements are specified
in weight percentages, shall verify the relation hereafter:
H I >S* J M#? K >P J S#? K 10
4
L 1:0 (target 150)
Furthermore the high purity level of the steel shall be such that P, Sn, Sb and As be as low
as possible to meet BRUSCATO parameter X:
M I >10PJ4S#J5S,JA/?/100 L 15 22(
All elements mentioned here above have to be checked on ladle and on product.
M-18"#*1"! P'&2-'.*-/
Project Name
D10169B904LI1001
Sheet / of
17/6
Revision
00
Tensile Properties
- Tensile tests shall be carried out respectively at room and design temperature.
- Room temperature tensile properties shall meet the requirements of the material
standard.
mpact Test Properties
- Charpy V-notch impact testing is required for all pressure retaining components,
welds and heat affected zone. The impact test specimens shall be carried out on
each plate. The average of three impact test values at a temperature of -18 C (0
F) shall not be less than 40 ft. lb (55J) without individual value below 35 ft.lb (47 J).
Materials suppliers should indicate the conditions (plate thickness and heat
treatment) under which this guarantee can be extended to -30 C (-22 F).
Hardness Properties
- The material hardness shall not exceed 220 HB.
Responsibility for Base Material Tests
- Mechanical tests may be performed by the base materials Manufacturer or the
reactor Manufacturer. The base materials Manufacturer shall guarantee that the
minimum mechanical properties required will be met after all anticipated heat
treatments of the reactor during and after fabrication.
**? B"/- M".-'*"! F&'6*#6
S.--! M"$*#6 2'&1-///8-". .'-".(-#.
Forgings including those used for shell, heads and nozzles, shall conform to all
requirements of the grade SA 336-F11 and the additional requirements given for plate
defined above.
All forging shall be ordered from steel made by the electric furnace and vacuum degassed
process.
Note : Forgings can be made from hollow ingots.
C8-(*1"! A#"!9/*/
n addition to the requirements of material standard, the specific restrictions exposed for
plates shall be fully applied.
M-18"#*1"! P'&2-'.*-/
All impact testing requirements given for plates are applicable for forgings.
3? C-!3*#6
*? G-#-'"!
The plate, or forging edge preparation for welding as well as the nozzle openings will be
carried out by machining. Flame cutting may be allowed by the contractor provided the heat
affected zone is completely removed by machining or grinding.
**? C-!3*#6 P'&1-//-/
Welding processes are:
SAW : Submerged Arc Welding
SMAW : Shielded Manual Arc Welding
GTAW : Gas Tungsten Arc Welding
Project Name
D10169B904LI1001
Sheet / of
1:/6
Revision
00
Note: All the welds in hydrogen service, including the internals, have to be full penetration
type. f this is not possible, there will be a vent drill-hole of the not welded area.
***? C-!3*#6 C&#/4(",!-/ C8-(*1"! A#"!9/*/
The deposited weld metal shall match with the nominal chemical composition of the base
material and the mechanical properties of the deposited weld metal shall meet those of the
base material.
The Bruscato parameter in the weld deposit shall be follows:
M I >10P J4S#J 5S,JA/?/100 L15 22(
(All chemical elements specified in PPM)
-? O;-'!"9
*? G-#-'"!
The weld overlay is applied using a two-layer technique:
First layer : 309L
Second layer : 347
Minimum effective thickness of undiluted alloy after final machining shall be those required
on equipment data sheet specification.
However, single layer weld deposit overlay may be used provided the fabricator can
demonstrate to the contractor the use of a qualified and acceptable procedure.
**? F-''*.- C&#.-#.
The ferrite content of the weld deposits will be less than 8%, but more than 3% by Delong
diagram to prevent hot cracking.
%? P&/. C-!3 @-". T'-".(-#.
The equipment shall receive PWHT as required by ASME and/or applicable code cases.
Unless otherwise specified by steel maker the recommended range of temperature is 655-
720 C during 5 hours minimum to be confirmed by reactor manufacturer according to wall
thickness.
All welding will be completed before final PWHT.
6? N&# D-/.'41.*;- T-/.*#6
Reactors can be submitted to non-destructive tests after PWHT:
Radiographic examination (prior to PWHT).
Ultrasonic examination
Magnetic particle examination
Dye penetrant examination of weld overlay
Hardness measurement (hardness tester)
Ferrite checking (magnetic ferritescope) in addition to ferrite evaluation based upon
sampling and chemical analysis. Acceptance criteria of ferrite content by magnetic
ferritescope shall be 3% to 10%.
5.3 F*'-3 @-".-'/
Project Name
D10169B904LI1001
Sheet / of
19/6
Revision
00
Fired heaters shall be designed for maximum efficiency. LSTK contractor shall consider both
options i.e. air pre-heating & steam generation & select the one with higher payback with due
consultations with PMC/OCL.
As 036-FF-001 is a small furnace; air preheating or steam generation may not be feasible.
Heaters will be provided for gas firing only. Fired heaters to be designed to meet the process
requirement for fuel gas qualities as specified under utilities specifications.
Safety instrumentation shall be provided as per OSD-152 (latest edition) applicable for
Process Heaters.
n common stack, sample points are to be provided for sample collection by Pollution
Control Board, as per their guidelines provided in Annexure-.
Fired heaters and auxiliary equipment shall conform to AP Standard 560 except modified
& added by Licensor specifications / Data Sheet & by this specification or other
specification.
Heater terminals shall be designed to accept the moments and forces listed in Table 7 of
AP Standard 560, which shall be multiplied by a factor of 2.
The number, dimension and kind of instruments and auxiliary connections shall, as a rule,
conform to Piping & nstrumentation Diagram (P&D) at the minimum.
Preferred order of levels for steam generation, if required to be included for energy
optimisation, would be MP/LP Heaters shall be provided for gas / fuel oil firing. Each burner
shall have a pilot gas burner. Atomising steam shall be MP steam. Soot blowers shall be
pneumatic, locally operated, retractable with auto-manual sequential control. Steam air de-
coking facility shall be preferred if necessary.
Extruded fins to be used up to 290C. Flange type header up to 40 bar or if fouling above
0.0004 metric.
n all the fired heaters, extended tubes used in convection bank shall be studded tubes.
Thermal design of the heater is to be done accordingly.
A common stack for the two new heaters is preferred.
For multipass heaters the following will be specified:
Mixed phase: Symmetrical arrangement of the passes and board temperature indicator on
each pass outlet.
Liquid phase: flow control valve with a minimum flow stopper on each pass inlet and board
temperature indicator on each pass outlet.
Vapour phase: Symmetrical arrangement of the passes and board temperature indicator on
each pass outlet (except for box-type heaters: n this case see the manufacturer's
recommendations).
Skin thermocouple will be specified for each pass. Skin thermocouple should be duplex and
welded. type except for box-type heaters with a large number of passes: in this case, see the
manufacturer's recommendations.
Oversizing will be considered as follows:
To take into account the risk of undersizing of heat recovery systems (i.e. feed-effluent, feed-
bottom), following oversizing is typically specified:
Feed heater: 10 15% of heater duty or 5% of feed / effluent exchange duty, whichever is
greater.
Reboiler: 5% of feed / bottom exchange or 10 15% of reboiler duty, whichever is greater.
Tube sheet/hanger support should be 50Cr-48.5Ni-15Nb
Project Name
D10169B904LI1001
Sheet / of
0/6
Revision
00
5.4 @-". )=18"#6-'/ / A*' C&&!-'/ / C&#3-#/-'/ / R-,&*!-'/
"? G-#-'"! G4*3-!*#-/
Following general guidelines shall be followed:
Air-cooling shall be maximised for which the cut-off temperature of process streams shall be
55C. However, when further trim-cooling by water is necessary, the cut-off temperature of
process stream shall be 65 deg C. Dry bulb temperature 42 C to be considered for cooler
sizing. However, to avoid small trim cooler or air cooler these guidelines can be relaxed in
consultation with the OCL / PMC.
For all the coolers Axens has specified the cut off temperature which should be followed.
Preferred straight tube length is 6 meters
Preferred size for Carbon Steel and low alloy (up to and including 5 Cr, Mo) tubes is 20 x 2
mm and 25 x 2.5 mm.
Preferred size for brass and admiralty tubes is 20 x 2 & 25 x 2.5 mm respectively.
Preferred size for high alloy (above 5 Cr Mo and Austenitic) tube is 20 & 25 x t to suit
design.
Preferred tube pitch is square pitch in fouling services (Fouling < 0.0004 hC m
2
/ kcal)
Maximum allowable bundle weight 15 MT
Maximum allowable bundle diameter 1400 mm
Minimum over design of 110% on heat duty will be considered for the heat exchangers,
except:
Overhead condensers which have to be oversized to take into account the greater of either
110 115% of the estimated operating duty or the duty increase of the corresponding reboiler.
To take into account the risk of undersizing of heat recovery systems (i.e. feed-effluent,
feed-bottom), the following oversizing is typically specified:
- Effluent cooler (or feed preheater): 10% of cooler duty (or preheater duty) or 5% of
feed / effluent exchange duty, whichever is greater.
- Reboiler : 5% of feed / bottom exchange or 10% of reboiler duty, whichever is greater.
- Bottom cooler: 10% of cooler duty or 5% of feed / bottom exchange duty, whichever
is greater.
Over and above the overdesign on heat duty as mentioned above for heat exchanger, there
shall be a minimum margin of 10% overdesign on calculated surface area.
For water cooler back flushing facilities are required
Following overdesign will be considered for the air coolers (10% minimum):
Overhead aircondensers which have to be oversized to take into account the greater of
either 110% of the estimated operating duty or the duty increase of the corresponding
reboiler.
To take into account the risk of undersizing of heat recovery systems (i.e. feed-effluent,
feed-bottom), the following oversizing is typically specified:
- Reactor effluent aircooler: 10% of aircooler duty or 5% of feed / effluent exchange
duty, whichever is greater.
- Bottom air cooler: 10% of air cooler duty or 5% of feed / bottom exchange duty,
whichever is greater.
Project Name
D10169B904LI1001
Sheet / of
1/6
Revision
00
Over and above the overdesign on heat duty as mentioned above for air coolers, there shall
be a minimum margin of 10% overdesign on calculated surface area..
,? S8-!! "#3 T4,- 8-". -=18"#6-'/
M*# %&4!*#6 %"1&. .& ,- 1&#/*3-'-3 */ 0.0004 83-6C-(/E1"!
S"1'*%*1*"! "#&3- .& ,- *#1&'2&'".-3
Licensor has used following suggested fouling factors :
S466-/.-3 %&4!*#6 %"1.&'/>8' (N C/E1"!?
S.'-"( F&4!*#6 %"1.&' S.'-"( F&4!*#6 %"1.&'
Hydrotreater Reactor
Feed
0.0004 somerate 0.0003
Hydrotreater Reactor
effluent
0.0003 Stabiliser Feed 0.0003
Stripper feed /
overhead vapors
0.0003 Stabiliser
Overhead
vapors
0.0003
somerisation
Reactor feed/ effluent
0.0004
For stacked exchangers, maximum two shells should be stacked. f less than 500 mm shells,
three shells may be stacked.
Exchanger Type :
S8-!! /*3- %&4!*#6 T4,- /*3- %&4!*#6 T92-
> 0.0002 > 0.0002 Floating
< 0.0002 > 0.0002 Fixed T / sheet
> 0.0002 > 0.0002 U-tube bundle
> 0.0002 > 0.0002 Fixed T/sheet or U-tube bundle
Corrosion allowance
Unless otherwise specified corrosion allowance for all exchangers should be as per TEMA
standard (Class R).
For U tube exchanger, radius U bend should be at least 3 times tubes OD.
Project Name
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/6
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00
1? D-/*6# 2'-//4'- %&' 8-". -=18"#6- -74*2(-#.
Maximum anticipated operating pressure plus 10% or 2 kg/cm, whichever is greater. The
minimum design pressure is 3.5 kg/cm g.
Exchangers that are subject to pump shut off, in general, shall have design pressure equal to
maximum shut off pressure as follows.
Equipment which could have to bear the shut-off pressure of a pump in case of a valve closing
(either control valve or block valve) is designed for the following pressure:
Design pressure = Design pressure of the suction vessel + liquid height at vessel !! at pump
suction + "#$% of pump differential pressure&
n case exchanger is operating under vacuum or in steam service, design should be for full
vacuum.
The tubes of feed / effluent exchanger in high pressure service need not be designed for full
design pressure of the shell provided these components can never experience these
condition. Start-up, shutdown & emergency depressurisation condition should be considered.
n addition to above criteria, design pressure of an exchanger should reflect the location and
set pressure of the safety relieving valve protecting it. For high differential pressure, the
design pressure of lowest pressure side should be at least 0.77 x highest pressure side design
pressure.
3? D-/*6# .-(2-'".4'- %&' 8-". -=18"#6- -74*2(-#.
Exchanger operating between zero to 400 C shall be designed for the maximum anticipated
operating temperature plus 28 C but not less than 65 C.
n case of possible loss of flow of cooling media, the tubes may be subjected to full process
inlet temperature with no margin. These components should be designed for maximum
process anticipated temp. of hotter medium.
For feed / effluent exchangers of reaction section + 25C 35C to be added to max. operating
temperature to take into account the temperature profile modification at low capacity.
Exchangers operating at 0C and below should be designed for minimum anticipated
temperature. For operating temperatures below 0C, design temperature to be minimum
operating temperature 5 C or minimum ambient temperature, whichever is lower.
The effect of autorefrigeration due to depressurisation to atmospheric pressure will be taken
into consideration (LPG systems for example).
5.5 P4(2/
Spare philosophy :
100% spare for continuous service and critical intermittent service
Drive of pumps :
Electric Motor, unless otherwise for process/safety reasons
Equipment which could have to bear the shut-off pressure of a pump in case of a valve
closing (either control valve or block valve) is designed for the following pressure:
Design pressure = Design pressure of the suction vessel + liquid height at vessel HLL at pump
suction + 125% of pump differential pressure.
10% oversizing will normally be specified
20% oversizing will be specified on reflux and reboiler flow rates.
Project Name
D10169B904LI1001
Sheet / of
3/6
Revision
00
The pump data sheets specify the process flow without provision for the minimum flow which
will be specified by the pump's vendor. Wherever required, the LSTK contractor to add the
pump minimum flow, as per vendor information, to the process flow specified in the data sheet
to arrive at pump capacity.
Electrical motor drivers will be specified. Critical service drivers will be either steam turbines
or connected to electrical emergency network.
Continuous service process pumps will be specified with full spares.
Common spares can be specified whenever appropriate for metering pumps
Pumps on P&D's are shown with permanent strainers at suction.
All pump shall be provided with bridle cooling water lines (for bearing cooling, gland cooling,
seal cooling) , as per vendor information, even if these lines are not shown on Licensor's
P&D's in FEED package. The return from all the pumps to be taken into a vessel from where
the water to be pumped to the pumps shall be connected to a separate cooling water return
header which will run parallel to main return header. The dedicated cooling water return
