3006-5001-BP11601 A 0010 PDF

REFINING MAJOR PROJECTS GENERAL MANAGEMENT
PROJECT: RPLC DEEP CONVERSION PDVSA DOC. NO.

SUBPROJECT: GENERAL 3006-5001-BP11601
UNIT: GENERAL (U-00) CONFEED DOC. NO.
PHASE: BASIC ENGINEERING S-000-1222-0021
DISCIPLINE: PROCESS REV. A
DATE
TITLE: DETERMINATION OF MECHANICAL DESIGN CONDITIONS
PDVSA PROJECT NO.: 3006; CONFEED JOB CODE: 0-4675-20-0000 05 09 07
CONFEED PDVSA PDVSA

TOTAL
REV. DATE ISSUE PURPOSE / DESCRIPTION OF CHANGE PREP’D/CHK’D CHECKED APPROVED
PAGES
/APR’D BY BY BY
A 05-09-07 For Approval / First Issue 13 K.A./T.W./T.W. H. D.
CONFEED PDVSA CHECKED BY PDVSA APPROVED BY
PREPARED BY: Kazuo Akimoto

CHECKED BY: Tetsuya Watanabe SIGNATURE SIGNATURE
APPROVED BY: Tetsuya Watanabe
NAME: NAME: Humberto Diaz
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RPLC DEEP CONVERSION PROJECT
DETERMINATION OF MECHANICAL DESIGN CONDITIONS
UNIT 00
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Contents
1 INTRODUCTION ................................................................................................................................... 5
2 DEFINITIONS ........................................................................................................................................ 5
2.1 Operating Pressure and Temperature ............................................................................................... 5
2.2 Maximum Operating Pressure............................................................................................................ 5
2.3 Maximum Operating Temperature ..................................................................................................... 5
2.4 Minimum Operating Temperature ...................................................................................................... 5
2.5 Design Internal Pressure .................................................................................................................... 6
2.6 Design External Pressure ................................................................................................................... 6
2.7 Design Temperature ............................................................................................................................ 6
2.8 Short Term Piping Design Condition................................................................................................. 6
3 DESIGN PRESSURE ............................................................................................................................ 7
3.1 Design Internal Pressure: General..................................................................................................... 7
3.2 Design External Pressure ................................................................................................................... 7
3.3 Steam-out Condition ........................................................................................................................... 8
3.4 Pump Suction Line .............................................................................................................................. 8
3.5 Centrifugal Pump Discharge Circuit.................................................................................................. 8
3.6 Positive Displacement Type Pump Discharge.................................................................................. 8
3.7 Compressor Suction ........................................................................................................................... 9
3.8 Centrifugal Compressor Discharge ................................................................................................... 9
3.9 Reciprocating Compressor Discharge.............................................................................................. 9
3.10 Reactor Recycle Gas Loop ................................................................................................................. 9
3.11 Shell and Tube Heat Exchanger ......................................................................................................... 9
3.12 Piping at Low Operating Pressure................................................................................................... 10
3.13 Atmospheric Storage Tank ............................................................................................................... 10
4 DESIGN TEMPERATURE .................................................................................................................. 10
4.1 Design Maximum Temperature ........................................................................................................ 10
4.2 Design Minimum Temperature ..........................................................................................................11
4.3 Pressure Relief Valve and Its Tail Pipe .............................................................................................11
4.4 Flare Header ........................................................................................................................................11
_ __4.5 Steam Traced Pipe..............................................................................................................................11
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4.6 Jacketed Pipe .................................................................................................................................... 12

5 DESIGN CONDITIONS FOR UTILITY DISTRIBUTION SYSTEM ..................................................... 12
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1 INTRODUCTION
This document covers the general design criteria for the determination of mechanical design
conditions for the equipment in RPLC Deep Conversion Project.
This document summarizes the Owner’s requirements stipulated in following specifications:
(1) 3006-5001-BG14001 Basic Engineering Design Guideline
(2) MDP-01-DP-01 Process Design Manual, Design Criteria, Temperature and Pressure Design
(3) 3006-5001-BM11504 Basis of Design: Pressure Vessels
(4) 3006-5001-BM11511 Basis of Design: Piping
It is noted that any details not covered in this procedure should refer the relevant part of the PDVSA
Standard MDP-01-DP-01.
2 DEFINITIONS
2.1 Operating Pressure and Temperature
The operating pressure and temperature is the one which exists during any modes in normal
operation.
The operating temperature should incorporate the normal operation fluctuation, such as reactor
start-of-run and end-of-run operation, change on heat recovery in different mode of operation, etc.
The highest normal operating temperature is used to evaluate the corrosion rate for material
selection.
2.2 Maximum Operating Pressure

