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PROCESS FOSTER WHEELER ENERGY LTD GEN/DTA/11-02

SPECIFICATION PROCESS ENGINEERING Page 1 OF 139


SHEETS TECHNICAL WORK PRACTICE REV 3

REVISION ORIG REV 1 REV 2 REV 3 REV 4 REV 5


DATE OCT 96 OCT 96 MAY 03 JUN 04
ORIGINATOR CJS CJS GS A McGILLEWIE
CHECKED P. BENNET
APPROVED M.HARRISON

CONTENTS

SECTION SUBJECT
1. PURPOSE
2. SCOPE
3. REFERENCES AND GUIDELINES
3.1 Introduction
3.2 Customer's Name, Location
3.3 Service
3.4 Project No.
3.5 Unit No.
3.6 Item No. / No. Required
3.7 Document Category
3.8 Document No.
3.9 Document Sequence No.
3.10 Signatories
3.11 Design Record Sheet
3.12 Process Specification Index
3.13 Sheet Fluid Category
3.14 Client Requirements
3.15 Performance Guarantees

ATTACHMENTS
1 AGITATORS
2 AIR COOLED EXCHANGERS
3 CATALYSTS
4 COMPRESSORS
5 FILTERS
6 FIRED HEATERS
7 HEAT EXCHANGERS
R3 8 INSTRUMENTS
9 MECHANICAL HANDLING EQUIPMENT
10 PACKING
11 PROCESS SPECIFICATION (GENERAL)
12 PUMPS
13 RELIEF VALVES
14 TECHNICAL PROCESS SPECIFICATION
15 TRAYS
16 VESSELS

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1. PURPOSE

This Technical Work Practice gives guidance on the completion of FWEL


Process Specification Sheets.

2. SCOPE

This Technical Work Practice is to be used in the absence of specific alternative


instructions dictated by the Client. The Process Specification Sheets included
here cover the types of process equipment commonly encountered by Process
Engineers. Process Specification Sheets related to Process Control are covered
in a separate Work Practice.

3. REFERENCES AND GUIDELINES

3.1 Introduction

Each Process Specification Sheet is dealt with and presented separately in


Attachments 1 to 16. The guidelines presented below are common to all
Process Specification Sheets.

3.2 Customer's Name, Location

To be completed unless project is confidential and Process Specification Sheets


are likely to be seen by third parties (eg. Engineering Groups may use
Specification Sheets directly for enquiry requisitions to Suppliers).

3.3 Service

Always use a service description on the Process Specification Sheet which is


consistent with other documents (such as PFD, Equipment List, etc).

3.4 Project No.

Always enter the Project Number. This may be a study, proposal or contract.

3.5 Unit No.

If a project contains more than one process unit, enter the unit number, unit
name or both, to simplify identification.

3.6 Item No. / No. Required

State the item tab number (including A/B etc if applicable) as shown on the
Equipment List and state the number of identical items required.

NB. There is also a box at the bottom of each specification sheet for
duplication of the item number. This will facilitate location of a specific item in
a lever arch file.

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3.7 Document Category

This refers to the safety classification of the document. As all Process


Specification Sheets are categorised Class 1 the standard Process Specification
Sheets already indicate Class 1.

3.8 Document No.

This shall be in accordance with Contract Execution Procedure FWEL/48/L08.


Note that if a batch of Process Specification Sheets are being issued together,
this No. need only be included on the Process Specification Index Sheet (see
3.12)

3.9 Document Sequence No.

This number is issued by Document Control and should not be confused with
that in 3.8 above, but need only be applied in the same way.

3.10 Signatories

Prior to formal release, all Process Specification Sheets shall be independently


checked, and then approved by an Authorised Engineer.

The Process Specification Sheet shall be signed and dated by both the
originator and approver where indicated, for both the original and subsequent
issues. Add revision codes as required, in accordance with Contract Execution
Procedure FWEL/48/L08.

All first issue Process Specification Sheets shall be approved unless marked
"PRELIMINARY". (The space to the right of the revision codes is suitable for
the preliminary stamp or other special comments).

During proposal preparation it is often very difficult to obtain approval


signatures due to time limitations. For approximate designs the issue of data
sheets without approved signatures is acceptable, but beware proposals where
equipment sizes are frozen at contract award.

3.11 Design Record Sheet

It is often useful to attach a design record sheet to the Process Specification to


summarise the reason for each revision - including, for example, the reference
number of Client documentation requesting a change of duty, dimensions etc.
The blank Process Specification Sheet (see Attachment 11) should be used for
this purpose.

3.12 Process Specification Index Sheet

A Process Specification Index Sheet (FWEL 4270) should be used as a standard


cover sheet for Process Specification Sheets which are used in batches.

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3.13 Fluid Category

R2 For EU projects where the maximum allowable pressure is greater than 0.5bar above
normal atmospheric pressure (gauge pressure), it is compulsory to define the PED
Classification of Fluid. The fluid category is to be identified in the box now provided on
the relevant current Process Specification Sheets. The fluid category is to conform to
the current version of ASME V111, ASME B31.3 or the European Pressure Equipment
Directive (accessible via Engineering Dept.); which ever is applicable on the Project.
Where lethal service is identified, this must be brought to the attention of the Client and
FW project management in view of the likely cost implications. Refer to GEN/DTA/11-
16 Process Data for Pressure Equipment Directive.

R2 3.14 Client Requirements

Additional process data that is not as per Foster Wheeler’s datasheet but
required for engineering documents using client proformas should be provided in
the Notes section.
R2
3.15 Performance Guarantees

Specific details of performance guarantees relating to individual pieces of


equipment should be provided in the Notes section of the relevant datasheet.

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ATTACHMENT 1 – AGITATORS

1. GENERAL

The Agitator Process Specification Sheet (2068/1 7) is divided into 3 sections


with space for a sketch of the containing vessel and agitator.

The 3 sections are outlined as follows:

Part A - Operating Conditions

This section must be completed in full if the Supplier is required to provide


design information and/or guarantees of performance. The information
requested is of a process nature only; it should cover a single Agitator.

Part B - Specifications

This section covers mechanical design data in which Process Engineering


Department often become involved. Data on Materials of Construction should
normally be obtained from the Material Selection Diagram. Other data should
only be given if Process Engineering Department have specific requirements
(Foster Wheeler or Licensor).

Part C - Notes

Sketch A sketch of the vessel, indicating vessel dimensions, internal details,


baffles and any specific Agitator requirements should be drawn in the space
provided.

The vessel specification itself, however, contains more complete data on the
vessel and only data relevant to the Agitator should be shown here.

It is the duty of the Mechanical Equipment and Vessel Engineer to co-ordinate


the mounting details of the Agitator in the vessel.

Before completing an Agitator Process Specification Sheet, refer to Process


Standard 703.

The following sections give guidance on completion of the Agitator Process


Specification Sheet.

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ATTACHMENT 1 – AGITATORS (cont)

2 COMPLETION OF PROCESS SPECIFICATION

2.1 Part A - Operating Conditions

2.1.1 Type of Agitation

Indicate whether agitation is violent, medium or mild.

Standard 703 pages 3.0-2 gives a check list for defining the degree of
agitation.

2.1 .2 Operation

Indicate whether operation is continuous, semi-batch or batch. Subsequent


process data should be consistent with the mode of operation.

Tendency to foam )
Solids wet easily ) Tick these descriptions if applicable
Solids float )

2.1.3 Purpose of Agitation

Tick all suitable descriptions (more than one box may be ticked if relevant).
Process Standard 703 page 2.0-1 gives slightly different categories, but they
are useful for establishing the purpose of agitation.

2.1.4 Liquid/Solid Flows

The arrangement allows the specification of liquid streams, solid streams or


solid/liquid mixtures (i.e. slurries).

The section is also further divided into feeds (4 stream columns available) and
effluents (2 stream columns available).
Each unique feed stream should be given a flowrate (for continuous operation)
or a batch weight. This flowrate or mass is the sum of both liquid and solid
components (if applicable). The proportion of liquid to solid (if applicable) is
defined by the % by weight of solid parameter.

If a stream is only one phase put a line through the inapplicable data.

For liquid data: quote feed temperature and properties at that temperature
(Feed viscosity is necessary to assess the shearing forces required to get
mixing).

For solid data the settling rate and solubility should be specified if the stream is
mixed phase. Do not complete these data for a solid only stream as they are
influenced by the properties of the suspending liquid.

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ATTACHMENT 1 – AGITATORS (cont)

The effluent stream data will provide the settling rate/solubility data in the bulk
of the vessel. If the mixer is batch or plug flow (e.g. static mixer) and
solubility/settling rate vary over length of mixer, quote range.