header for pumps shall be connected to main return header at the battery limit with provision
for isolation. Cooling water to / from each pump line sizes shall be minimum 1 NB. Pump
vendor's battery limit for cooling water shall be 1 NB ANS 31.16 flange with counter flanges,
gaskets, fasteners for both CWS and CWR lines at individual pumps.
Sight glass for cooling water flow at pump (bearing housing, seals etc.) should be ball type.
Drains from pump base plates shall be routed, through an open funnel and pipeline, for each
individual pump, to nearest oily water sewer catch point.
5.6 C&(2'-//&'/
Spare philosophy :
For reciprocating compressors, provide 2 of 100%
For Centrifugal, no spare required
The recommendation given in the AP Recommended Practice 521, last edition, Appendix "F
and AP Recommended practice 520, last edition, Appendix "B, will be followed.
Electrical motor drivers will be specified. Critical service drivers will be either steam turbines
or connected to electrical emergency network.
Owing to the high reliability of centrifugal compressors, a spare will not be specified. Full
spare capacity will be specified for reciprocating compressors.
The compressor oversizing will be specified as follows:
Make-up (10 20% minimum)
Recycle Depends upon the process
Gas quench 20 25% minimum
5.7 S."'.-42 B!&<-'/ "#3 C&(2'-//&'/
Spare philosophy: No spare
Driver : Electric Motor
Rated flow for D fan: 120% of normal flow
Rated flow for FD fan: 115% of normal flow
Rated Head for both: 125% of normal head
Spare for D fan: No
Project Name
D10169B904LI1001
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Spare for FD fan: yes
Driver: Motor
Control: 110% of rated shaft power variable speed
5.: S."1$ @-*68. L*(*.".*&#/
Minimum stack height should be worked out using formula:
H = 14 x (Q)
0.3
or 60 metres whichever is higher
Where,
H = height of stack in metres
Q = SO2 emissions in kg/h
6.0 M".-'*"! &% C&#/.'41.*&# D-/*6# P8*!&/&289
6.1 I#.'&341.*&#
The criteria for selecting equipment and piping metallurgy for this project are based on
Licensor's extensive experience with hydro-processing technologies, and the general practices
of the refining industry.
The primary objective in material selection is to prevent failure resulting from environment,
normal operation, and upset conditions. The material selection for this purpose is based on
mechanical design conditions.
The secondary objective is to provide adequate protection against the gradual material loss by
corrosion, to achieve the targeted design life. Equipment or piping normal operating
conditions are used for selecting the appropriate metallurgy for a targeted design life.
Therefore, the selected material for a given service should satisfy both the objectives of
metallurgical stability, and design life.
6. R-1&((-#3".*&#/ %&' (".-'*"! &% 1&#/.'41.*&#
"? )74*2(-#. D-/*6# L*%-
The following design life may be applied to the design of the unit as a
standard base:
Heavy wall reactors / vessels: 30 years
(including non removable internals and catalyst bed support beams)
Reactor removable internals: 20 years
Columns, vessels: 20 years
Heat exchangers shell and similar services: 20 years
High alloy exchanger tube bundles: 10 years
Furnace tubes: 10 15years
Piping: 10 15 years
Project Name
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Sheet / of
5/6
Revision
00
Carbon steel / low alloy heat exchanger tube bundles: 10 years
,? C&''&/*&# "!!&<"#1-
The following values are resulting from Licensor's experience based on process know-how in term
of design criteria and also on operating Units feedback. They might be reviewed following detail
engineering or client specific requirements. However, it must be noted that such a decision would
be under the detail engineering or client responsibility and should be made by taking into account
the procedures of inspection used by the owner.
*? P'-//4'- R-."*#*#6 )74*2(-#.
Licensor specifies that the calculated corrosion allowance shall be based on the designed
number of years in service.
For carbon steel, consider a minimum corrosion allowance (CA) of 1/8 (3 mm) in general for
non-corrosive environment as regular hydrocarbon.
n normal operation under Wet H2S Service, carbon steel shall have a CA of (6mm).
For other materials, minimum CA is 3 mm (1/8) for low alloyed steels (up to 2.1/4% Cr
included), 1.5 3.0mm (1/16) for low alloyed steels (up to 9% Cr included) and 0.75 mm (1/32)
for stainless steel.
The corrosion allowance of 1.5 mm for low alloyed steels (up to 9% Cr) may be extended, in
accordance with owner / user, to 3mm for critical equipment (i.e. Reactors, HP Vessels and
Furnaces).
f equipment is cladded or overlayed, undiluted thickness of clad or overlay is considered as
CA allowance.
**? I#.-'#"!/
Definitions:
"Non removable internals means: welded internals to vessels (support rings, support lugs, etc).
"Removable internals means: Non welded internals to vessels (fractionation trays,
distributor trays, mixing trays, catalyst support trays, support
beams, inlet diffusors, outlet collectors, Quench pipes,
thermocouples supports, etc.).
Removable parts of carbon steel and low alloyed steels (up to 9% Cr) internals shall have a
minimum CA of one half of total vessel shell CA on each side in contact with the operating
fluid.
Fixed internals carbon steel and low alloyed steel (up to 9% Cr) made shall have the full
corrosion allowance on each face (in total 2 times the designed CA of shell).
Ref to BEDQ P-46/96
Project Name
D10169B904LI1001
Sheet / of
6/6
Revision
00
For Carbon Steel and Low Alloyed Steel (up to 9 % Cr included):
Minimum corrosion
allowance (CA)
Axens standard
recommendation
Client request
Removable internals
On each exposed
surface: of total
CA applied to vessel
shell
Agreed
ixed internals and
structural support
beams (!)
On each exposed
surface: full CA
applied to vessel shell
Agreed
(!) i"e" Catal#st bed support beams and distributor $ %uench tra#s support beams
of reactor
n general, no corrosion allowance will be given for removable internals made of stainless
steel (13% Cr and above) as also for those made of non-ferrous high alloyed. However, a
corrosion allowance shall be specified for some internals exposed to severe conditions such
as non removable internals of reactor, catalyst bed support beams of reactor. These internals
shall therefore have the CA, based on the reactor design life specified in paragraph
"Equipment Design Life, on each exposed surface.
No corrosion is considered for internals made with V wire screen or wire mesh.
***? P'&1-// P*2*#6
For uniform corrosion, corrosion allowance for piping can be distributed as follows:
)=2-1.-3 '".- C&''&/*&# "!!&<"#1-
> 5 mpy 1/16 (1.5mm)
5 mpy <rate > 12 mpy 1/8 (3 mm)
12mpy < rate > 18 mpy 3/16 (4.5 mm)
18 mpy < rate > 25 mpy (6mm)
> 25 mpy Upgrade the Material Specification
mpy : thousands of inch per year
As a standard general practice, corrosion allowance for carbon steel piping can usually be split
into four different levels of specifications as mentioned here below:
Non-corrosive environment 0 1.5 mm
Compressed Air, Nitrogen,
Dry Hydrocarbon, etc.
Mildly-corrosive environment
Cooling water, Humid Hydrocarbons, 1/16 (1.5mm)
Steam, etc.
Project Name
D10169B904LI1001
Sheet / of
7/6
Revision
00
Moderately-corrosive environment 1/8 (3mm)
Sour Water, Wet Sour Gas, Amines
Caustics, etc.
Severely-corrosive environment 1/4 (6mm)
Aerated water, Hot sulfur or sulfide
(>260C), wet salts, wet CO2
(ambient temperature), Hot steam (>540C),
etc.
'ote: E(cept for specific cases) or following owner requirements) it is the !icensor*s general
practice to specif+ a minimum corrosion allowance of ,&-$ "&$ mm on the stainless steel made
piping components&
1? M*#*(4( D-/*6# M-."! T-(2-'".4'- >MDMT?
MDMT parameter shall be defined during material design in order to select materials capable of
resisting brittle fracture at the said Minimum Design Metal Temperature. This is purely a
mechanical design requirement (no corrosion concern).
Three different criteria may be used to establish the minimum design temperature:
t may be based on consideration of the lowest expected operating temperature, the lowest
ambient temperature or an operational upset such as auto-refrigeration, or any kind of other
source of low temperature. A transient condition such as auto-refrigeration may be governing,
particularly if the restarting procedure does not permit warm-up before re-pressurising.
t may be established as the minimum exemption temperature allowed by the applicable
engineering code. For example, the ASME B31-3 piping code permits most carbon steel
piping with wall thickness of 12.7mm or less to be exempt from impact testing if used at
temperature not colder than 29
o
C.
f the material of construction is impact tested, the Minimum Design Temperature is usually
taken to be the said impact test temperature (which is, for example, the case for HDT reactor).
The impact test conditions being defined as a function of the steel grade. Minimum Design
Metal Temperature for reactors components is usually specified as 30
o
C or 18
o
C
(depending on steel grade considered) unless process conditions and/or owner requirement
dictate a lower temperature
n the same manner, suitable measures shall be taken in respect of the water temperature during
the hydrostatic test to avoid any brittle fracture.
3? T-(2-'".4'- )(,'*..!-(-#.
Low alloy steel such as 2.25Cr 1Mo, 2.25Cr 1 Mo V and 3Cr 1 Mo V are susceptible to
temper embrittlement when operated in the temperature range of typically 300 550
o
C (i.e.
hydrotreaters or hydrocrackers).
Under such operating conditions, embrittlement phenomena may appear in connection with the
behaviour of Cr-Mo steels after long term service exposure.
Affected material can show a considerable reduction in toughness properties at ambient
temperature, and special precautions need therefore to be taken to avoid brittle fracture,
especially during transient phases (start-ups and shut-downs) and hydraulic pressure tests.
This mainly applies to the components made from steel grade specified here above for such
equipment as the reactors, associated vessels and certain HP heat exchangers. t is stressed that
temper embrittlement effects are normally much more moderate for lower alloyed steels (e.g.
1.25Cr-0.5Mo).
i) R-/.'*1.*&#/ .& 18-(*1"! 1&(2&/*.*&#
Project Name
D10169B904LI1001
Sheet / of
:/6
Revision
00
Refer to section for specific recommendations for the metallurgy of the reactors
**? I#1'-"/- &% .'"#/*.*&# .-(2-'".4'-
n addition to the stringent restriction of the chemical composition, most users specify a sampled
step cooling of steels coupons issued from material used for fabrication of shell and heads
susceptible to Temper Embrittlement. Step cooling treatment, imperatively performed after
PWHT, will simulate a fraction of the increase in the ductility-brittle transition that should occur
after long-term service.
For information only, a typical step cooling sequence could be:
Heat to 595
o
C Hold for 1 hour, cool at 6
o
C/h max. to 540
o
C.
Heat to 540
o
C Hold for 15 hours, cool at 6
o
C/h max. to 525
o
C
Heat to 525
o
o
C/h max. to 495
o
C
Heat to 495
o
o
C/h max. to 470
o
C
Heat to 470
o
o
C/h max. down to 315
o
C and then Air cooling.
This simulated isothermal embrittlement results in a certain increase (shift) of the material's
transition temperature. The increase in transition temperature (TT55) from its original value has
become an accepted tool for the determination of temper embrittlement susceptibility. n order to
characterise a material for temper embrittlement resistance, a relationship was developed using
the original or "as fabricated TT55 and the increase in TT55 (A TT55).
After step cooling heat treatment for impact properties (Charpy-V at 1/4T and 1/2T material
thickness ) should meet the following requirements:
TT55 + 3ATT55 < 10
o
C
Where : TT55 : the 55 Joule transition temperature
ATT55 : (TT55 [step cooled] TT55 [original value])
The method generally used to avoid brittle fracture consists in maintaining pressure at a low level
until reactor vessel exceeds the Minimum Pressurising Temperature (in that way, resulting
stresses are then reduced below a stress value which could lead to brittle fracture propagation).
This MPT takes into account the TT55 estimated for the embrittled conditions and a safety margin
which mainly takes into account the effect of hydrogen absorbed during operation (effect
depending on wall thickness, steel quality and process conditions, it is the vessel vendor
responsibility to guaranty the MPT values for the considered equipment).
Below the MPT, the pressure should be kept not exceeding 25% of the design pressure for
equipment built per ASME Code Section V, Div. 2 (some owners may allow higher value for
equipment built per ASME Code Section V, Div.1 considering the higher safety factor on
allowable stress values in that case). Any way, the MPT criteria for HP Reactors should always be
given or approved by vessel vendor.
-? S.",*!*A*#6 @-". T'-".(-#.
Austenitic stainless steel can become sensitised after prolonged exposure at elevated
temperatures in the range of 425 850
o
C (800 1600
o
F). This structural transformation during
long term service at elevated temperature is due to a precipitation of chromium carbides
(generally Cr23C6). n fact, this precipitation at the grain boundaries does not affect the mechanical
properties. On the other hand, it involves sensitising to intergranular corrosion (refer to
"Polythionic acids).
Although stabilised types of stainless steels (such as 321, 347 and 316Ti) have a much higher
resistance towards sensitisation than the non-stabilised ones, literature indicates that their
resistance can be further improved by stabilising heat treatment (around 900 C) of the solid SS
individual components. This procedure encourages the formation of stable carbides, formed
either from Titanium for Types 321 and 316 Ti or from Niobium/Columbium for Types 347, without
chromium depletion.
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Therefore such stabilisation heat treatment is recommended for the furnace tubes. n addition it
could even be decided to apply such heat treatment also for (the hottest parts of) the stainless
steel piping despite its operating temperature remains somewhat lower.
Note that no fissuring corrosion experiences have been reported to Licensor when using overlaid
347 SS (refer to Polythionic Acid Attack here after).
%? M-."!!4'69 S-!-1.*&# G4*3- D-/*6#
The various modes of main corrosion concerns that are specific to refinery hydro-treating units
are exposed and discussed in the following.
*? @*68 T-(2-'".4'- @ A.."1$
n services containing hydrogen, materials are selected based on their resistance to high
temperature hydrogen attack. Hydrogen attack can occur at temperature above about 220C.
Dissolved hydrogen can react with iron carbides generating methane gas (CH4) which is trapped
into the metal. As the concentration of methane gas increases, increasing pressure begins to tear
the grain boundary, causing fissures and then cracks. Simultaneously, the loss of carbides lowers
the strength of the metal.
Material recommendation is based on the Nelson curves (refer to AP RP 941: "Steels for
Hydrogen Service at Elevated Temperatures and Pressures in Petroleum Refineries and
Petrochemical Plants) for hydrogen resistance. The material is selected based on the maximum
operating temperature, and hydrogen partial pressure, with appropriate allowance added to each
of the variables to account for various operating modes.
As the figures considered in AP RP 941 are based largely upon empirical experience, safety
margin of 28
C (50