The maximum operating pressure is the highest expected operating pressure considering the
flexibility of control. If the control flexibility is not exactly defined, where it seems to be likely in many
cases, the maximum operating pressure could be assumed equal to the operating pressure.
2.3 Maximum Operating Temperature

The maximum operating temperature is the highest expected temperature of the fluid due to
expected deviations from the normal operation. These deviations include start-up, shutdown, drying,
regeneration, decoking, etc.
If the maximum operating temperature is not defined clearly, the maximum operating temperature
could be assumed equal to the highest normal operating temperature.
2.4 Minimum Operating Temperature

The minimum operating temperature is the lowest expected operating temperature deviating from
the normal operation considering the control flexibility, and the alternative modes of operation, such
as depressuring, start-up, shutdown, etc.
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2.5 Design Internal Pressure

The design internal pressure is the gauge pressure at the top of equipment and is used as the basis
to determine the minimum thickness of equipment part at the most severe coincident temperature.
The design internal pressure does not include the liquid static and the pressure drop across trays or
vessel internals, as they will be added by the mechanical detail engineering based on the
information given on process specification.
2.6 Design External Pressure

The design external pressure should be considered for the equipment which is required to operate
at sub-atmospheric internal pressure during normal operation or is subject to sub-atmospheric
internal pressure at any modes of operation, including evacuation, start-up and shutdown.
Steaming-out operation is considered as a cause of sub-atmospheric internal pressure even if the
adequate operating procedures are known to every operator so as to prevent the equipment from
falling into vacuum conditions.
The design external pressure is used to determine the minimum thickness of equipment at the
coincident temperature.
2.7 Design Temperature

The design temperature is the highest and lowest metal temperature at which equipment may be
subject to the most severe coincident pressure and is used to determine the minimum thickness of
equipment.
The design temperature is used for material selection to prevent hydrogen attack, etc.
2.8 Short Term Piping Design Condition

Any increase in pressure and/or temperature during emergency or upset condition may be regarded
as the short term design condition where the allowance for variation stipulated in ASME B31.3 could
be applied.
The short term design conditions are defined as below as per ASME B31.3.
Operating Conditions Continuous operating Total operating period Permissible excess in

period at any one time per year pressure rating or
allowable stress for
pressure rating
Normal Operation Longer than 50 hours Longer than 500 -
hours
Intermediate Term 10 – 50 hours 100 – 500 hours 20%
Short Term 0 – 10 hours 0 – 100 hours 33%
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3 DESIGN PRESSURE
It is noted that the statements below is general philosophy and unit specific requirement should be
examined individually.
Any deviations from general philosophy which may need to be considered for specific equipment
item should be consulted with the Owner.
3.1 Design Internal Pressure: General

Design internal pressure should generally be established from the maximum operating pressure
(MOP), plus a margin summarized below:
• If MOP≦247 psig, MOP + 25 psi
• If 247<MOP≦1450 psig, MOP x 110%
• If MOP>1450 psig, MOP + 145 psi
The margin shown above may be increased if the process design anticipates higher pressure
surges.
The criteria above might not be applicable for the equipment located in HDH/SHP reactor loop.
Licensor’s design philosophy would be applied instead.
The design pressure should, in principle, be rounded up by every 5 psi.
The minimum design internal pressure for a pressure vessel should be 50 psig, or the flare design
pressure if the vessel is connected to flare, whichever is greater. The minimum design internal
pressure is standardized to be 50 psig, and the use of 51 psig should be avoided for the minimum
design pressure.
If the vessel is open to atmosphere, a vessel should be designed for atmospheric pressure, and is
not necessary to be designed at 50 psig. For the vessels which are not subject to 50 psig minimum
design pressure, but operates considerably higher than atmospheric pressure, the design pressure
should be the highest value of the operating pressure plus 10% or plus 15 psi.
3.2 Design External Pressure