2.1.5 Gas Flows

Quote data for feed and effluent gas streams where applicable. Even in batch
operation quote maximum gas rates to ensure that satisfactory gas evolution
and/or dispersion is achieved.

Quote the superficial gas velocity (i.e. m3/s of gas flow per m2 of empty
cross-sectional area) in m/s if it is a critical parameter.

2.1.6 Operating Pressure

If batch process, indicate pressure in agitated vessel at start and finish


of batch.

For continuous operation, delete START/FINISH prefix and indicate operating


pressure above liquid.

Indicate whether pressure is g or abs.

2.1.7 Operating Temperature

If batch operation, indicate temperature at start and finish of batch. Otherwise


delete START/FINISH and quote continuous running temperature.

2.1.8 Residence/Batch Time

Delete inapplicable prefix and state relevant time.

2.2 Part B - Design Requirement

2.2.1 Materials

State the materials of construction as given on the Materials Selection


Diagram. Normally the Process Engineer is only concerned with the wetted
surfaces, but other components can be detailed if specific information is
available, e.g. from Licensor.

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ATTACHMENT 1 – AGITATORS (cont)

2.2.2 All other data

In some instances Licensors or FW may have specific design requirements that


must be met to ensure guarantees are valid.
Typical parameters are given on the specification sheet, i.e.:

RPM of shaft State speed or speed range and whether


continuously variable.

Rotation (Clockwise or anticlockwise viewed from


coupling end)

Power Input (actual power into liquid)

Impeller Tip Speed (possibly a maximum or minimum limitation)

Impeller Number off (quote number per Agitator).


Type, e.g. radial/axial turbine, propeller.
Diameter.

Baffles Number off


Type

Seal Packed or Mechanical. State special seal fluid


requirements etc. by means of notes.

The Process Engineer need not provide any of this information, but if he does
then the Mechanical Equipment Engineer will incorporate it into his design.

Any other specific requirements should be provided in the Notes or on a


separate sheet.

2.3 Part C - Notes

Provide supplementary data if required.

For proposals it may be necessary to estimate installed motor sizes, overall


shaft length etc. Process Standard 703, Section 3.0 gives suitable calculation
procedures.

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ATTACHMENT 1 – AGITATORS (cont)

2.4 Sketch

Quote the item number of the vessel in which the Agitator is mounted. The
sketch is essential to show Agitator positioning in the vessel. Draw a sketch of
the vessel (vessel normally dotted to show that there is more complete data on
the Vessel Specification) and indicate details that are relevant to the Agitator
i.e.

Vessel dimensions

Internals

Type of head (if known)

Baffle dimensions (if critical)

Impeller positioning (if critical)

Where Agitator/Baffle data is not given, it is assumed that the Agitator Supplier
has a free hand to specify his own choice. State "By Supplier".

Details such as impeller dimensions, baffle spacing, impeller type etc. are not
normally determined by Process Engineering Department. These details may
however be specified by the Process Licensor. However, Process Standards
703 gives approximate guidelines which can be used for preliminary sizing.

3. PROCESS SPECIFICATION SHEET

A copy of the Agitator Process Specification Sheet (Ref 2068/17) is included


overleaf.

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ATTACHMENT 1 – AGITATORS (cont)

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ATTACHMENT 2 – AIR COOLED EXCHANGERS

1. GENERAL

For Air Cooled Exchangers (Process Specification Sheet 2068/6), the process
fluids flow through the tubes and cooling is provided by air flow induced or
forced across the tube bundle by a fan.

The Process Engineer has therefore only to specify detailed flow and property
data for the single process stream.

Properties and design limitations of the ambient air will be available to the air
cooler specialist engineer via the project Basic Engineering Design Data. The
Process Engineer is however required to specify the maximum air temperature
to be used for process design. This is not necessarily the absolute maximum
air temperature, but may be a temperature which is only seldom exceeded and
hence provides an "economic" design point (see Process Standard 302.3.2). A
winter minimum air temperature should also be specified to highlight potential
freezing problems.

Process Standard 302 gives an extensive discussion of air cooler features, and
equipment estimation procedure.

2. COMPLETION OF PROCESS SPECIFICATION

2.1 Process Side Data

Two columns are available for defining the design case and an alternative case.

Complete the alternative case if the maximum heat duty does not correspond
to the maximum viscosity, pour point or flowrate.

The following procedure for completing the air cooler specification sheet
supersedes Process Standard 302 Section 3.1.

2.1.1 Fluid Name

This describes the nature of the fluid e.g. vacuum column overheads, steam
etc. If full analysis of the stream is relevant, then supply as a note on a
separate sheet.

R2 2.1.1a PED Fluid Type / State

Refer to Section 3.13 Fluid Category.

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ATTACHMENT 2 – AIR COOLED EXCHANGERS (cont)

2.1.2 Fluid Fouling/Corrosive Compounds

State whether the fluid is fouling and advise the nature and concentration of
corrosive compounds if present.

Heavy fouling may lead to a very low inside heat transfer coefficient, which
may make high ratio of finned surface uneconomic.

2.1.3 Fluid Flowrates

Flowrates corresponding to the design heat duty are required. If this is not the
maximum flowrate, specify this also, as it will probably control the pressure
drop through the exchanger. Additionally, where a fluid has a high pour point
or high viscosity it is mandatory to specify the minimum flowrate. At low flow
and with a low allowable design pressure drop laminar flow may result in poor
heat transfer and hence plugging in the tubes.

Provide data in the six different categories as shown on the Process


Specification.

Exclude steam from the vapour flowrate and quote it separately.

Quote the molecular weight of the vapour and non-condensables as separate


streams (Steam MW does not need stating).

2.1.4 Temperature

Provide inlet and outlet temperatures for the process fluid (for both design and
alternative case where applicable).

Ensure that these temperatures are consistent with the heat duty quoted below
or clarify with a note.

2.1.5 Inlet Pressure

Quote for streams containing vapour only. For liquid only coolers, operating
pressure is not relevant data and should be omitted (it is influenced by detailed
hydraulics which may not be complete at this stage).

2.1.6 Pressure Drop Allowable

Refer to Process Standard 302 Section 3.1 for typical pressure drop
allowances. If the only process limitation is a combined pressure drop for a
number of exchangers, state this using a note.

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ATTACHMENT 2 – AIR COOLED EXCHANGERS (cont)

2.1.6 Pressure Drop Allowable (cont)

The allowable pressure drop for product cooling and non-critical services should
not control the size of the exchanger, as this may result in an uneconomic
design which could be avoided by reconsidering the hydraulics of the process
circuit. Special consideration is required for wide temperature range cooling of
viscous liquids, low pressure gases or condensation of vapours at very low
pressures. In these services, pressure drop is a critical requirement that greatly
influences the size of the heat transfer surface.

Under these conditions discuss the allowable pressure drop with Heat
Exchanger Department.

Pressure drop allowable should be consistent with flowrate given in 2.1.3


above.

2.1.7 Specific Heat

Provide specific heat data for both liquid and vapour components at inlet and
outlet conditions.

For vapour streams ensure that specific heat is corrected for pressure.

2.1.8 Viscosity

Specify the viscosity of the fluid at inlet and outlet temperatures. If the
exchanger has a range of duties specify also the maximum viscosity case. For
fluids with very high viscosity, it may be necessary to increase the allowable
design pressure drop to ensure turbulent flow.
(See also dew point / bubble point discussion paragraph 2.1.15)

2.1.9 Thermal Conductivity

Provide thermal conductivity data for both liquid and vapour components at
inlet and outlet conditions.

For vapour streams ensure that data is corrected for pressure.

2.1.10 Liquid Density

Provide density of liquid components (vapour density follows from


temperature/pressure/MW and compressibility data given elsewhere on the
form).

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ATTACHMENT 2 – AIR COOLED EXCHANGERS (cont)

2.1.11 Vapour Compressibility

Provide compressibility factor for the mixed stream at inlet and outlet. (Include
steam and non-condensables).

2.1.12 Liquid Surface Tension

Provide liquid surface tension at inlet and outlet for air coolers in condensing
service.

2.1.13 Critical Pressure/Temperature

Provide critical pressure/temperature for the vapour mixtures.

R2 2.1.14 Hydrate / Pour Points

Specify the hydrate formation point (temperature) or pour points of fluids that
contain waxy deposits or have high viscosities. The exchanger should be
designed so that the tube wall temperature at the cold end under conditions of
minimum flow, no fouling and winter design air temperature, is at least 5oC
above the higher of the hydrate formation or pour point.