F

) and 3.4 bar (50 psi) below the relevant curves (respectively for maximum
operating temperature and maximum operating hydrogen partial pressure) are typically used when
selecting steels.
'otes:
.he (/).) values for 'elson 0urves application shall not be compared with the 1echanical Design
/ressure and .emperature which are used for mechanical calculation&
2f the temperature and pressure fall on one of the curves) then the higher allo+ shall be used&
There is no credit taken for a corrosion resistant stainless steel cladding, since hydrogen can still
diffuse through the cladding. Where alloy cladding is used, the base metal shall consequently be
selected for H2 Service.
**? @*68 T-(2-'".4'- @/@S C&''&/*&#
The choice of material for services containing H2S in hydrogen rich environment is based on the
acceptable corrosion rate, to obtain the desired equipment life. At temperatures higher than
200C, the corrosion rate is estimated as a function of temperature and H2 S partial pressure for
the selected material. The corrosion rate curves for the various metallurgy is based on the
original NACE data (Couper & Gorman curves), and this is considered to provide a desirable
degree of conservatism in the design.
***? @*68 T-(2-'".4'- S4!28*3- C&''&/*&# *# @ F'-- )#;*'&#(-#.
The corrosion rate for services containing organic sulphur at temperatures above 260C in
hydrogen free environments (considered to be with ppH2 < 50 psia) is obtained from curves based
on the original NACE and AP data.
The estimated corrosion rates may be obtained, by using the Mc Conomy curves, as a function of
normal operating temperature and organic sulphur content.
*;? N"28.8-#*1 A1*3 C&''&/*&#
Naphthenic acid is the collective name given to the organic acids contained in some crude oils.
The naphthenic acid content of the raw feed is generally expressed as neutralisation number, as
determined by ASTM test methods D 664 or D974.
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t can cause corrosion at temperatures as low as 175