Vessels required to operate at sub-atmospheric internal pressure should be designed for full
vacuum. Vessels subject to steam out, partial vacuum during start-up, shutdown, or regeneration
evacuation should also be designed for full vacuum.
The following equipment and piping should also be designed for full vacuum conditions:
- Services generating steam condensing during normal operation, such as Amine Regenerator,
Sour Water Stripper, Waste Heat Boiler, Steam Generator, Deaerator, etc.
- Vessels which normally operate liquid full and that can be blocked-in and cooled down or
drained out simultaneously.
- Fractionators and associated equipment that can undergo a vacuum through the loss of heat
input. The vapor pressure of fluid contained in fractionation column should be carefully
_ __ examined if it becomes vacuum condition or not.

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Full vacuum design should be considered with the coincident temperature.

All pressure vessels which are not subject to steam out operation should be designed for a minimum
external pressure of 2.5 psi at 100 oF (maximum ambient temperature).
3.3 Steam-out Condition

When a vessel is subject to the steam-out operation, the steam-out condition of “50 psig @ 300 oF”
and “FV @ 300 oF” should be specified together with the design internal pressure conditions.
3.4 Pump Suction Line

The design pressure in pump suction lines should be evaluated as below:
Design pressure =
Design pressure of suction vessel +
Pressure losses thru vessel internals +
Pump suction liquid head at vessel HLL
(Note: This definition is same with the one for pump maximum suction head.)
However, for the section up to first valve from the centrifugal pump, should be set equal to the
design pressure for pump discharge circuit, unless this section is protected by dedicated pressure
relief valve.
3.5 Centrifugal Pump Discharge Circuit

Any equipment located in pump discharge circuit and not protected by a pressure relief valve should
be designed based on the pump shutoff head under highest suction head conditions. In this case,
the design pressure should be:
Design pressure =
Design pressure of suction vessel +
Pressure losses thru vessel internals +
Pump suction liquid head at vessel HLL +
Pump shutoff head
If the actual performance of pump is not available, pump shutoff head could be assumed as 125% of
rated head. However, the pumps should be selected to meet this limitation, inclusive of all
tolerances.
For the pumps with turbine drivers, the pump shutoff head is set to the one generated at turbine
maximum continuous speed which is normally specified at 105% of speed required at pump rated
condition. The pump shutoff head is thus 125% x (1.05)^2 = 138% of pump rated head.
3.6 Positive Displacement Type Pump Discharge

The design pressure of the equipment located on the discharge side of positive displacement type
pump is defined equal to the set pressure of pressure relief valve.
_ __ The pressure relief valve is normally set at 110 % of the rated discharge pressure, or 25 psi higher
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3.7 Compressor Suction

Any equipment located downstream of spillback recycle point should preferably be designed for
settling out pressure which develops when the compressor stops and the gas flows backward from
compressor discharge.
CONFEED is to check the design pressure at compressor suction system. If it is found that
Licensor/Designer uses different criteria than stated above, CONFEED is to report such finding to
PDVSA.
3.8 Centrifugal Compressor Discharge

The design pressure of the equipment located on the discharge side of centrifugal compressor is
defined as the highest pressure which can exist in the compressor under the most severe operating
conditions. It will be the maximum suction pressure to be encountered, plus the maximum
differential pressure that the compressor is able to develop in the system when operating under the
most severe combination of conditions.
However, if the higher design pressure occurs only in rare combination of operating conditions, it
may be advantageous to limit the design pressure to a lower pressure by installing pressure relief
valve.
3.9 Reciprocating Compressor Discharge

The design pressure of reciprocating compressor discharge should have following margin on the
rated discharge pressure in accordance with API 618.
Rated Discharge Pressure Margin above Rated Discharge Pressure
Upto 150 psig 15 psi
Upto 2500 psig 10 percent
3.10 Reactor Recycle Gas Loop