For services where pour point is critical, Supplier's design should be given close
scrutiny to ensure that design has allowed for process requirements.

Steam coils and manual louvers are required for start-up operation in services
where fluids have high pour points. A rough approximation for the steam
requirement can be obtained by ratio from the following: for 9.lm (30 ft) tube
length about 45kg per hour of steam is required per metre of bundle width.
However, it is recommended that each case be considered separately taking
into account the properties of the process fluid and the minimum air
temperature. Additionally, the process fluid outlet temperature may be
controlled to prevent sub-cooling. Generally, temperature control is only used
where the tube wall outlet temperature is less than 10oC above the pour point
at the winter minimum temperature and minimum fluid flowrate. Control is
accomplished using automatic louvers, 50% or 100% auto-variable fans and/or
air recirculation. The Supplier may also consider designing the exchanger with
co-current flow and/or bare tubes.

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ATTACHMENT 2 – AIR COOLED EXCHANGERS (cont)

2.1.15 Dew Point/Bubble Point

If the exchanger acts as a condenser and handles superheated vapour or sub


cooled liquid, quote the dew point and/or bubble point of the fluid as
appropriate.

Note that, if sub cooling is required, then the air fin must be supplied with a loop
seal to ensure the provision of sub cooling surface.

Physical properties of the liquid and vapour should also be provided at the
bubble point and dew point on a separate sheet.

2.1.16 Latent Heat (for condensing service)

Supply latent heat data at condensing conditions or provide a cooling curve if


latent heat varies through the condensing range.

R2 2.1.17 Heating Curve Attached Yes/No

Refer to Attachment 7 Heat Exchangers, Section 2.20

2.1.18 Velocity Allowable

Specify any limitations on velocities. To minimise fouling, minimum velocities


are specified where the process fluids contain solids such as catalyst, or where
the process fluid is water (for these services the velocity is generally not less
than 1m/sec). In addition maximum velocities are sometimes specified to
prevent erosion.

2.1.19 Fouling Factors

Only the fouling resistance of the fluid on the inside of the tubes is required.
The Standards of Tubular Exchanger Manufacturers Association (TEMA) give
fouling resistances for various process fluids.

The resistance should be referred to inside tube diameter.

For proposal calculations, it may be more relevant to omit fouling factor data
but include an estimate of the overall dirty (service) heat transfer coefficient
(see Table 2 on Figure 3 in Process Standard 302 for typical data).

2.1.20 Mechanical Cleaning Requirements

Indicate whether the fouling nature of the fluid requires mechanical cleaning.
Engineering/HED will determine the effect on the hardware.

State also if provision for chemical cleaning is required.

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ATTACHMENT 2 – AIR COOLED EXCHANGERS (cont)

2.1.21 Cyclic Service

Indicate if the service is cyclic, frequency of cycles and pressure/temperature


limits. Use separate sheet if necessary.

Note that there should be discussion with Heat Exchangers Department (HED)
to review the implications of short term conditions on exchanger design.

2.1.22 Heat Exchanged

Heat exchanged should be consistent with temperatures and physical properties


listed above.

R2 2.1.23 Margin Required on Duty / Flow

Design margins are introduced for several reasons; to account for uncertainties,
flexibility, de-bottlenecking, or future expansion. The purpose of the design
margin should be specifically identified and understood, and the use of blanket
design margins as "comfort factors" avoided.

• Design margins for guarantee purposes

When FW are required to guarantee the performance of a plant, the design


margin should be clearly stated and included in the mass balance
calculations/simulations for this purpose. No additional margin should be added
to the sizing flow/duty of the specific equipment item for guarantee purposes.
• Design margins for uncertainty, flexibility or de-bottlenecking

These should be stated on the process datasheet, although they can be stated
in many ways.

Some clients may dictate the fouling coefficients to be used, in which case the
Process Engineer should determine whether this already includes a design
margin.

One approach to allow for uncertainties in the mass balance is to add a note to
the process datasheet to "de-rate the heat transfer coefficient by x% to provide
excess surface area". Alternatively, a design case could be selected where for
instance the hot inlet stream is reduced in temperature to give a lower LMTD
and therefore higher area. This can explained by a note, and is common
practice on pump around streams in refinery units.

If a margin is required for future capacity, it is customary to specify the design


margin by adding a note to "provide x% margin on flow and duty". If the
margin is specified in this way, then it should be made clear in the note
whether the allowable pressure drop refers to the exchanger, with or without
the additional flow and duty.

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ATTACHMENT 2 – AIR COOLED EXCHANGERS (cont)

2.1.23 Margin Required on Duty / Flow (cont)

It is important to understand the impact of design margins on clean exchanger


operation. For instance, the sizing of exchanger bypass control valves should
take clean operation into account, and consideration should also be given to the
downstream temperature when the exchanger operates cleanly.

Applying a design margins on duty and flow rather than surface area is the
approach generally preferred by HED, because this is clearer and gives more
flexibility for design.

2.2 Air Side Data

Air side data is covered by the project Basic Engineering Design Data. However,
in view of its importance to the specification of an air cooler, the following
information should be given:-

2.2.1 Maximum Air Temperature (for Process Design)

This determines the approach temperature which is usually the limiting factor
for sizing the exchanger. Choosing a high value may result in an unnecessarily
large surface whereas a value which is too low may adversely affect operation
of the exchanger during peak ambient air conditions.

The cost of the air cooled heat exchanger is directly related to the chosen
design air temperature and careful consideration should be given to its
selection. The actual figure to be used may be specified by the client. If the
client does not specify a design air temperature; he should be consulted with
regard to the period of time that reduced capacity can be tolerated as a result
of the design air temperature being exceeded.

Consideration should be given to selection of services on a critical/non-critical


basis. For instance, partial condensation of tower overheads to provide
reflux can be considered critical whereas product cooling is usually non-critical.
Different design air temperatures may be selected for the two categories.

The common practice for determining the design air temperature is to select a
temperature from meteorological data which is not exceeded for more than a
percentage of time throughout the year. This percentage of time varies
according to the period over which the meteorological data is assessed and on
the location but is usually between two and a half and five percent upon annual
hourly readings.
It is important to remember that consideration must also be given to the effect
of local refinery heat sources on the air temperature. The design air temperature
may be increased by say 20C to allow for this.

See Appendix A of Process Standard 302 for a statistical method to calculate


the design air temperature from meteorological data.
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ATTACHMENT 2 – AIR COOLED EXCHANGERS (cont)

2.2.2 Winter Minimum Design Temperatures

This temperature is required to establish the precautions to be taken when


operating with high pour or freeze point fluids.

This temperature is also used to determine driver power requirement where it


is mandatory for the driver to be capable of operation at the low air design
temperature with fan blades set to the pitch required for maximum air flow
(summer conditions). The temperature is determined in a similar manner to the
summer design air temperature.

2.3 Mechanical Design

Complete the tubeside mechanical design data as described for vessels in


Attachment 16.

2.4 Materials of Construction

State material of construction requirements for the exchanger tubes and


headers. This data should be copied from the Materials Selection Diagram as
agreed with Technology Group.

In addition the minimum permissible tube thickness and header corrosion


allowance should be stated.

If Process Engineering Department or Licensor have any other specific material


requirements, these should be stated. However, materials of fins, louvers, etc.
should normally be left to Supplier.

Specify any materials which must be excluded in a note. (e.g. no copper in


presence of ammonia).

2.5 Equipment Selection

Data in this section is optional and should only be completed if either:

1. Process Design Department or Licensor have specific requirements on a


contract or,

2. Process Design Department are making equipment selection themselves


for a proposal.

See Process Standard 302 for means of choosing air cooler type and estimating
equipment details.

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ATTACHMENT 2 – AIR COOLED EXCHANGERS (cont)

2.5 Equipment Selection (cont)

Data such as control scheme required (louvers, variable speed or variable pitch
fan etc.) and heating coil requirements can also be stated here.

Heat transfer rate is normally left to an air cooler specialist. However, on


proposals or studies the Process Engineer can provide estimate of dirty (service)
coefficients using Table 2 and Figure 3 in Process Standard 302. Heat transfer
rates are normally based on outside surface area of the tubes.

2.6 Additional Data

Additional data important to air cooler design should be given separately.

2.6.1 Potential High Operating Temperatures

In particular note the possibility of a process temperature range greater than


1110C during alternative operation (including start-up and maloperation) even if
this does not control thermal design. This may occur, for example, at reduced
throughput or when auto-variable pitch fans are operated under manual control.
In order to reduce thermally induced stresses under these conditions provision
of restraint relief (e.g. split headers) will require investigation (see API 661).