C (350
F). However, serious corrosion,

pitting and/or grooving type, usually does not occur until the temperature exceeds 230
C (450
F).
Type 316L or 317 L SS (SS containing at least 2,5% wt. of molybdenum) should be used when
neutralisation number exceeds 1.5 mg KOH/g oil for operating temperatures above 230
C.
Type 317 being preferred for severe combinations of TAN (Total Acid Number), Temperature, and
velocity/turbulence, since the molybdenum content of this grade ranges from 3.0 to 4.0 wt. %.
Carbon steel metallurgy is considered to be sufficient for equipment and piping for Total Acid
Number TAN < 1.5 mg KOH/g and temperatures below 230C. For all other conditions stainless
steel specification shall be considered.
;? C-. @S C&''&/*&#
Wet sour services are common in the hydrocarbon producing and processing industries. The
major concern for such services is the various forms of hydrogen cracking produced by wet
hydrogen sulphide corrosion.
As a matter of fact, H2S dissociation in presence of free water leads to atomic hydrogen formation
(particularly) in the cold part of the reaction section after the washing water injection in the reactor
effluent, H2S amine absorbers and strippers overhead equipment are concerned), and can cause
the following:
Sulphide Stress Corrosion Cracking (SSCC)
Hydrogen blistering, Hydrogen nduced Cracking (HC), Stress Oriented Hydrogen nduced
Cracking (SOHC).
The susceptibility of deterioration by the above mentioned risks are lowered, by specifying the
following for the carbon steel metallurgy:
Definition of different types of associated specifications
Typical Applicable Documents:
- Material requirements for Sulfide Stress Corrosion Cracking Resistant Metallic
Material as per NAC) S."#3"'3 MR 01-75, latest edition.
- Materials and Fabrication Practices for New Pressure Vessels Used in wet H2S
Refinery Service as per NAC) I#.-'#".*&#"! P4,!*1".*&# :M194.
- Methods and Control to Prevent n-Service Environmental Cracking of Carbon Steel
Weldments in Corrosive Petroleum Refining environments as per NAC) S."#3"'3
RP047, latest edition.
Licensor's general recommendations for carbon steel in "H2S Service.
Carbon steel must be Fully Killed Carbon Steel type
Maximum Allowable Hardness 22 HRC
Ni content less than 1%
Carbon content shall be 0.20% maximum
Plate material shall be supplied in Normalised condition, regardless of thickness
Typical limitation of Carbon Equivalent are the following:
- Ceq < 0.42% for plate less than 2 thick
- Ceq < 0.45% for plate from 2 thick to 4 thick
- Ceq < 0.48% for plates greater than 4 thick
With Ceq = C+Mn/6 + (Cr+Mo + V)/5 + (Ni + Cu)/15
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.hese 0eq values are indicative and ma+ be re-considered if needed regarding the
used steel grade& 2n that case) new proposed values should be submitted to E/0 for
approval&
Thermal Stress Relieving required for all welds (PWHT) and/or for cold bend zone, even if
it is not required by code.
Typical recommendations for Process Piping and accessories in "H2S service
- Process piping shall be seamless type piping
- /iping and accessories:
Recommended Maximum allowable Phosphorus content 0.030%
Recommended Maximum allowable sulphur content 0.020%
An acceptable designation is ASTM A-106 Gr.B (applicable also for vessel's
nozzles as ASME SA-106-B)
- 3langes and accessories:
Recommended Maximum allowable phosphorus content 0.030%
Recommended Maximum allowable Sulphur content 0.025%
An acceptable designation is ASTM A-105 for forging and ASTM A-216 WCB
for castings (applicable also for vessel's flanges as ASME SA-105).
.hese impurities level criteria are given for information) the final specification concerning the /
4 5 impurities contents will be decided b+ the E/0 (based on the owner specification if an+)
following its t+pical practice for 6/iping in 5our 5ervice7&
Licensor's recommendations for Carbon Steel Plates "HC resistant:
The most important factor to avoid HC is the purity (cleanliness) of the steel. The non-
metallic inclusions must be very low.
n addition to the general recommendations relative to "H2S Service, when "HC resistant
steel is specified, the following requirements should also be met:.
/lates for /ressure /arts of the 8essels:
Carbon steel made by vacuum degassing process
Oxygen content less than 0.002%
Maximum allowable Phosphorus content 0.008%
Maximum allowable Sulphur content 0.002% (0.007% if inclusion shape
controlled by calcium treatment)
Calcium treatment, if any, shall be Ca/S ratio > 1.2
t is required to pass the NACE standard TM 0284 (Evaluation of Pipeline and
Pressure Vessels Steels for Resistance to Hydrogen-nduced Cracking) by
using the acidified test solution specified in NACE standard TM0177
(Laboratory Testing of Metals for Resistance to Sulfide Stress Cracking and
Stress Corrosion Cracking in H2S environments) with:
Crack Length Ratio (CLR) 5%
Mill test reports shall include the values for the crack length ratio (CLR), crack
sensitivity ratio (CSR) and crack thickness ratio (CTR) as defined in NACE
standard TM-02-84 and also carbon equivalent (CE).
A possible designation is ASTM A 516 gr60.
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'ote : .he use of a standard carbon steel grade with 55 cladding can be an alternative to
620 resistant steels7 especiall+ for thick-wall vessels like cold / separator since it should
involve onl+ a small cost premium over 620 resistant steel7 construction (the procurement
could even be sometime more eas+)& .he resulting protection against corrosion would be
enhanced provided that 55 solution would not lead to other kind of corrosion and9or
deterioration&
;*? A(*#- S.'-// C&''&/*&# C'"1$*#6
Amine solutions can cause pitting and stress corrosion cracking in carbon steels.
Amine stress corrosion cracking can attack non-stress-relieved CS piping and equipment. Hence,
stress relieving (PWHT) is recommended for all the welds and the cold formed parts of CS
equipment and piping, regardless of operating temperature. AP RP-945 (Avoiding Environmental
Cracking in Amine Units) and the guides from technical committee NACE T- 8-16 would apply to
these services for equipment and lines.
Killed carbon steel is usually considered as acceptable under amines operation when fluid
velocities are limited to a maximum of 0.9 m/s (3 ft/s) for rich amine and of 2.1 m/s (7 ft/s) for lean
amine.
On the other hand, it is recommended to specify type 316 stainless steel for turbulence and/or
flash zone and/or high fluid velocities.
Note that it is generally preferred to use stainless steel as cladding and not as solid form on
account of possible presence of chlorides, highly dangerous for SS, in the fluid.
The recommendations outlined for the wet H2 S corrosion are applicable for the amine service as
well. n particular, HC resistant steels should be used for amine H2S absorbers.
;**? A((&#*4( B*-S4!28*3- C&''&/*&#
Water injection upstream of the reactor effluent coolers is required to prevent plugging from water-
soluble ammonium bi-sulphide salts. The water injection rate should be adequate for saturating
the vapour phase, and to provide about 25% excess water as liquid phase, at the coolers inlet.
The water injection rate should also be sufficient to reduce the salt content of the sour water to
less than 4 wt %.
Licensor had specified Killed CS metallurgy for this service in several units.
Based on Licensor's experience, Killed CS metallurgy is sufficient for this service if the sour water
salt content is maintained at less than 4 wt %, and the total fluid velocity is kept in the range of 3
to 6 m/s. Also, it is important to control the wash water quality as recommended by Licensor,
especially the oxygen (less than 15 ppbw) and chloride (less than 50 ppmw) content to minimise
corrosion.
;***? P&!9.8*&#*1 A1*3 A.."1$
Where austenitic stainless steels have been selected, chemically stabilised types (321 SS and
347 SS) are required for processes in which the normal maximum sustained operating
temperature exceeds 425 C, because of their higher resistance to intergranular corrosion and
stress corrosion cracking caused by polythionic acid attack. This kind of attack can occur,
especially during the shutdown periods as a result of sensitisation during service.
As a matter of fact, once opened to the atmosphere, the association of iron sulphides produced
during operation and air/moisture leads to formation of polythionic acids H2 SxO6 . The resulting
acid corrosion leads to the formation of intergranular cracks, typical of polythionic SCC corrosion
(mainly into Heat Affected Zone).
t is therefore strongly recommended to passivate the unit before contacting the equipment with
atmosphere. The NACE Standard RP 0170 should also be followed as a guideline to carry out the
soda ash washing of all the zones to be in contact with atmosphere after shut-down. This
procedure is recommended in all the cases, even in the case of stabilized SS use.
Based on Licensor's experience, 347 SS shows a better resistance to sensitisation than 321 SS,
and is recommended for severe services.
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However for maximum resistance to sensitisation, types 321 and 347 SS should be subjected to a
stabilising heat treatment.
*=? C8!&'*3- A.."1$
Aqueous chlorides provide an excellent electrolytic environment for corrosion.
Austenitic stainless steels are well known for their susceptibility to failure by chloride stress
corrosion cracking (CSCC).
This phenomenon may appear under almost any set of circumstances relative to the following
critical variables:
Temperature : CSCC is virtually unknown for neutral pH solutions at temperature below 60C
(140 F).
Chloride concentration : n evaluating the risks for CSCC, consider concentration
mechanisms such as evaporation, which can increase low contents to dangerous levels. For
this reason, vapour-liquid interfaces and crevices such as socket welds are to be avoided.
Even trace of chloride into water is sufficient to induce stress corrosion cracking.
Stress: Stresses are usually due to the residual tensile stress caused by welding or cold work
such as U-Bending heat exchanger tubes. Stress relieving heat treatment is also sometimes
used to reduce cold forming or welding induced residual stresses in austenitic stainless steels.
n consequence of the difficulties to guaranty the environment state in presence of chloride, CSCC
resistant alloys should be specified where CSCC is anticipated.
ncrease in molybdenum content enhances resistance of austenitic stainless steel to chloride
attack (317L > 316 > 304, 321). Super austenitic stainless steel (904L), or duplex alloy stainless
steel, as alloy 2205 (22 Cr-5.5 Ni-3 Mo-N/UNS S31803) or higher nickel alloys types such as Alloy
400 and Alloy 825 which are significantly more resistant to CSCC than austenitic 18-8 SS should
also be considered.
Notes :
1onel) which ma+ be specified where resistance to h+drochloric acid is required (top section
of the crude tower for e(ample)) shall not be used when ammonia is in:ected for corrosion
control due to its high susceptibilit+ to stress corrosion cracking&
;ater used for flushing or during h+dro-tests in presence of austenitic stainless steel materials
should t+picall+ have a chloride content of <, ppm) not e(ceeding $, ppm&
=? C"4/.*1 S&3"
Carbon steel is the basic recommended material of construction for moderate temperatures and
concentrations.
Threshold of operating limits are usually determined by using existing NACE caustic soda services
curves which indicates preferred material at various temperatures and concentrations.
PWHT is recommended for Carbon Steel welds in services above these thresholds to minimise
the risk of stress corrosion cracking.
Austenitic stainless steels may sometimes be specified up to 120 C (beyond this temperature
threshold, these alloys can be susceptible to caustic stress corrosion cracking).
However, caustics being often contaminated with chlorides, and since there are other competitive
materials choices, selection of austenitic stainless steels for caustic service is usually avoided.
For high severity services, Nickel Alloys such as Monel will be preferred.
Anyway, it is highly recommended in caustic soda services to avoid at one and the same time
piping low points where caustic could become highly concentrated, and hot spots.
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Note :
Systems in which carbon steel could be in contact with caustic soda carryover during upsets
should be stress relieved/postweld heat treated. f not possible, this system should be made of
appropriated alloys as defined here above.
7.0 P'&1-// C&#.'&! "#3 I#/.'4(-#.".*&#
7.1 Unit operations shall be controlled from a central control room common to other units and shall
be a microprocessor based Distributed Digital Control with Supervisory computer system. All
process and product streams shall be measured and recorded. Level alarms wherever required shall
be used. Dial thermometers shall be provided at inlet and outlet of heat exchangers. n case of very
critical services hardwired alarms shall be provided as stand by unit.
For Thermocouples in Temperature Control Loop, closed loop or connected to PLC, Temperature
Transmitters shall be used.
7. C&#.'&! P8*!&/&289
The plant shall be operated through Video Consoles along with Console panel with few dedicated
nstruments, Recorders, Annunicators etc. and a Console desk having selector switches, push
buttons, status indicators. The field switches, which are required to be triplicated for this purpose
are shown on the P& Diagram. The nterlocks (LOGC) for the unit shall be performed in PLC
capable of communicating with DCS. 2 out of 3 voting logic is envisaged for critical interlocks
only.
7.3 I#/.'4(-#./
All alarm points, Software and hardwired to be indicated in P&D with proper legend as per
SA symbol.
All specification data sheets shall be as per SA.
For security interlocks transmitters shall be used as field instruments connected to Analog
nput card of PLC directly. No switches shall be used.
For temperature, Flow and interface level Transmitters shall be used, Switches shall not be
used.
N& /<*.18-/ .& ,- 4/-3 "#9<8-'- *# .8- 4#*. *#1!43*#6 .8- 2"1$"6-3 *.-(/
All OCL standards and instrument hook-up drawings may be used
For all Temperature closed loops, field mounted temperature transmitters to be used.
1 " flanged type thermowell with minimum flange rating of 300# shall be considered.
Screwed type thermowells shall not be used.
Dedicated field instruments (Transmitters) shall be used for trip activation and critical alarms.
Separate nozzle / tapping shall be used for such instruments.
Limit switch : proximity type limit switch may be used.
The symbols to be used will be in accordance with SA (see General legend diagrams).
Alarms and shutdown devices:
Alarms and shutdown devices will be specified where required for process, safety or
equipment protection considerations.