The design pressure for equipment located in closed circuit where no means exist for blocking any
of the equipment component being protected from the installation of single pressure relief device
should follow the recommendation given in API 520/521. The minimum design pressure should
generally be higher than the compressor settle-out pressure.
3.11 Shell and Tube Heat Exchanger

For all shell and tube heat exchangers, not protected by the pressure relief valve for tube rapture
scenario, the lower side design pressure should be set at 10/13 of the high side design pressure.
Higher pressure rating should be applied for the exchanger only when the associated piping is
connected to the nearest pressure relief valve without any blocking devices (valves etc.) [Case A],
_ __ or between the section of first (closest) valve upstream/downstream of the exchanger when blocking
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devices are provided around the exchanger [Case B]. In either case, pressure built-up due to the
passing fluid through rupture should be evaluated and the justification should be made for installing
additional pressure relief valve or increasing pressure rating of associated piping.
For the design of high-pressure exchangers, a maximum differential pressure of 725 psi should be
considered except where otherwise recommended by Licensor/Designer or approved by Owner.
[Case A] [Case B]
High Pressure Fluid

High Pressure Fluid
High Pressure Rating High Pressure Rating
3.12 Piping at Low Operating Pressure

The design pressure for piping which is not subject to the minimum design pressure of 50 psig
should be designed for the maximum operating pressure plus 2 psi, but not less than 16 psig.
3.13 Atmospheric Storage Tank

Atmospheric storage tanks should be designed as per the API regulations.
4 DESIGN TEMPERATURE
It is noted that the statements below is general philosophy and unit specific requirement should be
examined individually.
Any deviations from general philosophy which may need to be considered for specific equipment
item should be consulted with the Owner.
4.1 Design Maximum Temperature

The design maximum temperature should not be less than the operating temperature plus a margin
of 50 oF. The design temperature should not be set below 176 oF except for the predefined design
temperatures for utility distribution systems.
If the maximum operating temperature over the normal operating temperature is anticipated, the
design temperature should be at least 18 oF above the maximum operating temperature, but not
less than 50 oF above the normal operating temperature.
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The design maximum temperature should, in principle, be rounded up by every 5 degrees, unless it
affects the material selection.
The design maximum temperature at downstream of coolers should be set equal to the normal
maximum operating temperature at upstream of coolers considering the coolant failure.
If the operating temperature exceeds 750 oF, economic alternatives may need to be studied to
reduce the margin required on the operating temperature.
4.2 Design Minimum Temperature

For the equipment operating below 32 oF, the design minimum temperature should be the minimum
operating temperature minus 9 oF.
The design minimum temperature should be rounded down to the whole number.
The effect on auto-refrigeration due to depressurization to atmospheric pressure should also be
taken into consideration. However, the design minimum temperature determined by
auto-refrigeration is to be taken without any margin on the equilibrium temperature at atmospheric
pressure. As required, the heat transfer calculation will be carried out to determine the minimum
design temperature in case of auto-refrigeration.
When the minimum design temperature is not defined, the temperature of 70 oF which is taken from
the minimum winter temperature recorded could be used as the minimum design metal temperature
(MDMT).
4.3 Pressure Relief Valve and Its Tail Pipe

The pressure relief valve and their tail pipes should have a design temperature that is determined
from the relieving conditions, except for the fire incident, taking the temperature change across relief
valves and the thermal effects in discharge piping into account.
4.4 Flare Header

The design temperature of flare header should be set at the highest relieving temperature for
plant-wise failure scenario, i.e. loss of electric power, instrument air, cooling water, but be limited to
650 oF according to the feedback from operability meeting held between PDVSA and JGC.
The highest relieving temperature taking the auto-refrigeration effect and the heat release to
ambient into account should however be specified as short term design condition. This temperature
will be used for piping thermal stress analysis.
4.5 Steam Traced Pipe

For the steam traced piping without thermo-cement design, the piping design temperature should be
determined by the normal temperature plus margin, or the maintaining temperature, whichever is
higher.
For the steam traced piping with thermo-cement design, in the case of high maintaining temperature
or high pour point service where process requirement intends to have strengthened tracing, the
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piping design temperature should be set equal to the steam saturation temperature at maximum
supply pressure.
4.6 Jacketed Pipe