R2 2.6.2 Fluid Composition

Provide the fluid composition on a separate sheet.

Indicate also, whether the service is Sour, Hydrogen or Lethal. The definition of
these terms is usually driven by the client. Hydrogen service is typically if the
H2 partial pressure is above 7 bar. According to API 617, sour service is
classified under NACE MR 0175. In many applications, small amount of H2S are
sufficient to require materials resistant to sulphide stress corrosion cracking.
When trace quantities of wet H2S known to be present or there is uncertainty
about the quantity of wet H2S present, consideration should be given to use of
materials that are resistant to sulphide stress corrosion cracking.

Lethal service should be in accordance with client or local legislation


requirements. Where lethal service is identified, this must be checked with
the Client in view of the likely cost implications.

3. PROCESS SPECIFICATION SHEET

R2 A copy of the Air Cooled Exchanger Process Specification Sheet (Ref 2068/6) is
included overleaf.

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ATTACHMENT 2 – AIR COOLED EXCHANGERS (cont)

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ATTACHMENT 3 - CATALYSYTS

1. GENERAL

Use the Catalyst Process Specification Sheet (2068/26) to define the quantity
and type of catalyst required for fixed bed applications. In many cases the
client will purchase the catalyst direct from the manufacturer, but in other
cases FW may need to establish catalyst details with Suppliers.

Catalysts are requisitioned by the Project Engineer.

The General headings for the specification are similar to those for other
specifications, except that the Process Engineer should identify the catalyst by
the Item No. of the containing vessel(s). Therefore use a separate Catalyst
Process Specification Sheet for the catalyst in each vessel.

The detail on this sheet should be completed once the catalyst type has been
established. This sheet will therefore form the basis of a requisition. If Process
Engineering Department has yet to establish the catalyst type and quantity,
then the process parameters should be detailed on continuation sheets. This
front sheet will initially contain heading data only, but will be progressively
completed as data is generated.

If alternative catalyst types are acceptable, then these should be listed in


separate columns, clearly stating that these are alternatives.

The following section (2.) gives guidance on completion of the catalyst


specification. Section 3, outlines the process data to be supplied when the
catalyst details have not been finalised.

2. COMPLETION OF PROCESS SPECIFICATION

2.1 Supplier and Catalyst Type

State Supplier's name and catalyst identification details.

2.2 Purpose

Indicate outline function e.g. Hydrodesulphurisation, H.T. Shift, Ammonia


Synthesis.

2.3 Size and Shape

Describe physical size of particles e.g. 3mm granules, 5mm spheres

2.4 No. of Vessels

State number of identical vessels.

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ATTACHMENT 3 - CATALYSYTS (cont)

2.5 No. of Beds/Vessel

State number of identical beds within a vessel.

If beds are of different dimensions then provide separate data.

2.6 No. of Tubes/Bed

Indicate the number of tubes if the catalyst is inside tube. State 1 if whole
cross sectional area is catalyst packed.

State "outside tube" if applicable.

2.7 Length of Catalyst Bed

State length or height of catalyst bed.

If the catalyst tubes contain a supporting medium (e.g. ceramic balls) quote
only the true catalyst length.

2.8 Tube Diameter (I.D.)

State l.D. of each tube if catalyst is inside tube. If whole vessel is packed
quote vessel l.D.

2.9. Total Installed Volume (m3)

Calculated from above parameters. If catalyst is outside tube, state volume of


catalyst. State volume per vessel.

For small diameter reactors, the volume of redundant nozzles, man ways or
manholes can be significant. The volume of these should be included in the
calculation of required volume. Alternatively nozzle inserts can be specified
which have the additional advantage of smoothing the flow. Catalytic volumes
should be checked even when defined by third parties e.g. Licensors.

2.10 Max Packed Density (kg/m3)

Catalyst Suppliers often quote a density range. State maximum figure here to
ensure sufficient weight is purchased.

2.11 Total Installed Weight (kg)

Calculate from volume and maximum density.

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ATTACHMENT 3 - CATALYSYTS (cont)

2.12 Breakage Allowance %

State a suitable allowance if known from previous FW experience (check with


Commissioning Group). Otherwise leave to Supplier or Project Engineer.

2.13 Purchase Weight (kg)

Follows from Total Installed Weight and Breakage Allowance.

2.14 Purchase/Storage Requirements

Highlight requirements such as: - inert atmosphere

- max temp / min temp.


- max storage time.

2.1 5 Loading/Unloading Requirements

State particular requirements such as:

- direct from
- state of vessel when loading
- avoidance of attrition etc.

2.16 Start Up Requirements

State procedure required to activate or pretreat catalyst,

e.g. Dimethyl Sulphide, air/steam oxidation.

2.17 Design Press Drop (bar)

State the design pressure drop, as quoted on the containing vessel


specification. This is quoted to ensure that the packing/catalyst has sufficient
strength to withstand this pressure drop without damage.

3. CATALYST PROCESS PARAMETERS

Where FW requires a catalyst Supplier to specify and guarantee a catalyst for a


particular process duty, the Process Engineer must supply sufficient process
data to enable guarantees to be given.

In such cases the Catalyst Specification Sheet should be included as a heading


sheet (even if no information can be completed) with the process data
presented on continuation sheets.

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ATTACHMENT 3 - CATALYSYTS (cont)

3. CATALYST PROCESS PARAMETERS (cont)

As FW/Supplier dialogue proceeds, the Process Engineer will be able to


progressively complete the data on the Catalyst Specification Sheet.

Process data may either be specified by Process Engineering, or the Supplier


may be asked to advise certain performance data. In all cases however, the
Supplier will be required to guarantee his data.

Typical data required to fully define a catalytic operation is as follows:-

3.1 Brief Description of service (including a flowsheet and details of


quench, interbed cooling etc. as necessary).

3.2 PFD and Mass Balance Data

All the following will be presented by FW if the heat and mass balance is
established. Otherwise certain parameters may be required from Suppliers.

Flow Rate
Feed Composition (including trace presence of any components which could be
a catalyst poison)
Molecular Weight (of vapours)
Density
Viscosity
Inlet pressure
Max. pressure drop
Inlet temperature
Max. outlet temperature
Product composition and / % conversion of a particular component.
Give data for all cases which influence the project. Typically cases are:
- Start of catalyst run
- End of catalyst run
- Alternative feedstock
- Turndown (if catalyst flow regime changes)
- Design Case (i.e. including an FW margin on a particular parameter).

(N.B. The above data assumes solid phase catalysis. Some catalysts operate
in the liquid phase and consequently design parameters would be required in
different form to above).

3.3 Catalyst Bed Configuration Limits

The crush strength of a catalyst is normally greater than the strength of the
bed supports, but Supplier should be asked to advise any limitations on
height/diameter limits.

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ATTACHMENT 3 - CATALYSYTS (cont)

3.4 Catalyst Life

Either FW states desired guaranteed life (e.g. for design case) and/or Supplier
states expected life for non-critical cases.

Supplier should also advise whether regeneration is feasible, and if so what


facilities are required.

3.5 Start up Requirements

Supplier should be asked to advise start up requirements (see 2.16).

3.6 Loading/Unloading Requirement

Supplier should be asked to advise loading/unloading requirements (see 2.15).

3.7 Catalyst Details

Supplier should be asked to advise or confirm:

- Catalyst volume required


- Catalyst physical properties
- Support/retention requirements etc.

These data are needed to confirm the purchase details listed on Specification
Sheet.

3.8 Catalyst Vessel Details

Supplier should be asked to state any specific vessel requirements (e.g.


multiple feeds, etc.).

If the catalyst is being retrofitted into an existing vessel then FW should state
the vessel design conditions and supply geometry of the vessel.

4. Process Specification Sheet

A copy of the Catalyst Process Specification Sheet (Ref. 2068/26) is included


overleaf.

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ATTACHMENT 3 – CATALYSYTS (cont)

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ATTACHMENT 4 – COMPRESSORS

1. GENERAL

Co-ordination between the Mechanical Equipment Group and the Process


Engineer is vital at the start of a project particularly as Compressors are often
long delivery items which determine overall project schedule.

Process Standard 400.2 gives guidance on completing Compressor Process


Specification Sheets. Section 2 and 3 below give additional comments relevant
to the FW sheet.

Process Standards 400.2 "Compressors" and 400.3 "Reciprocating


Compressors" give additional information and should be referred to during
development of the Compressor Process Specification (2068/1 2).

2. COMPLETION OF PROCESS SPECIFICATION

2.1 Machine type

Indicate suitable machine type by ticking appropriate box. See Process


Standards 400.2 p.6 for machine selection guidelines. Check your selection
with the Mechanical Equipment Group.