Shutdown device connections will be independent from instrument connections.
All safety devices are connected to a PLC (Programmable Logic Controller
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nstrument impulse lines to be insulated / traced, wherever required, to avoid condensation /
congealing.
Critical rotating equipment to have vibration monitoring system with control room indication.
7.4 S"%-.9 D"!;-/
Double safety valves shall be provided with isolation valves, such that on-stream isolation and
maintenance of a safety valve is possible without affecting unit operational safety
requirements. This shall be considered for all operation failure cases (guided or no-guided).
Where safety valve provision is guided by fire case, single safety valve with isolation valve
(locked open) shall be provided. However, in case of provision of safety valve considering fire
case as governing case and where such provision is also required from process point of view,
stand-by safety valve is to be considered. All isolation valves of pressure safety valves shall
be lock open/close type. The isolation valves shall be mechanically interlocked where ever
two PSVs are provided.
Pressure relief valves are normally installed on the equipment.
Pressure relief valves in hydrocarbon vapour service will normally discharge to a vapour
system.
All relief valves load and size shall be calculated according to the following mentioned codes:
- AP 520
- AP 521
- AP 526
- AP 527
- AP 2000
The size of relief valves are based on either over-pressure condition, fire exposure or vacuum
situation for a particular system.
Typical over pressure conditions are:
- Blocked Discharge
- nadvertent Valve Opening
- Utility Failure
- Electrical / Mechanical Failure
- Loss of Air Cooler Fans
- Loss of Heat in Fractionation
- Loss of nstrument Air or Electric Power
- nstrument Failure or Blow-by
- Reflux Failure
- Abnormal Heat nput From Reboilers
- Heat Exchanger Tube Failure
- Trapped Liquid Expansion
The following guidelines shall be applied for safety valve selection and line sizing:
- Valve selection will be based on maximum operating temperature and relief valve
set pressure.
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- Conventional type relief valves shall be used for the cases where the built-up back
pressure and the variable superimposed backpressure doesn't exceed 10% of the
set pressure. For the cases, where it exceeds 10%, but is below 50 % of the set
pressure, balanced bellow type relief valves shall be used.
Pilot operated relief valves shall be used for the systems where maximum set point
accuracy is required. Such relief valves shall be installed in equipment, which
operate very close to the set pressure.
- Safety valves on column circuits are preferred to be located at the highest point in
the overhead vapors lines.
- Pressure drop in a PSV inlet line must not exceed 3% of the set pressure of the
PSV.
- PSV inlet and outlet line size has to be equal or greater as the PSV nozzle sizes.
- PSV discharge to be free draining to flare header. PSV inlet to be free draining
towards the source.
- nlet and outlet valves to be full port.
- Relief valves, which are susceptible to plugging, shall be steam traced and have a
rupture disc installed under them.
- Staggered pressure setting may be specified to minimise losses.
- For atmospheric relief, the open end of discharge will be located 30m from any
source of ignition. Discharge is usually 3m higher than any equipment or manholes
(ladder, platform etc.) within 15m radius.
- Relieving device discharge lines, shall be sized based on the back pressure data
- The flare header shall be sized according to pressure drop constraints.
All drains on safety valves (wherever provided) shall be connected to the CBD. All safety
valves shall normally have carbon steel body with stainless steel trim. Other trim material can
be considered if any particular service demands a different material. Bronze or cast iron
bodied valves shall not be used.
7.5 C&#.'&! D"!;-/
As a default, control valves upto 8 size and in steam service shall be provided with a
manifold of block and bypass valves. Bypass valves shall be globe valves. For control valve
above 8 size, block and bypass requirement shall be decided on case to case basis.
However, Control valves not having block and bypass provision shall be provided with
handwheel for manual operation.
All control valves should have two isolation valves and min one bypass valve.
All control valves shall be provided with 3/4 drain valves, which can be provided as:
Upstream and downstream of all control valves
Drain valve shall be capped (n non-hydrocarbon & non-BR LP steam service)
Drain valve shall be blind flange (n all Hydrocarbon, toxic/hazardous chemicals & BR
steam service)
Shut down valves shall not be provided with block and bypass valves.
The control valve pressure drop should be the greater of the following
50 60 % of the total frictional loss excluding the control valve
0.7 Kg/cm
2
15 % of the pump differential head
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For valves installed in extremely long or high pressure drop lines, the percentage drop across
control valve may be lower, but at least 15 % up to 25%, where possible, of the system friction
drop.
The selected control valve must allow maximum flow through it at 80% opening (maximum)
and minimum flow at 15 to 20% opening minimum.
Control valves must be evaluated for flashing / cavitation and choked flow condition before
selection.
7.6 F!&< I#3*1".*&#
F&' (".-'*"! B"!"#1- "!! %!&< *#3*1".*&#/ /8&4!3 ,- &% ("// %!&< .92-
A#9 &.8-' %!&< *#/.'4(-#./ /8&4!3 8";- 2'-//4'- "#3 .-(2-'".4'- 1&(2-#/".*&#.
Flow indications with totaliser for the following streams entering / leaving the battery limit shall
be available in the control room over and above those required for process control of the unit:
- All Feed to the unit
- All Products from the unit
- Fuel gas to the unit
- Hydrogen rich gas to the unit
- Hydrogen for start-up
- Hydrogen to the unit
- Any other relevant streams
Flow indications with totaliser for the following utility streams shall be available in the control
room:
- HP/MHP steam to/from the unit
- MP steam to and from the unit
- LP steam to and from the unit
- Cooling water to the unit
- Condensate from the unit
- Condensate from other units
- Nitrogen to the unit
- BFW to the unit
- Plant Air & nstrument Air to the Unit
- DM Water to the Unit
7.7 L-;-! I#/.'4(-#./
Standpipes with a default size of 2 NB shall be considered for only clean, non-viscous and
non-crystallizing services. Standpipes shall be used if more than 4 vessels nozzles are
anticipated for mounting all the level instruments in a given service.
Standpipes bottom tapping should be from side only. Standpipe bottom tapping not to have
any low pocket in order to ensure free draining of standpipe liquid into the vessel.
For other cases level instruments shall be mounted directly on the equipment. n this case
minimum liquid level indicated shall be 150 mm above the BTL of the equipment.
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Following specific requirements for standpipes is to be followed:
Standpipe shall not have instruments other than for level.
Standpipe accommodating level gage / transmitter shall be separate from standpipe / vessel
tappings for level switches for alarm and trip.
Standpipe shall not be connected to process lines
Standpipes to have isolation valves at top and bottom tapping.
Standpipe bottom tapping to have slope towards the vessel.
Standpipe connections to be on sides only.
Radar type of level gauges shall be specified for tanks
Diaphragm seals shall be specified for congealing / high viscosity / corrosive / crystallizing
services (pressure upto 600#).
7.: U.*!*.9 L*#-/ ,"..-'9 !*(*. I#/.'4(-#.".*&#
Utility Lines : As a minimum, the following shall be provided in unit utility headers:
UTLTY Local
P
DCS
P
DCS
PAL/
PAH
Local
T
DCS
T
DCS
TAL/
TAH
DCS
F
DCS
FAL/
FAH
DCS
FQ
MP/LP Steam YES YES YES YES YES YES YES
Condensate YES YES YES YES
CW supply YES YES YES YES YES YES YES
CW return YES YES YES
nstrument Air YES YES YES YES YES
Plant Air YES YES YES
Nitrogen YES YES YES YES YES
Fuel Gas YES YES YES YES YES
Hydrogen YES YES YES YES YES
BFW YES YES YES YES YES YES
DM water YES YES YES YES
Service Water YES
Potable water YES
Flare YES YES
7.9 S."#3"'3 @-". )=18"#6-' I#/.'4(-#.".*&#
solation valves at both inlet & outlet in cooling water service
solation and bypass valves for only exchangers which can be taken out for maintenance
when plant is running.
Local T at process inlet and outlet of each service
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DCS T at cooling water outlet of each exchanger.
DCS T at process inlet and outlet of each service
Local and DCS P at process inlet & outlet
Local PG in inlet and outlet of CW
N&.-B
T8- 3-."*! 3"." /8--. %&' "!!.8- *#/.'4(-#.//CD//SDD// F*#"! C&#.'&! )!-(-#. *#1!43*#6 T/C
!-#6.8, %!"#6- /*A-,3*"(-.-' .& ,- 2'&;*3-3.
A!! *#/.'4(-#./ /8&4!3 ,- 1!&/- 1&42!- .92-.
N& ,!&1$ & ,!--3 ;"!;- .& ,- 4/-3 "/ *#/.'4(-#. ."22*#6 .
&4. &% 3 ;&.*#6 /8"!! ,- 1&##-1.-3 .& DCS/PLC *# 3*%%-'-#. 1"'3/.
:.0 U#*./ &% M-"/4'-(-#.
MKS (Old Metric)
Temperature C
Pressure kg/cmg
Vacuum mmHg
Weight kg
Volume m
Flow of Process fluid
Liquid - Mass flow kg/h
Volume flow m/h
Flow of steam kg/h
Enthalpy Kcal/Kg
Heat duty MMKcal/h
Power kW
Heat Transfer rate Kcal/m C.h
Fouling resistance m C.h/Kcal
Viscosity cP
Equipment size mm
Pipe length km
Pipe diameter in
Vessel nozzle sizes in
The normalized conditions for gas measurement are:
Standard : 760 mmHg, 15.5C (60F) (Sft/mn or SCFM)
Normal : 760 mmHg, 0C (Nm/h)
9.0 C&3-/, S."#3"'3/ & P'"1.*1-/
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Latest revisions of following documents
P!-"/- 2'&;*3- .8- !".-/. -3*.*&#/ &% .8- 1&3-///."#3"'3/ "/ 6*;-# ,-!&<. F&' -="(2!-
%&' C-#.'*%46"! 24(2/ .8- !".-/. -3*.*&# &% API /."#3"'3 610 */ 10
.8
-3*.*&# "#3 #&.
:.8 -3. >A46. 95?
9.1 P!&. P!"#
OSD-STD-118 Rev 1, July 1995
9. D-//-!/
ASM) >1995?, /-1.*&# DIII B
Div. 1
Div. 2 (High pressure services)
9.3 C&(2'-//&'/
Reciprocating : AP standard 618, 4th ed. (June 95)
Centrifugal : AP standard 617, 6th ed. (Feb. 95)
9.4 P4(2/
Positive displacement Reciprocating : AP standard 674, 2nd ed. (June 95)
Positive displacement Controlled volume : AP standard 675, 2nd ed. (Oct. 94)
Centrifugal : AP standard 610, 8th ed. (Aug. 95)
9.5 F*'-3 8-".-'/
AP standard 560, 2nd ed. (Sept. 95)
9.6 S8-!! "#3 T4,- @-". )=18"#6-'/
AP standard 660, 5th ed. (June 93)
TEMA, 8th ed. (1999)
9.7 A*'-1&&!-3 8-". -=18"#6-'/
AP standard 661, 4th ed. (Nov. 97)
TEMA, 8th ed. (1999)
9.: P*2*#6
ASME/ANS B 16.5 (1996, Add. 98)
B 31.3 (1996)
9.9 M".-'*"!//C&''&/*&#
Hydrogen service : AP standard 941, 5th ed. (Jan. 97)
Amine service : AP standard 945, 2nd ed. (Oct. 97)
Wet H2S service : NACE 8X 194 (June 94)
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NACE MR 175-95
Polythionic Acid service : NACE RP 0170 (1997)
9.10 P'-//4'-- R-!*-;*#6 "#3 D-2'-//4'*#6 S9/.-(/
AP recommended practice 520 Part , 6th ed. (March 93)
Part , 4th ed. (Dec. 94)
AP recommended practice 521, 4th ed. (March 97)
ASME section (Boiler and pressure vessels code)
9.11 I#/.'4(-#.".*&#
SA 55.1 (July 92)
ASTM
9.1 Q4"!*.9 C&#.'&!
SO 9001, rev. 2 (1994)
10.0 )74*2(-#. D-/*6#".*&# "#3 N4(,-'*#6
10.1 U#*. #4(,-'*#6
U#*. #"(- N4(,-'
Naphtha Splitter 034
Reformate Splitter 035
HDT 036
somerisation 037
10. )74*2(-#. #4(,-'*#6 "#3 *3-#.*%*1".*&#
"? )74*2(-#. *3-#.*%*1".*&#
S9(,&! )74*2(-#.
FF Heaters
RB Reactors
CC Towers and Columns
VV Drums, Separators
EE Heat Exchangers
EA Air coolers
DR Dryers
RP Pumps
KA Compressors
T TT Storage Tanks
M Miscellaneous
PM Motors (pumps)
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KM Motors (compressors)
KT Turbines (compressors)
Type of Equipment
CF Centrifugal
GR Geared
RP Reciprocating
SC Screw
MT Metering
SM Submersible
Axens has kept identification code "M for all the packages under PMC/EPCC scope. However PMC should
assign equipment identification code as the list provided above.
,? )74*2(-#. #4(,-'*#6
Example : 034 - PA - CF - 001 A/B
Where:
034 is unit number
PA is equipment symbol
CF is type of pump, i.e. centrifugal type
001 is equipment number
11.0 L*#- N4(,-'*#6 "#3 I3-#.*%*1".*&# S9/.-(
11.1 G-#-'"! N&.-/
Numbering will start at 01.
The number changes after control valves and main equipment..
The number is different for the lines connected to equipment in parallel.
Each type of fluid will have a separate numbering sequence.
Drains and vents without permanent flows are neither identified nor listed.
Design pressures and temperatures are shown on piping specification sheets.
11. )="(2!- &% L*#- #4(,-'*#6
Line number: 6 -P - 034 - 0103 - A1A-H
Where:
6 is nominal pipe size
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P is fluid code
034 is unit number
01 is P&D number
03 is line sequential number
A1A-H is piping specification
Example of line numbering:
11.3 F!4*3 1&3-/
@-".*#6 / C&&!*#6
@O Heat transfer fluid
SL Low pressure steam CL
LC
Low pressure steam condensate
SM Medium pressure steam CM
MC
Medium pressure steam condensate
SM@ Medium high pressure steam C@ High pressure steam condensate
S@ High pressure steam
SSL Low pressure superheated steam
SSM Medium pressure superheated steam
SS@ High pressure superheated steam
CCS Cooling water supply CCR Cooling water return
FR Refrigerant
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M - P - 0MM - GGMM + B1AS - I@
5. S2-1*%*1".*&# J /2-1*"! '-74*'-(-#.
><-. @S %&' *#/."#1-?
. F!4*3
1. N&(*#"! 2*2- /*A-
4. L*#- #4(,-'
6. I#/4!".*&#
3. U#*. #4(,-'
FG Fuel gas FO Fuel oil
C8-(*1"!/
IG nert gas OS
NA
Caustic soda
N Nitrogen OA
GA
Ammonia
CT CA Catalyst OC C Chemicals
AI IA nstrument air AP
PA
Process air (oil free)
AS UA Utility air
CR Raw water CP
PC
Process water
DC DM Demineralised water CT
TC
Tempered water
BFC Boiler feed water CDE Drinking water
FC Fired Water SC Service Water
)%%!4-#./ 3*/2&/"!
BD CBD Close Blow down CS Chemical sewer
SCS Sour water sewer OS
OCS
Oily Water sewer
ATM DA Vent to atmosphere FL Flare
P SL Slops CAS Closed amine system
SS Storm Sewer
P'&1-// %!4*3/
P Process AMN Amine
Piping Specification: T8- (".-'*"! /2-1*%*1".*&# .& ,- %&!!&<-3 */ 6*;-# */ 8-'- ,-!&<B
11.4
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M".-'*"! %&' 2*2- >1 3*6*. - !-..-'?
T92- M".-'*"! ASTM /2-1/. 4/-3 ,9 A=-#/ %&'
/18-34!- &' .8*1$#-// 1"!14!".*&#
A CS A106-B
B Killed CS A 333 Gr6
C C-1/2 Mo A 335 P1
D 1 Cr Mo A335 P12
) 11/4Cr Mo A335 P11
F 21/4Cr 1 Mo A335 P22
G 3Cr 1 Mo A335 P21
@ 5Cr-1/2 Mo A335 P5
I 9Cr 1 Mo A335-P9
H SS-TP316 A31 - TP316
E SS-TP316L A312 - TP316L
L SS-TP304 A312 - TP304
M SS-TP304L A312 TP304L
N SS-TP321 A312-TP321
P SS-TP347 A312 TP347
U Monel 400 B-165
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C&''&/*&# "!!&<"#1- >1 3*6*. + #4(,-'?
0 0.25 mm
1 1.0 mm
1.5 mm
3 3.0 mm
6 6.0 mm