The design temperature for inner pipe of jacketed piping would in general be set equal to the design
condition of heating steam. Any constraints arising from higher design temperature should however
be considered and the justification might be required lowering the design temperature.
5 DESIGN CONDITIONS FOR UTILITY DISTRIBUTION SYSTEM

The mechanical design conditions for utility distribution system should be as summarized below:
(1) Steam System

Pressure Temperature
HPS: 770 psig 750 oF
MPS: 210 psig 550 oF
MLPS: later later
LPS: 25 psig 370 oF
NOTE: Full vacuum design conditions should be considered for all steam distribution system with
the maximum operating temperature.
(2) Boiler Feed Water

Design Pressure / Temperature: 1050 psig / 300 oF
(3) Condensate Return System

MP Condensate: 198 psig 550 oF
LP Condensate: 25 psig 370 oF
NOTE: Full vacuum design conditions should be considered for all condensate return system with
the maximum operating temperature.
(4) Cooling Water

Design Pressure / Temperature: later / 90 oF (Supply) and 250 oF (Return);
(Design temperatures are same with PDVSA VALCOR project.)
NOTE: Full vacuum design conditions should be considered for all cooling water distribution system
_ __ with the maximum operating temperature. Full vacuum design is due to the elevation difference
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(5) Utility or Fresh Water

(6) Demineralized Water

(7) Air System

Instrument Air 153 psig 250 oF
Plant Air 125 psig 250 oF
(8) Nitrogen System

High Purity Nitrogen 155 psig 150 oF
Low Purity Nitrogen 155 psig 150 oF
(9) Fuel System

Refinery Fuel Gas 150 psig 125 oF
Natural Gas 275 psig 160 oF (HOLD)
(10) Caustic
Design Pressure / Temperature: later / 200 oF
(Design temperature is same with PDVSA VALCOR project.)
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REFINING MAJOR PROJECTS GENERAL MANAGEMENT

PROJECT: RPLC DEEP CONVERSION PDVSA DOC. NO.

CONFEED PDVSA PDVSA

A 05-09-07 For Approval / First Issue 13 K.A./T.W./T.W. H. D.

CONFEED PDVSA CHECKED BY PDVSA APPROVED BY

PREPARED BY: Kazuo Akimoto

RPLC DEEP CONVERSION PROJECT

DETERMINATION OF MECHANICAL DESIGN CONDITIONS

_ __4.5 Steam Traced Pipe..............................................................................................................................11

4.6 Jacketed Pipe .................................................................................................................................... 12

2.2 Maximum Operating Pressure

2.3 Maximum Operating Temperature

2.4 Minimum Operating Temperature

2.5 Design Internal Pressure

2.6 Design External Pressure

2.7 Design Temperature

2.8 Short Term Piping Design Condition

Operating Conditions Continuous operating Total operating period Permissible excess in

3.1 Design Internal Pressure: General

3.2 Design External Pressure

_ __ examined if it becomes vacuum condition or not.

Full vacuum design should be considered with the coincident temperature.

3.3 Steam-out Condition

3.4 Pump Suction Line

3.5 Centrifugal Pump Discharge Circuit

3.6 Positive Displacement Type Pump Discharge

__ RA| than the rated discharge pressure, whichever is higher.

3.7 Compressor Suction

3.8 Centrifugal Compressor Discharge

3.9 Reciprocating Compressor Discharge

3.10 Reactor Recycle Gas Loop

3.11 Shell and Tube Heat Exchanger

High Pressure Fluid

High Pressure Rating High Pressure Rating

3.12 Piping at Low Operating Pressure

3.13 Atmospheric Storage Tank

4.1 Design Maximum Temperature

4.2 Design Minimum Temperature

4.3 Pressure Relief Valve and Its Tail Pipe

4.4 Flare Header

4.5 Steam Traced Pipe

4.6 Jacketed Pipe

5 DESIGN CONDITIONS FOR UTILITY DISTRIBUTION SYSTEM

(1) Steam System

(2) Boiler Feed Water

(3) Condensate Return System

(4) Cooling Water

(5) Utility or Fresh Water

(6) Demineralized Water

(7) Air System

(8) Nitrogen System

(9) Fuel System

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