2.2 Number of Machines Required

Indicate the number of operating machines and the number of installed spares
(i.e. standby machines).

Uninstalled spares are not indicated here.

See Process Standards 400.2 and 400.3 for sparing requirements for different
machine types.

If more than one machine is normally operating, use notes to state whether the
operating machines are required to operate in series, parallel or separate
streams.

Parallel operation should be discussed in detail with the Mechanical Equipment


Engineer.

2.3 Type of Driver

Indicate whether electric motor, steam turbine, gas turbine, gas expander, or
perhaps even a combination of these. For steam turbine state whether
condensing (water or air cooled), back pressure or extraction.

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ATTACHMENT 4 – COMPRESSORS (cont)

2.4 Duty

State whether continuous or intermittent.

Duration of each operating case (hrs/yr max) is requested below. (Section


2.5.2)

2.5 Process Requirements per Machine

Process data should be given for all cases which might determine some aspect
of the machine (e.g. casing size, motor size, spillback or anti-surge
requirements).

Remember cases such as start up, running in on air, alternative campaigns,


winter/summer operation etc.

2.5.1 Operating Cases

Clearly identify Case(s) to be guaranteed. The Normal Case is commonly


guaranteed in the context of establishing overall Process Unit Utility
Consumption guarantees but the Supplier must guarantee that the Compressor
can cope with the Rated Case too.

API standards allow no negative tolerance on capacity of reciprocating or


centrifugal machines. For variable speed centrifugal machines the head and
capacity are guaranteed by the vendor on the understanding that the
horsepower may vary by 4% from the guaranteed value.

For constant speed centrifugal machines the vendor will guarantee the capacity
with the understanding that the head may be up to 5% above the specified
value; the horsepower may exceed the guaranteed value by up to four
percent.

For reciprocating compressors API uses the concept of guaranteed maximum


horsepower. FW Standards stipulate that the guaranteed maximum
horsepower shall not exceed the rated horsepower by more than four percent.
Ensure operating cases given are sufficient for Supplier/Mechanical Equipment
Group to fix driver speed variation required.

2.5.2 Approximate Number of hrs/yr (max)

Indicate approximately the frequency and duration of the various operating


cases.

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ATTACHMENT 4 – COMPRESSORS (cont)

2.5.3 Gas Handled

This describes the nature of the gas e.g. C3 refrigerant, inert gas, hydrocarbon
vapour etc. Complete gas analysis is shown under "gas composition".

Liquid or solid should not normally be present in compressor suctions, as it can


lead to mechanical damage to machines.

If liquid or solids are present, state the percentage by volume and maximum
particle/droplet size.

If compressor is required to operate on air or other gases during start-up this


must be shown. Compressors are normally run in on air.

2.5.4 Gas Composition

State composition for each case. Use wet basis if the gas contains moisture.

Include all components which affect physical properties so that the Supplier
can confirm the compressibility factor and Cp / Cv.

2.5.5 Corrosion/Erosion Due To

Process materials and contaminants such as sulphur oxides, hydrogen sulphide,


acidic compounds, chloride, hydrogen etc. are to be specified by the Process
Engineer as they may determine the selection of materials made by FW or the
compressor Supplier.

2.5.6 Capacity at NTP (m3/hr)

Convert mass flow to volume @ 00C and 1.013 bar abs.

2.5.7 Mass Flow (kg/hr)

Minimum, normal (i.e. PFD material balance) and rated quantities are required.
The rated flow for a centrifugal compressor, in many cases, represents about
105% of normal flow. This assures obtaining an adequately sized driver to
cover process contingencies. Design margins for critical machines should be
discussed with the relevant Group Manager or Chief Process Engineer.

2.5.8 Molecular Weight

Quote molecular weight for all cases. Low molecular weight cases can
determine machine details such as number of stages, power, etc. and should be
carefully considered.

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ATTACHMENT 4 – COMPRESSORS (cont)

2.5.9 Inlet Volume Flow (actual m3/hr)

This data is influenced by the compressibility factor of the gas, which the
Supplier is normally asked to confirm. However the inlet volume flow should be
estimated using "in-house" data, the vendor will then confirm this volume.

2.5.10 Inlet Pressure (bar abs)

This is normally quoted as the pressure at the suction flange of the compressor,
i.e. downstream of filters, pulsation dampers, etc. Bar abs is preferred unit.

There may be occasions however where the Process Engineer is unable to


establish pressure drops of equipment supplied as part of the compressor
Supplier's package (e.g. inlet filter). In this case the basis of the suction
pressure quoted should be clearly stated using a note (e.g.” Upstream of inlet
filter").

For machines with atmospheric suction, ensure that variations of atmospheric


pressure are considered (see Table 1 of Process Standard 400.2). It is usual to
allow the compressor Supplier to also be responsible for the supply of the
suction filter in this case and make the allowance for filter pressure drop. For
compressor specification it may not be necessary to consider the ultimate range
of atmospheric pressures; use the process design range of pressures in the
Project Basic Engineering Design Data.

2.5.11 Inlet Temperature (0C)

State normal temperature and full max-mm range for each operating case so
that compressor design and driver rating are correctly chosen. This is important
for process air compressors with atmospheric inlet since minimum temperature
controls maximum power requirements.

2.5.12 Cp / Cv at Inlet (actual)

Correct the values of Cp and Cv for non-ideality and quote actual Cp/Cv ratio.

In view of non-ideality, particularly at or near critical conditions, the vendor is


required to confirm the Cp/Cv ratio used in performance calculations.

See Process Standards 400.2.2.04 and Chapter 7 of API data book.

2.5.13 Compressibility at Inlet (PV/RT)

In view of non-ideality, particularly at or near critical conditions the Supplier is


required to confirm the compressibility factor used in performance calculations.

For in-house estimates and proposal work this value should be stated (and used
to calculate actual suction volume).
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ATTACHMENT 4 – COMPRESSORS (cont)

2.5.14 Discharge Pressure (bar abs)

This is normally quoted at the discharge flange of the compressor, and does not
include pulsation damper etc. pressure drops. However other pressure bases
may be used if clearly covered by a note.

Bar abs is preferred unit (use same units as for inlet pressure).

2.5.15 Cp/Cv at Discharge

Quote actual Cp/Cv at required discharge pressure. As indicated under 2.5.12


above Supplier will be required to confirm value.

2.5.16 Compressibility at Discharge

Quote estimated value at discharge conditions. As indicated in 3.13 above


Supplier will be required to confirm the value.

2.5.17 Differential Pressure (bar)

This is Discharge Pressure minus Suction Pressure.

2.5.18 Compression Ratio

= Discharge Pressure (bar abs)


Suction Pressure (bar abs)

2.5.19 Maximum Allowable Temperature (0C)

This information is to be supplied by Process Engineer when a known limitation


exists. Discharge and interstage temperatures are limited by gas reactions, e.g.
polymerisation or safe lubrication temperatures. Some compressors are limited
by mechanical considerations which will be determined by the Mechanical
Equipment Group and Supplier.

Isothermal compression (i.e. infinite intercooling) is the most efficient (least


power) operation, and therefore temperature limits may be specified after
discussion with Mechanical Equipment Group to save power.

See also Process Standard 400.2.

2.5.20 Estimated Absorbed Power (kW)

Power consumptions are ultimately the responsibility of the Mechanical


Equipment Group, but the Process Engineer should estimate the power
absorbed (including gear losses) for utility balances and to establish the “size”
of the compressor being considered.

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ATTACHMENT 4 – COMPRESSORS (cont)

2.5.20 Estimated Absorbed Power (kW) (cont)

The absorbed power can be calculated from the Process Standards 400.2 or
400.3 or from Suppliers’ charts. Any assumptions used in determining the
power (e.g. number of stages assumed; presence of inter-coolers etc.) should
be clearly stated by means of notes.

Gear losses data may be obtained from Process Standard 400.2.3.20.

When a compressor is to be used in vacuum or refrigeration service, peak driver


load may be required during start-up, and a note to this effect should be added
to the form.

2.5.21 Settle Out Pressure

Data is not required for reciprocating machines. Information on system


pressure following sudden compressor stop is required in order to ensure that
compressor suction can withstand resulting high pressure. A knowledge of
vessel and piping volumes is required for this, the initial estimate of settle out
pressure is therefore likely to be preliminary. If revisions in settle out pressure
are anticipated this must be stated and the implications discussed with the
Mechanical Equipment Group.

2.5.22 Materials of Construction (Process Minimum)

State the minimum acceptable materials of construction, as stated on the


Materials Selection Diagram.