S2-1*"! R-74*'-(-#. >I 3*6*. + !-..-'?
S Sulfide stress cracking resistant
@IC Hydrogen induced cracking resistant
R nternal lining
F!"#6- '".*#6 >1 &' 3*6*./ + #4(,-'?

I.-( ANSI R".*#6
1 150 lbs
3 300 lbs
6 600 lbs

F!"#6- .92- >1 3*6*. + !-..-'?

F Raised face
H Ring type Joint

I#/4!".*&# >1 3*6*. + !-..-'?

I.-( D-/*6#".*&#
@ Heat conservation
P Personal protection
C Refrigeration conservation
T Tracing
H Jacketing

Special requirement (1 digit - letter)
Wet
!
S or amine ser"ices Specific requirement
S "ategor& 1: Moderate ser,ice
12et )
2
3 resistant steels1
.40
# 5nternal lining
"ategor& 2: 3e,ere ser,ice
1)5" resistant steels1
.40
$ 62)7
.440
mandator& +or corrosion reason
(%) 8e+er to Axens 3tandard Material
3-eci+ication 5N-9
(%%) 62)7: 6ost 2eld )eat 7reatment
&nsulation
&tem 'esignation &tem 'esignation
& )eat conser,ation &T 7racing
&P 6ersonal -rotection &( :ac;eting
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&$ 8e+rigeration conser,ation
1.0 I#/.'4(-#. #4(,-'*#6
1.1 S9(,&!/
According to SA code
1. N4(,-'*#6
Example: 34 T 0101
Where:
35 (two digits) is Unit number
T (2 to 4 letters) is instrument symbol as per SA code
01 (2 digits) is P&D number
01 (2 digits) is instrument serial number
On P&D's: T XX01 (XX = P&D number)
On data sheet : 34 T XX01 (34 = Unit number)
Example of instrument numbering:
A/B : One PSV to remain as standby WTH NDVDUAL SOLATON VALVES HAVNG following locking
ARRANGEMENT:
13.0 A#"!9/*/ 2&*#. #4(,-'*#6
The analysis points will be listed with their type (A, B, C..). The type conforms to the typical
analysis point schemes (see General legend diagrams).
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U#*. #4(,-'
L"/. .<& 3*6*. &% P&ID/ #&.
I#/.'4(-#. 3-/*6#".*&#
0MM - GGGG + OOGGA/B
S-'*"! #& /."'.*#6 %'&( P01Q %&' -"18 P&ID/
Example: 34AP.A 0101
Where:
34 is unit number
A is type of analysis point
01 is P & D number
01 is serial number
Example : )** - S+ - ,,--
W.ere/ )** : 0nit 1o
+ : T2pe of sample point
,, : P3&' 1o
-- : Serial 1o

14.0 P'-//4'- '-!*-% ;"!;- #4(,-'*#6
Same as for instruments
Example:
On data sheet : 34 PSV XX01 (XX = P&D number)
On PD: PSV XX01
Example of PS4 numbering:
A/B B O#- PSD .& '-("*# "/ /."#3,9
15.0 S"%-.9 R-1&((-#3".*&#/
PSM (Process Safety management) regulations (e.g. OSHA 1910.119) refer to the need of using
good engineering practices (GEPs).
A GEP is a generally recognised and acceptable way of accomplishing a technical goal.
n the VPP (Voluntary Protection Program) Participant's Association Conference, Sept. 1995, OSHA
for instance indicated that GEPs published by AP, ACHE are sources of GEPs. This is also
outlined in the Appendix C to regulation 1910.119 : ' Compliance guidelines and Recommendations
for Process Safety management'.
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U#*. #4(,-'
PSD NUMB)R
I#/.'4(-#. 3-/*6#".*&#
0MM - PSD + OOGG A/B
P&ID/ #&.
t is the duty and responsibility of the refiner in order to protect the safety of its employees and
public make sure that GEPs are incorporated in the design of the plant.
The following safety recommendations are derived from the use of GEPs.
15.1 SIS >S"%-.9 I#/.'4(-#.-3 S9/.-(/?
"? SIS '-!".-3 .& 18-(*/.'9
n case of risk due to the chemistry of the reaction, Licensor advises the SL (Safety ntegrity
Level) in order to specify the corresponding SS
For this project i.e. Units 85/86/87, 034/035/036/037 the SS for chemistry risk is not applicable (as
per SA 584 or EC 61 508)
,? SIS #&. '-!".-3 .& 18-(*/.'9
The SL and the corresponding SS connected to equipment protection will be the responsibility of
the LSTK contractor. Licensor has shown on P&D a simple configuration of the SS
15. F"/. 3-2'-//4'*/".*&#
Fire case: Normally considered for the reaction sections operating at a pressure < 17 barg,
the depressurisation shall be done normally through HC from DCS. Also, a push button shall
be provided at field DCS at grade level with protection from spurious operation. Duration of
depressurization : 15 minutes.
Fast depressurization shall be done in two steps i.e. 7 kg/cm
2
per minute and 21 kg/cm
2
per
minute depending on the requirement.
For vessel with thickness lower than 25 mm or for vessel with light hydrocarbons (C
3
to C
5
) the depressurization shall be done to 7 barg (or 50 per cent of the vessel design
pressure if lower), duration : 15 minutes.
Runaway case : Considered for the possibility of runaway in the reactor, Axens will
specify depressurization device and the activation in accordance with the SL level. The SS
corresponding to this depressurization shall be in accordance with the SL level already
specified for the risk of runaway.
15.3 S84.3&<# &% 24(2/ ,9 !&< !-;-! *# 42/.'-"( ;-//-!
Licensor will specify automatic shutdown of the pumps by low level in upstream vessel for:
feed pumps with high delta P< 70 barg
Sealless pumps
For all other cases, LSTK Contractor will check with the pump's vendor if automatic shutdown is
required.
15.4 M*#*(4( %!&< ,92"// &# 1-#.'*%46"! 24(2/ <*.8 %!&< 1&#.'&!
Licensor will indicate a minimum flow bypass with flow control for centrifugal pumps for the
following cases:
high differential pressure multistage pumps (water differential head <360m)
large pumps with driver power > 180 kW
for process reason (turndown), flow rate > 30% of max flow rate
the control valve at the pump discharge fails in close position
The pump data sheet will specify the process flow without provision for the minimum flow which
will be specified by the pump's vendor.
15.5 A4.&(".*1 */&!".*&# ;"!;-/ ,-.<--# 2'&1-// ;-//-! "#3 24(2/
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Licensor has considered automatic isolation valves for:
an inventory of the process vessel over 8 m of light ends (LPG)
an inventory of the process vessel over 8 m and with a product above its autoignition
temperature or at a temperature above 250C
an inventory of the process vessel above 16 m and a flammable product.
15.6 @*68 !-;-! *# %--3 3'4( &' '-"1.*&# /-1.*&# /-2"'".&' 3'4(
To avoid overfilling, an independent high high level alarm via LT (LAH LLHH) to be has been
specified
15.7 P'-;-#.*&# &% ,"1$ %!&< &;-'2'-//4'-
Following devices will be considered at the pump discharge:
P > 40 barg: one check valve
40 > P > 80 barg: two check valves of different conception
P < 80 barg: two check valves of different conception plus an automatic shut-off valve in case
of reverse flow
15.: B"1$ %!&< 2'-;-#.*&# &% " %*'-3 8-".-'
n case of tube rupture in a fired heater and to minimise the consequences of a fire, check valve
or motor operated isolation valve will be installed at the outlet of a fired heater in the following
cases:
heater operation at high pressure < 70 barg
reboiling heater of a large a column with high gas inventory
15.9 S-"!/ &# 24(2/
Dual mechanical seals (pressurised or unpressurised according to process considerations) shall be
considered in the following cases:
LPG
Hydrocarbons above their auto ignition temperature or at a temperature > 250C
Toxic or carcinogenic fluid (HCl, benzene etc.)
High pressure pumps (> 50 barg)
15.10 C&#/.'"*#./ 34- .& 8"#3!*#6 &% ,-#A-#-