Mechanical Equipment Department or Supplier may wish to provide higher


grade materials if required for strength reasons (e.g. SS impellers are less
susceptible than CS to pitting by liquid impingement).

Cover any unacceptable materials by a note, e.g. no copper alloys.

2.5.23 Control Scheme

Operating - Typical schemes are described in Process Standards 400.3 from


which an appropriate selection should be made and should include anti-surge
arrangements where necessary. Consultations with the Mechanical Equipment
Group and Instrument Group are usually required. Process Standard 509 refers
specifically to Compressor Control.
Start-up - Methods are to be considered by the Process Engineer since items
such as anti-surge control systems, by-pass lines, valve filters and pockets on
reciprocating machines, etc. are involved. In addition, compressors generally
require a running-in period during which time an alternative feed gas may be
used. If air is to be used for running-in, then suitable vents, etc. may be an
additional requirement.

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ATTACHMENT 4 – COMPRESSORS (cont)

2.5.23 Control Scheme (cont)

Emergency - Such as shutdown switches, recycle lines, etc. are required on


Engineering Flow Diagrams. A preliminary review with Compressor and
Instrument Engineers is desirable.

Use separate sheets as necessary to fully define control schemes; include a


flow diagram to clarify design requirements and refer to it here.

2.5.24 Seal Requirements

State any specific process requirement (e.g. hydrogen buffer gas, leakage out
prohibited when running or stationary).

Indicate lube and seal oil system requirement if known, e.g. combined systems,
sour seal oil recovery or disposal.

If no specific requirements, state "by Supplier".

Requirement for acoustic enclosure may influence the choice of seals and
permitted leakage.

2.5.25 Extent of Supply

Ensure that process requirements for compressor peripheral equipment are


adequately defined, refer to additional notes if necessary. Requirement for
equipment such as lube/seal oil systems will be defined by Mechanical
Equipment Group. If an aftercooler is required also specify required outlet
temperature.

2.5.26 Site Conditions

Compressor process specifications are frequently issued at an early stage in the


job and before the Basic Engineering Design Data. It is therefore useful to give
preliminary data which may affect compressor design. Such data may include
site temperature extremes, maximum/minimum atmospheric pressure, and
presence of dust or corrosive materials in the atmosphere. Minimum
temperature case may govern selected driver horsepower.

R2 In addition information on compressor location may be given, e.g. within


compressor house, in open/covered structure, etc.

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ATTACHMENT 4 – COMPRESSORS (cont)

2.5.27 Other information

Give any further information which may be of value to Mechanical Equipment


Group in specifying and selecting the required machine. If known, give
capacity at surge point as percentage of that at rated capacity. Use additional
Process Specification Sheets (2068/21) as necessary. Specific guarantee
requirements should also be highlighted including selected case. If a
performance curve is available, for example on revamp projects, provide these.

3. PROCESS SPECIFICATION SHEET

R2 Copies of the Compressor Process Specification Sheets (Ref 2068/12-1/2) are


included overleaf.

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ATTACHMENT 4 – COMPRESSORS (cont)

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ATTACHMENT 4 – COMPRESSORS (cont)

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ATTACHMENT 5 – FILTERS

1. GENERAL

The Filter Process Specification Sheet (2068/25) is intended for use on general
purpose in-line filters and strainers for both gas and liquid service. It is not
intended for use with special filters such as rotary vacuum filters, vacuum belt
filters, filter presses etc. For items such as these the blank Process
Specification Sheet, (2068/21) should be used; for some applications it may be
possible to adapt the Filter Process Specification to suit.

The following section gives guidance on completion of the Process Specification


Sheet.

2. COMPLETION OF PROCESS SPECIFICATION

2.1 Fluid & Solids

Give name of fluids and solids present in the process stream. If Supplier is to
select all or some materials of construction then give details of contaminants
which may influence selection e.g. chloride, hydrogen sulphide, caustic or acid.
Consider also alternative operations which may affect materials selection.

2.2 Flowrate

Normal flowrate is material balance volume flow. Consider all aspects which
may have a bearing on maximum flow e.g. start-up, shutdown, recirculation.
In many cases, especially where solids loading cannot be closely defined it may
be prudent to add a margin of 25% or more when defining maximum flow.

2.3 Operating Pressure and Temperature

As well as normal conditions consider transient conditions and give


approximate frequency and duration.

2.4 Pressure Drop Over Filter

Indicate maximum permitted pressure drop over clean and/or dirty filter. This
will be the pressure drop at maximum flow specified as in 2.2 above.
Allowable pressure drop will depend on duty, typically about 0.7 bar
depending on solids loading. If in doubt consult Supplier's literature or consult
Supplier.

For filters on critical duties consider the use of a differential pressure gauge
across the filter. A differential pressure switch may also be advisable.

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ATTACHMENT 5 – FILTERS (cont)

2.5 Fluid and Slurry Properties

Complete according to headings given; consider alternative cases e.g. high


viscosity which may govern filter sizing, and give information by means of
notes.

2.6 Solids Properties

As much information as available on the solids should be entered on the


Process Specification. In many cases not all the information is available - for
example when piping changes from carbon steel to stainless steel a filter is
included to remove rust. The sieve analysis of solids (rust) and most probably
settling velocity is not available.

Wherever possible solids content of fluid should be given together with particle
size distribution or sieve analysis of solids.

2.7 Performance

Filter performance must be stated on all occasions; this may be in terms of


"Particle size of solids to be removed" which will normally apply to in-line filters
or strainers, i.e. surface filters. This will be the size of particle above which
100% will be removed.

Alternatively filter performance will be specified in terms of efficiency of


removal of particles of a given size. This is normally the case for fabric type
i.e. in-depth filters. If necessary reference should be made to an accepted test
dust to British or other standard.

2.8 Type of Filter

Specify the type of filter to be used e.g.

Basket filter
Bag filter
Pressure filter etc.

The Process Engineer should rely on previous experience and/or Supplier


information to establish the most suitable filter type.

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ATTACHMENT 5 – FILTERS (cont)

2.9 Design Temperature

Design temperature should be consistent with the Design Pressure and


Temperature Diagram (refer to TWP GEN/DTA/31-08). Transient excursions
beyond this limit should be detailed in separate notes. Ensure that any
cleaning process used is covered by the design temperature. Identify the
possibility of auto-refrigeration effects which could occur if the filter is
depressurised (i.e. state atmospheric boiling point if below 00C).

2.10 Design Pressure

Design pressure should be consistent with the Design Pressure and


Temperature Diagrams. Transient conditions should be specified by separate
notes.

If there is a large pressure drop across filter internals in vessels, this may affect
the vessels design pressure. Refer to 'Vessels' Attachment 16 for guidance
concerning how pressure drops across internals affect design pressures.
Consider the need for pressure relief valves.

2.11 Cover for Cleaning

Many small basket filters have either a bolted top cover or a quick opening one.
State preferred type.

2.12 Materials

State the materials of construction for the body of the filter and also the
internals and any other parts of the filter if there are specific process
requirements. The materials for the body of the filter should be obtained from
the Materials Selection Diagram. Filter element/cartridge materials are not so
straight forward though the preferred type should be stated. The materials
used vary from cotton to metals and high performance plastics. If the material
selection for the element/cartridge is in doubt it is best to leave the choice to
the filter Supplier.

2.13 Insulation

Indicate whether the following typical types of insulation are necessary:

Heat conservation
Cold conservation
Fireproofed
Traced
Jacketed

Do not include any requirements for personnel protection or winterisation,


these will be added by the project engineer according to project standards.
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ATTACHMENT 5 – FILTERS (cont)

2.14 Connections

Depending upon the type of filter, a sketch of the equipment may be required.
Tagging of the filter connections should in any case be as described under
'Vessels' in Attachment 16.

2.15 Miscellaneous Data

Any additional data should be included under 'Notes' or on additional attached


Process Specification Sheets (2068/21). E.g. data on fluids for filter cleaning,
abnormal operating conditions which could affect filter design, details on filter
media materials etc:

For bag filters in particular, the following points should be considered:

Requirement for explosion relief panels


Method of cleaning - reverse jet or vibration
Requirement for integral extraction fan

R2 The performance guarantee criteria e.g. particle size removal, pressure drop
guarantee etc. should be indicated in the ‘Notes’ Section.
R2
If materials of construction or brand/ trade name is mandatory (e.g. client’s
requirement), then state this in the Notes section. If not mandatory, indicate as
‘xxxxx or equivalent’.

3. PROCESS SPECIFICATION SHEET

A copy of the Filter Process Specification Sheet (Ref 2068/25) is included


overleaf.

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ATTACHMENT 5 – FILTERS (cont)

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ATTACHMENT 6 – FIRED HEATERS

1. General

These guidelines should be used when completing the Fired Heater Process
Specification Sheet (2068/4-1/2).

Also refer to Process Standard 306, Heaters/Furnaces

Note that if two fired heaters are specified with a common stack, they should
be considered together during the Process Safety Review. This is particularly
relevant when a combination of fired and natural draught heaters is planned.
This should also be taken into account when specifying the heater trip and
interlock system.

2. COMPLETION OF PROCESS SPECIFICATION

R2 2.1 Service

State the duty for each coil and/or each operating case including the fluid name
e.g. vacuum charge heater, LP steam superheat, BFW preheat etc. If necessary
give the fluid composition by means of separate notes. Use additional
specification sheets if necessary.

2.2 Feed flow

The feed flow should be specified in both m3/hr and kg/hr. This feed flow is
taken as the process fluids and does not include steam injected into the coil in
the heater. The volumetric flowrate should have a reference temperature.

2.3 Feed Density

State feed density at 150C.

2.4 Temperature/Pressure

State temperatures and pressures at the inlet to and outlet from the coil.

2.5 Liquid Properties

The flowrate, density and viscosities of the liquids should be specified at both
inlet to and outlet from the coil. The viscosities should be given at two
reference temperatures.

2.6 Vapour Properties

The flowrate, molecular weight and density of the vapour should be specified
at both inlet to and outlet from the coil. The injection steam should NOT be
considered in this section.

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ATTACHMENT 6 – FIRED HEATERS (cont)

2.7 Vaporisation % wt

State the weight percentage vaporised in the heater of the original feed liquids.

2.8 Maximum Velocity in Tubes

State any limitations in tube velocities. These limitations are frequently quoted
as a percentage of sonic velocity e.g. 80% sonic velocity for vacuum heater in
lube oil plant.

2.9 Corrosive/Erosive Components

List any components that could cause corrosion or erosion problems with tube
metals, especially if the components are in trace amounts. This will aid
material selection.

2.10 Fouling Factor

Where fouling factor information is available this should be included.

2.11 Allowable Bulk Temp.

State the maximum allowable bulk temperature for the process fluid. A
limitation is applied generally to minimise coking in the furnace tubes and is
influenced by the downstream use of the products. A lower bulk temperature
will be specified for a vacuum charge heater in a lube oils block than for a
similar service in a fuels block.

2.12 Max. Allowable Inside Film Temp

Supply the information if available; the same criteria affect its selection as for
bulk temperature.

2.13 Distillation Data Attached

State whether distillation data is attached or not. Refer to notes on relevant


distillation data in section on 'Miscellaneous Information'.

2.14 Max Allowable DP

State the maximum allowable DP through the fired heater for the fluid under
dirty conditions.

2.15 Heat Absorption Rate

The peak absorption rate (i.e. max. allowable) must be specified. It is also
advantageous to specify the allowable average heat absorption rate if the
information is available.
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ATTACHMENT 6 – FIRED HEATERS (cont)

2.16 Heat Gain by Fluid

The heat gain by the fluid entering the coil (i.e. excluding injected steam) is to
be specified.

2.17 Process Steam

Details of any steam injected into the heater coils are to be provided. This will
define its points of injection (e.g. near outlet to control bulk temperature)
flowrate, pressure and temperature.

2.18 Heat Gain by Steam

The calculated heat gain by the injected steam should be given.

2.19 Total Heat to Coil

This is the summation of 'Heat Gain by Fluid' and 'Heat Gain by Steam'

2.20 Total Heat Absorbed

This is the summation of the heat absorbed by all the coils in the heater for the
particular operating case.

2.21 Excess Air

The excess air requirement must be quoted for any statement on guaranteed
minimum net efficiency to be meaningful. The statement on excess air will
ensure a uniform approach by all Suppliers and eliminate the use of inoperable
low excess air values as a means of achieving high efficiencies.

As a rule of thumb the following excess air figures may be used unless other
information is available.

1) for forced draught gas fired heaters 15%


2) for natural draught gas fired heaters 20%
3) for forced draught oil fired heaters 20%
4) for natural draught oil fired heaters 30%

For dual fuel firing use the figure for oil fired heaters.

2.22 Min. Net Efficiency Required

A minimum net thermal efficiency the fired heater should be specified in terms
of percentage of fired fuel based on the fuel lower heat value LHV. A
reference temperature for the combustion air should also be given.

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ATTACHMENT 6 – FIRED HEATERS (cont)

2.22 Min. Net Efficiency Required (cont)

For example 85% based on air at 150C, 92% based on air at 950C (probably
after air preheat). Unless otherwise stated net heating values for the fuels will
be taken at 150C.

The heater guarantee run may be conducted under winter conditions i.e. low
ambient temperature and possibly high wind. When checking requisitions
ensure that Supplier does not expect to achieve guaranteed efficiency under
conditions of no wind and high ambient temperature.

2.23 Type of Fuel

State type of fuel(s) to be used e.g. fluxed vacuum residue, natural gas etc.
Where one fuel is used for a particular operating case this should be made
clear.

2.24 Heating Value

The higher and lower (net) heating values for fuels are shown on the
specification sheet. It is the lower heating value which is important. This
assumes that water vapour does not condense out, giving up its latent heat.

2.25 H/C Ratio (by weight)

Where a composition of the fuel is not available a Hydrogen/Carbon ratio is


required by the fired heater Supplier. This is used to calculate the combustion
air requirements of the fuel.

2.26 Density, Temperature Pressure

Density, temperature and pressure of the fuel are supply conditions at the inlet
flange to the fired heater Supplier's supply. The Supplier must then take into
account pressure drops etc. in his own supply.

2.27 Viscosity

Viscosities should be given for the fuel at two reference temperatures to allow
viscosity data graphs to be constructed. The fuel oil temperature should be
high enough to ensure a fuel oil viscosity of 20-25 centistokes at the burners
to ensure adequate atomization.

2.28 Atomising Steam Pressure

The pressure quoted should be that at the inlet flange to the fired heater.

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ATTACHMENT 6 – FIRED HEATERS (cont)

2.29 Sodium and Vanadium Content (Liquid Fuels Only)

Sodium and vanadium contained in the fuel affect tube metal properties over a
period at the elevated temperatures present in the combustion chamber. This
can cause cracks leading to tube failure.

2.30 Type of Heater

The type of heater required should be indicated as should whether heat transfer
is conducted in both the radiant and convection sections or just the radiant
section. If the Process Engineer has no special requirement choice of heater
type should be left to the Supplier.

2.31 Auxiliary Equipment

Requirement for soot blowers, air preheaters, and fans will usually be
determined by Supplier in which case state "Supplier to advise". If Process
Engineering have any overriding requirements these should be stated as
"required" or "not required". Further information on these items should be
given by notes.

2.32 Coil

The coil number must correspond to the numbers used in the 'Process
Requirements' section.

2.33 Tubes

The material corrosion allowances for the tubes should be as agreed in the
Materials Selection Diagram review.

Tube thickness (if specified) should be indicated as either minimum average


wall thickness or minimum wall thickness. For example 8" Sch 40 pipe has a
minimum average wall thickness of 0.322" and a minimum wall thickness of
0.282".
The design temperature of the fluid should be specified. This leaves the
Supplier to allow for fouling resistances etc. in calculating the design
temperatures for the tube material. Any short term exposure to high
temperatures (e.g. during steam/air decoking) should be noted. Also indicate if
any tube (e.g. steam superheating coil) should be designed for no flow
conditions. Give approximate annual duration for any such transient conditions.

Design pressure of the tube should be in accordance with the Design Pressure
and Temperature Diagram.
If the Process Engineer has any preferred tube sizes or number of tube passes,
or if extended surface tubes are required, this should be noted.

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ATTACHMENT 6 – FIRED HEATERS (cont)

2.34 Return Fittings

Two types of return headers are commonly used, 1800 all welded bends and
plug headers. Unless the Process Engineer has specific requirements for one
type of fitting, this should be left to the Supplier/engineering to specify. The
all welded bends are cheaper than the plug headers. Return fitting may be
internal or external to the heat transfer section. If they are external their
metallurgy will probably be different to that for the coil.

2.35 Terminals

Specify (if necessary) the type and size of inlet and outlet connections to the
coil.

2.36 Stack

The type of stack and its minimum height above grade is usually left to the
Supplier or to engineering. Combined stacks for forced and natural draught
heaters should be avoided if possible. If two heaters are specified with a
common stack they shall be considered together during a Process Safety or
Hazop Review.