Due to the known carcinogenity of benzene, the following provisions shall be taken when
applicable:
For all streams containing 1% weight or more of benzene and 25% weight or more of C7 through
C9 aromatics, the following shall apply:
closed sampling
closed aromatics collection system with an underground drum receiving all drains of the
corresponding process part
pumps will be equipped with dual mechanical seals or pumps will be sealless if operating
conditions allow it
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detailed engineering of valves, flanges and joints shall be such as to satisfy the requirements
of TWA (Time-Weighted Average) exposure limit of 1 ppm for an 8 hour workday (OSHA's
requirement)
All water streams saturated with aromatics shall be sent to a suitable processing or treating facility
in order to minimise aromatic emissions to the environment.
15.11 C&#/.'"*#. 34- .& /.'-"(/ <*.8 8*68 1&#.-#. &% @S
When a process unit contains streams with high H2S content, the following precautions shall be
taken into account to avoid release of H2S to atmosphere:
Sample connections will be with a closed loop
Draining of pressurised liquids which could release H2S after expansion shall be sent to a
dedicated system:
underground drum for hydrocarbons
sour water treatment system for acid waters
LSTK Contractor shall provide adequate H2S detection system in the process unit.
15.1 F&!!&<*#6 "33*.*&#"! /"%-.9 '-74*'-(-#./ .& ,- 1&(2!*-3 <*.8 ,9 LSTE 1&#.'"1.&'B
Push buttons for stopping critical motors, if identified, shall be provided at a safe location,
away from the fire-zone of the respective motors and also in control room. This is in addition
to usual start stop push buttons provided for such motors. All feed and reflux pumps are to be
treated as critical.
Air cooler stop push button to be located at grade level in addition to start / stop button near
the fan at platform.
Suction / discharge valves and suction filter should be close to the pump in order to avoid
hydrocarbon wastage during filter cleaning and pump maintenance.
Flare line isolation valve at unit battery limits should be installed only in the horizontal line with
stem in vertical downward position to avoid free fall of gate and blockage of flare system.
Each flare header leaving a unit shall be provided with such isolation valves to facilitate
maintenance of flare piping and pressure relief valves within the unit.
Dip hatch for the tanks should have the aluminum guide extended upto top surface of the
tanks (Short guides may cause serious hazards). Dip hatch cover should be ensured with a
rubber gasket for non sparking.
Harmful effects of liquids / gases handled in the plant on FRLS cables / PVC cables / XLPE
cables / Aluminum / Copper / Brass to be considered and suitable precautions to be taken.
Any specific recommendation for lightning protection and protection against static charge.
Emergency lights in plant area and control room shall be provided.
Communication system to cover all areas of plants and offsites shall be provided (field
intercoms and talk-back paging systems, closed circuit cameras and TVs)
Pumps shall have a DCS stop facility in central control room along with running lamp
indication
Emergency trips if specified for HT motor will be wired directly to switch gear in addition to
control room.
Double isolation valves with spectacle blind are to be provided at each battery limit in all the
process lines.
All the valves are to be provided at approachable height with suitable platforms ensuring
accessibility, safety and ease of operation.
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Double isolation valves shall be provided on all vents and drains for high pressure service with
end blind.
16.0 )#;*'&#(-#."! R-74*'-(-#./
16.1 C"/.- C".-'
Process waste water: To be routed to Oily Water Sewer(OWS) by Gravity.
Boiler blow-down: To be routed to storm water sewer after cooling to around 45-50 deg C
16. B!&< 3&<# "#3 F!"'-
Process drain will be routed to either OWS or Closed Blow-Down (CBD) vessel inside battery
limit.
All hydrocarbon / combustible gases and vapors shall be relieved to the flare.
Bleed from double block and bleed to be vented to safe location.
Liquid relief system shall be separate from vapour relief system to CBD.
n case two phase is envisaged in the relief system, provide knock out pot at the battery limit.
Knock out Pot will be designed by other on bases defined by Licensor.
Flare header back pressure at battery limit.
Normal Max
HC flare kg/cmg 0.7 1.7
Acid flare kg/cmg 0.5 1.5
For reference for gaseous emission please refer to the attached file on Expert
Committee report.
&xpert Committee
MeetingMo&'("""
Gaseous emission shall be within the following stipulations:

Particulate matter, max 150 mg/NM
Carbon monoxide, max 500 PPM volume
NOX, PPM vol, max 210 for FO w/o preheat
240 for FO with preheat
NOX, PPM vol, max 50 for FG w/o preheat
80 for FG with preheat
SOx emission To be reported
Only low NOx burners to be provided for NOx emission control. However, the achievable emission
level is to be indicated.
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16.3 S"%-.9 D"!;-/
All drains of safety valves shall be connected to the Blow down vessel. All safety valves shall
normally have Carbon steel Body with stainless steel trim. Other trim material can be considered
if any particular service demands a different material. Bronze or Cast iron bodied valves shall not
be used.
16.4 N&*/- L-;-!
Maximum noise level generated by any new item of equipment shall be less than 85 dB(A) at a
distance of 1 m.
16.5 O2-# &' C!&/-3 D'"*#"6- S9/.-(/
T<& .92- &% CBD /9/.-( <*!! ,- -(2!&9--3.
CBD1 B F&' "!! @C !*74*3 3'"*#
CBD B F&' "!! 18-(*1"! "#3 C8!&'*3- /.'-"( <*.8 1"4/.*1 !*#- %&' #-4.'"!*A".*&#.
The following closed drainage systems shall be provided at battery limit:
Oily sewer system (CBD) gathering all drainage contaminated with hydrocarbon oil. 3
systems are provided for this project:
Oily sewer system containing chlorides (CBD-CL)
Closed Amine sewer system
Contaminated rain water from SBL area shall be routed to underground sewers system
(CRWS).
Oily water (OWS) is an open system, but effluent is carried through underground piping
network.
16.6 R-74*'-(-#./ &# 18!&'*3- -(*//*&#/
No chloride shall be burnt at the non acid flare or in furnace firing system
somerization reactions are catalyzed on a fixed bed catalyst (chlorinated alumina catalyst). A
continuous injection of C2Cl4 is made up to maintain an optimum HCl concentration in
reactors.
Licensor's design is based on following arrangement in order to ensure that no chloride is sent
to non acid flare:
Discharge of isomerisation reactor PSV to HC acid flare
Discharge of Stabilizer PSV to HC acid flare
Discharge of Caustic Scrubber PSV to HC (non acid) flare
Depressurization line of reactors discharges to stabilizer
Depressurization line of stabilizer discharges to scrubber
Please elaborate
Please refer to Process Package Page No -37
5'isc.arge of c.loride to flare s.all be minimi6ed
Discharge of chloride to flare shall be minimized for environmental reasons but also because HCl is corrosive
when in presence of traces of water.
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somerization reactions are catalyzed on a fixed bed catalyst (Chlorinated alumina catalyst). A continuous
injection of C2Cl4 is made up to maintain an optimum HCl concentration in the reactors.
AXENS design is based on following arrangement in order to ensure that discharge of chloride to flare is
minimized:
The Caustic Scrubber has been designed in order to ensure full neutralization of the gas effluent that
contains HCl.
Discharge of the isomerization reactor PSVs and stabilizer PSV are connected to the flare. However unit has
been carefully designed, in order to minimize the PSV discharge risks for these relief valves (redundant
PSHH at stabilizer overhead, dedicated PSV on liquid feed to isomerization reactors, from feed pump
discharge to feed surge drum).
Depressurization line at stabilizer is connected to the flare. Depressurization is designed for fire
case and temperature excursions in reactors
The Caustic Scrubber has been designed in order to insure neutralisation of gas effluent,
containing HC1, based on maximum stabilizer offgas flow rate (this flow rate is maximized when
LPG recovery section s bypassed. This system will insure that all gas effluent containing HCl will
be neutralised, before sending to (non acid) flare system in case of upset on the reaction or
stabilizer sections.
Moreover, Stabilizer and somerization reactors have been located (see Preliminary Plot Plan ) in
different fire zones, in order to avoid cumulative fire cases on both sections.
No Chloride shall be sent to drainage systems
All drains (control valves, pumps, block valves) containing hydrocarbon and HCl must be
connected to a dedicated header (CBD3). Effluents shall be routed to a dedicated drum
full of caustic that will neutralize HCl.
Chloride in final products (somerate LPG)
n case of Stabilizer or LPG recovery unit upset, some chlorides may contaminate the
final products. n order to reduce the risk of contamination of final products with chlorides,
Chloride guard beds have been installed on isomerate and LPG.
These guard beds have been designed to cover the worst upset cases.
The chloride maximum content in the final products shall be below 0.5 ppm wt.
Fire-safe area for C2Cl4
C2Cl4 is not flammable. Fire around C2Cl4 storage can only result from an external
process fire.
C2Cl4 storage area should consequently be located outside and preferably upwind of the
process area that can be affected by a fire.
Furthermore, C2Cl4 storage area should be surrounded by a small wall to contain possible
spills of C2Cl4 (to be adsorbed by an inert material). This wall will also impede
propagation of a process fire towards C2Cl4storage tank. The location of this wall can be
located at 30 meters of the drainage point of the paved process area, where a process fire
can occur. n these conditions the C2Cl4 storage area may be considered in a fire safe
area. This does not exclude the fact that C2Cl4 storage should be reached by water for fire
fighting equipment, to cool it during an external fire.
17.0 S.-"( & C&#3-#/".- S9/.-(
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All steam consuming equipment including heat exchangers shall be thermally rated based on
NORMAL steam conditions. However, LSTK contractor to verify the design for minimum
steam conditions also.
NORMAL steam conditions shall be used for operating utility estimates, heat and material
balances and battery limit connectivities.
Condensate recovery will be maximized from process consumers. n order to minimize the
liquid effluent generation from the units, all condensate shall be collected and effort shall be
made to minimize condensate drain to OWS / storm water sewer.
Condensate from steam trap discharge and steam coils in tanks shall be recovered by
connecting these consumers to condensate header.
The MHP condensate is flashed to generate MP condensate & MP steam.
MP condensate & LP condensate shall be routed to battery limit separately.
1:.0 U.*!*.9 S.".*&#/, S"%-.9 S8&<-'/ & )9- <"/8
Drinking water is to be used for eyewash and safety showers, which are to be located
strategically in unit.
LP steam, plant air and service water outlets shall be furnished at utility stations.
A dedicated LP steam header (parallel to main header) shall be provided for supplying LP
steam to only Utility stations.
All utility outlets at utility stations are to terminate with a hose connection of minimum size 1.
Assuming a maximum hose length of 25m, utility stations for LP steam, plant air and service
water shall be provided at the following locations :
At grade to serve all equipment within maximum 25m radius
At all platforms of structures
At those platforms of self-standing towers
where man-holes/hand holes are located.
Top and bottom platform
Every alternate platform
At top platforms of drums located at the grade
Near the pumping stations and tanks
Fired Heater Structure One LP steam point at every platform.
Technological Platform two (minimum) per platform level including grade, beyond 15 m
length/width, provide additional utility point.
Reactor Structure Same a Technological Platform
Compressor House
Three stations at compressor level
Two stations at grade level
Air Cooler Maintenance Platform
Two stations minimum below plenum
Project Name
D10169B904LI1001
Sheet / of
56/6
Revision
00
19.0 IBR R-74*'-(-#.
Steam generators/steam users shall meet BR regulations. Major BR requirements are
summarised below:
Vessels : Any closed vessel exceeding 22.75 liters (five gallons) in capacity which is used
exclusively for generating steam under pressure and include any mounting or other fittings
attached to such vessels, which is wholly or partly under pressure when steam is shut-off.
Piping : Any pipe through which steam passes and if:
- Steam system mechanical design pressure exceeds 3.5 kg/cm
2
(g) or
- Pipe size exceeds 254 mm internal diameter
The following are not in BR scope
- Steam Tracing
- Heating coils
- Heating tubes in tanks
- Steam jackets
All steam users (heat exchangers, vessels, condensate pots etc.) where condensate is
flashed to atmospheric pressure i.e. downstream is not connected to BR system are not
under BR and BR specification break is down at last isolation valve upstream of
equipment.
All steam users where downstream piping is connected to BR i.e. condensate is flashed to
generate BR steam are covered under BR.
BR starts from BFW pump discharge.
Safety valves / Relief valves on BR system will not have isolation valve.
Material Certificate
All items which are part of steam piping i.e. pipes, valves, fittings, traps, safety valves
must have material certificates, countersigned by the local boiler inspectors.
For imported items Certificates issued by an authority empowered by Central Boilers
Board (As per BR) or under the law in force in a foreign country in respect of boilers
manufactured in that country may be accepted. n case of imported boiler BR items, prior
advice of Director of Boiler, West Bengal State shall be obtained.
All drawings coming under preview of BR shall be certified by Local Boiler nspector.
0.0 P!&. P!"#
Plot Plan #equirements
somerization reactor 037-RB-001, 037-RB-002 and 037-RB-003 shall not be located in the
fire zone of stabilizer 037-CC-001.
somerization regeneration section shall be located as close as possible to dryers section.
C
)
Cl
*
drum 037-M-001 shall be located in a fire safe area as defined hereafter.
Project Name
D10169B904LI1001
Sheet / of
57/6
Revision
00
C
)
Cl
*
is not flammable. Fire around C
)
Cl
*
storage can only result from an external process fire.
C
)
Cl
*
storage area should consequently be located outside and preferably upwind of the process
area that can be affected by a fire.
Furthermore, C
)
Cl
*
storage area should be surrounded by a small wall to contain possible spills of
C
)
Cl
*
(to be adsorbed by an inert material).
This wall will also impede propagation of a process fire towards C
)
Cl
*
storage tank. The location of
this wall can be located at 30 meters from the drainage point of the paved process area where a
process fire can occur.
n these conditions, the C
)
Cl
*
storage area may be considered in a fire safe area. This does not
exclude the fact that C
)
Cl
*
storage should be reached by water for fire fighting equipment to cool it
down during an external fire.
1.0 S2-1*"! D-/*6# R-74*'-(-#./
n case of motor operated valves, (critical service) indication of valves position should be
available in the control room. Shut-down valves should be operable from the control room.
The blow-down from stream drum if any should be routed to storm water sewer after cooling it.
Use of blow-down from the steam generators of Hydrogen Unit to the extent it is possible
within the unit. Excess quantity, if any, should be drained to storm water sewer after flashing
and cooling in a blow-down drum.
nstrument and electrical cables shall be above ground and under ground respectively inside
the unit battery limit.
General HAZOP analyses should be considered in the design of the unit.
Furnace with 8-10% excess air.
The following non-standard line sizes shall not be used unless approved by PMC-, 2,
3, 5, 7, 9
The following guidelines for minimum line / nozzle sizes shall be applied
2 NB Minimum nozzle size for vessels, tanks and heat exchangers
2 NB Minimum process (hydrocarbon) line size
1 NB Minimum utility line size
NB Minimum bridle drain or pump casing vent / drain
NB Minimum chemical injection line size. Tubing size to be 10 mm
1 NB Minimum on pipe rack
4 NB Minimum for underground lines
The following roughness coefficients shall be used unless stated otherwise
Material Roughness (inches)
Carbon Steel 0.0018
Flare / Vent headers (Heavily corroded) 0.018
Stainless Steel Pipe 0.001
Glass Reinforced Epoxy Pipe 0.0001
A margin of at least 0.6 m between NPSH available and required NPSH shall be applied. n
case of requirement of lower difference, concurrence of PMC/OC is to be obtained.
Project Name
D10169B904LI1001
Sheet / of
5:/6
Revision
00
NPSH test shall be performed where ever the difference between NPSH available and NPSH
required is less than 0.9 m.
Vents & Drains in Heat Exchangers
Provide 1 NB x 300# (min.) flanged vents and drains at high and low points respectively on
all heat exchangers. All vents and drains shall be valved and blanked off.
Exchangers in total condensing service shall be provided 2 vent connection at the opposite
end of the shell inlet.
Sizes of multi-purpose connections and pressure gauge connections on exchanger nozzles
shall be 1 NB x 300# (min.) for below 12 nozzles and 2 NB x 300# (min.) for 12 " & above
nozzles.
Vents & Drains in Piping
Pipe Size in nches Vent Size, inches Drain Size, nches
4 & below
6 to 10 1
12 & above 1 1
Vents & Drains in Air Coolers
On air coolers, one no. 2 vent shall be provided at the highest point on the inlet header and
one no. 2 drain at the lowest point in the outlet header. These connections shall be valved
and blanked off.
Vents & Drains in Pump Casing
For non-volatile services, casing vents and pump drains shall be piped into a sewer or closed
drain system.
For volatile services, casing vents and drains are to be piped to the relief header and sewers.
Double Block Valves Philosophy
Double block valves shall be provided for the following conditions
For cases where cross contamination can't be tolerated.
For vents and drains in ANS Class 600 rating and above
For drains containing C5 or lighter hydrocarbons. n this case, the double block valves must
be minimum of 1000 mm straight pipe apart.
Where high pressure (above ANS 300# rating) is likely to be removed on the run; e.g. spare
machinery or equipment
For gas stream > 100 bar g or liquid systems > 60 bar g or gas/liquids which are potentially
toxic.
For the equipment, which may be opened for maintenance on the run e.g. filters.
Fire proofing shall be carried out as per OSD-164.
Note:
1. PMC should develop a feed scheme for the MSQ Unit as per discussion with OCL as there will be
some variation from what has been proposed by Axens in the Process Package.
Project Name
D10169B904LI1001
Sheet / of
59/6
Revision
00
2. Specifying all speciality items identified or implied in process package such as strainers, filters, steam
traps, flame arrestors, special purpose valves, heat exchanger isolation valves with blinding provision,
nstrument tapping isolation valve, pump/heat exchanger drains to CBD/OWS, control valve upstream
& downstream side bleeders, sample points in CW return line, feed & product rundown lines.
3. nstallation of Gas Detectors as per OSD/ CCTV/Pegging System/ Fire Water & Foam Network as per
OSD, Fire Alarms etc for safety of the equipments & the units.
4. Sight glass may be provided in the drain to CBD lines. CBD/OWS system may be designed as per
advice of PMC/Owner.
5. Flare & Fuel gas (with KODs) network is to be developed. All field nstruments shall be suitable for
zone 1, C T3 shall be certified by a statutory body with gas grouping as per requirement.
6. Steam silencers with proper design are to be provided.
7. Automation (Sequance Logic Diagramfor pumps & dryer operation, will be developed and
implemented.
8. For reciprocating compressors, 2out of 3 voting system to be incorporated for important interlocks such
as vibration interlock.
9. Provision of DM water to be kept instead of Cooling Water for Compressor seal, Gear Box, Cylinder
jacket cooling etc.
10. Critical rotary equipment running signal to be provided at DCS
11. Utility connections to all Heat Exchangers/ Vessels/ Columns are to be provided for flushing. Steam
flushing in somerisation section is to be avoided..
12. Back flushing facility in water side in all water coolers to be provided.
13. Condensate Recovery network is to be developed.
a.Process assistance in development of PRDS and Steam de-superheater for 3 Bar steam from 10 Bar
steam
b.Steam (MP/P/LP)/ BFW/DM Water/ nstrument Air/Plant Air/ Cooling Water/ Service Water/ Drinking
Water/ Hydrogen gas/ Nitrogen Gas distribution networks are to be developed.
c. LCENSOR has recommended MOCs in equipment datasheet. However, the MOCs of all critical
equipments which are subjected to corrosive service are to be cross checked and confirmed.
14. Packages e.g Compressor with interstage KOD/s & ntercooler/s and other associated facilities like lube
oil system, cooling system, instrumentation & control philosophy with selection of proper unloading
technology, start-up ejector system, HDT fired heater with auxiliary facilities inclusive passivation facility
for heater tubes & flue gas analyzer, sulfiding agen (DMDS) injection & passivation package, corrosion
inhibitor (CHMEC 1044) injection package, chloriding agent (C2CL4) injection package, caustic solution
preparation package, dryer package, electrical heater with auxiliary facilities, steam condensate pots &
accessories, analyzer package, Ammonia & HCL dosing package etc Process interlocks/instrumentation
linked to central control room for operator interface are to be indicated.
15. Utility connection to be provided to Vessels/ Columns for flushing. Steam flushing in somerisation
section is to be avoided. Vessel isolation system, drain points and utility connections are to be shown in
upgraded P&Ds.
16. All Heat Exchangers isolation system, drains at both ends i.e tube side as well as shell side & utility
connections are to be provided in upgraded P&Ds.
Project Name
D10169B904LI1001
Sheet / of
60/6
Revision
00
17. Analyzer package for analyzers if required like Oxygen analysers e.g Orbisphere 410.
18. Flare Load Summary: PMC shall check the adequacy of flare header.
19. Details for package items like Feed Filter, Compressors Package, Fired Heater Package, Electric Heater
Package, Sulfiding Agent Dosing Package, Corrosion nhibitor Dosing Package, Chloriding Agent Dosing
Package, Dryer Package, Steam Condensate Recovery Package including condensate pots, Analyzer
Package, Caustic Solution Preparation Package, Ammonia & HCL Dosing Package Prefilter Coalescer,
Ejector, etc to be developed by PMC/LSTK.
Project Name
D10169B904LI1001
Sheet / of
61/6
Revision
00
I#3-= &% R-;*/*&#/
Rev. Sheet Prepared, revised Checked Approved Remark, kind of revision
Name Date Name Date Name Date Status
00
ALL CS 24.12.07 TSM 26.12.07 SMK 26.12.07 IFC ssued for Comments
Project Name
D10169B904LI1001
Sheet / of
6/6
Revision
00

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00 ALL CS 24.12.07 TSM 26.12.07 SMK 26.12.

07 IFC ssued for Comments

F). However, serious corrosion,

15.10 C&#/.'"#./ 34- .& 8"#3!#6 &% ,-#A-#-

Gaseous emission shall be within the following stipulations:

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