Where such a common stack is unavoidable the Process Safety Review and
Hazop Review shall consider the effect of a forced draught fan start up causing
loss of draught in the natural draught furnace, thereby starving the combustion
air supply to the natural draught burner(s).

Operating procedures shall incorporate a warning against such a start up with


precautions included to overcome the problem such as opening up stack
dampers on the natural draught furnaces in advance of starting forced/induced
draught furnaces.

Software logic should be considered to prevent running the forced draught fans
in excess of about 25% air flow during purging and prior to light-off.

The fired heater trip and interlock system shall protect the installation by the
use of high pressure trips in the natural draught furnace and high temperature
alarms at each flue gas mixing point in the ducting to the common stack to
detect local afterburning.

2.37 Burners

The type of burner must be specified. This should detail whether the burner
handles one or both of oil and gas. If no burner mounting position is noted it
will be assumed that burners are floor mounted. Pilot requirements should also
be noted together with the pilot fuel (generally gas).

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ATTACHMENT 6 – FIRED HEATERS (cont)

2.38 Miscellaneous Information

The following is not an exhaustive list but shows where provision of extra data
may be pertinent:

Distillation Data

Distillation data should be provided where vaporisation of process streams


(other than water) is occurring and should include the following:

1) Graph showing temperature versus wt % vaporised at


various pressures.

2) Liquid gravity (SG or 0API) versus wt % vaporised.

3) Vapour molecular weight versus wt % vaporised.

Other information should be supplied as requested.

Soot Blowers

Soot blowers use steam at pressures not below 10 bar ga; a pressure of 14 bar
ga is preferred for more effective cleaning. Pressures up to 40 bar ga may be
used. At low pressures not only will cleaning be less effective but also there is
the possibility of condensation on the tube surface and consequent corrosion.
State steam pressure levels available if soot blowers are required.

Turndown Requirements

The turndown requirements of the fired heater should be indicated and the
cases to which the turndowns are applicable. Any temperature limitations on
steam superheat at reduced flowrates should be clearly stated.

The Supplier may wish to add desuperheating equipment upstream of the


superheat coils or take other measures to limit temperature rise in the coils.
Likewise steam injection into the process fluid upstream of the fired heater may
be required for turndown operation.

Additional Gas Burners

Any additional facilities to burn waste offgas (e.g. sour offgas from vacuum
tower overheads) should be stated together with the details of the gas involved.

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ATTACHMENT 6 – FIRED HEATERS (cont)

Decoking

Requirements for steam/air decoking, abrasive decoking or other decoking


methods should be stated as necessary.

Note that temperatures reached in coils during steam/air decoking are very high
and this should be noted against tube design temperatures.

Special Instrument Requirements

The Process Engineer should clearly state any special instruments required for
process control of the fired heater or for protection against external equipment
failure.

3. PROCESS SPECIFICATION SHEET

R2 A copy of the Fired Heater Process Specification Sheet (Ref 2068/4-1/2) is


included overleaf.

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ATTACHMENT 6 – FIRED HEATERS (cont)

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ATTACHMENT 6 – FIRED HEATERS (cont)

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ATTACHMENT 7 – HEAT EXCHANGERS

1. GENERAL

Heat exchange equipment is divided into three categories for which the
following Process Specification Sheets are available.

2068/4-1/2 Fired Heaters (See Attachment 6)

2068/5-1/2 Exchangers (including shell & tube, plate, spiral, double


pipe etc). (This Attachment)

2068/6 Air Coolers (See Attachment 2)

R2 2068/5-3 Rev 2 Multipass Exchangers forms can be found on Zyqad. If


conversion to Excel is required, contact the Process Systems Group.

The use of separate sheets for exchangers and air coolers, assumes that the
method of cooling process streams (i.e. cooling water or air) has
been discussed and resolved.

If both alternatives are to be considered, then complete process data on both


sheets, and mark the specifications clearly as options. Process Standard 302
Section 2.1 discusses the relative merits of water and air cooling.

To avoid potential confusion if multiple stream exchangers are themselves later


found to be multishell, avoid quoting suffixes such as A/B after the item
number. Multiple stream requirements should be clarified by a note.

All heat exchangers except air coolers and fired heaters are covered by Process
Specification Sheet 2068/5-1/2. Although primarily used for shell and tube
type exchangers, the sheet is also suitable for other types, e.g.

Plate Lamella
Double Pipe Heat Pipe
Spiral Modular Block

The Process Co-ordinator and Heat Exchanger Department (HED) will hold a
review meeting before a formal issue of process specifications. This should be
when Process Engineering has completed the specifications on a complete
process unit. The purpose of this meeting will be to review job philosophy
regarding exchanger design, taking into account the applicable codes, licensor
requirements etc.; it will include a preliminary review of design and short-term
conditions. Where HED indicate that a short-term condition would govern
design, Process Engineering would have the opportunity, before official
issue, to review their requirements, and confirm or alter their data.
Engineering should be invited to attend since piping design conditions can be
affected.

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ATTACHMENT 7 – HEAT EXCHANGERS (cont)

2. COMPLETION OF PROCESS SPECIFICATION

2.1 Preferred Type

Tick the most appropriate exchanger type, and describe the "other" type if
selected.

In contract work, unless the Process Engineer or licensor have specific


preferences, the choice should be left to HED. In this case the
Process Engineer should indicate "No preference".

In proposal work where HED may not be involved, the Process Engineer must
make the choice, but HED advice should still be sought.

2.2 Total Performance of Each Item

The information contained in Sections 2.3 to 2.24 is of a process design nature


and is almost exclusively independent of the heat exchanger type. The only
exception is the fouling factor which tends to be lower for plate, spiral, etc.

If the exchanger has alternative duties which may influence the exchanger
design, then use a separate specification sheet for each duty.

2.3 Side

The two sides of the heat exchanger are labelled hot side and cold side and
should be completed accordingly.

If the process engineer has a mandatory requirement, complete Note 2.


Otherwise delete Note 2 (see Process Standard 301 p. 4.0-10 for "rules"
governing "orientation").

2.4 Fluid Name

This describes the nature of the fluid e.g. reactor feed, boiler feed water etc. If
full analysis of the stream is relevant, then give this on sheet 2. Delete note 3
if fluid composition is not given.

R2 2.4a PED Fluid Type/ State

Refer to Section 3.13 Fluid Category.

2.5 Corrosion/Erosion/Fouling by

State whether the fluid is fouling and advise the nature and concentration of
materials, if present, which are liable to cause corrosion or erosion.

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ATTACHMENT 7 – HEAT EXCHANGERS (cont)

2.6 Fluid Flowrates (kg/hr)

Flowrates corresponding to the design rate duty are required. If this is not the
maximum flowrate case, specify this as an alternative, as it will
probably control the pressure drop through the exchanger.

Additionally where a fluid has a high pour point or high viscosity, it is


mandatory to specify the minimum flowrate. With an associated low allowable
design pressure drop laminar flow and problems of poor heat transfer and
plugging in the tubes may result.

Provide data on the six different categories as shown on the process


specification.

Exclude steam from the vapour flowrate and quote it separately.

Quote the molecular weight of the vapours and noncondensables as separate


streams. (Steam MW does not need stating).

2.7 Temperature (0C)

Provide inlet and outlet temperatures for the two streams. Ensure that these
are consistent with the heat duty quoted below or clarify with a note.

2.8 Inlet Pressure (bar abs)

Quote for streams containing vapour. For liquid only exchangers, operating
pressure is not relevant and should be omitted (it is influenced by detailed
hydraulics which may not be complete at this stage.)

2.9 Pressure Drop Allowable (bar)

Refer to Process Standard 301 sect. 4.8 for typical shell and tube allowable DP
values. If the only process limitation is a combined DP for a number of
exchangers, state this using a note.

Where possible refer to thermal rating sheets from previous contracts to ensure
that allowable pressure drops quoted can be usefully used.

Note that shell side pressure drops are generally lower than tube sides.

For exchanger types other than Shell and Tube refer to Suppliers data for
typical values.

Note that the pressure drop given here should be consistent with the flowrates
as given under 2.6 above. If a margin is required on flow (see 2.24 below)
then a higher pressure drop will result at this increased flow condition.

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ATTACHMENT 7 – HEAT EXCHANGERS (cont)

2.10 Specific Heat (kJ/kg 0C)

Provide specific heat data for both liquid and vapour components at inlet and
outlet conditions.

For vapour streams ensure that specific heat is corrected for pressure.

2.11 Viscosity (cP)

Specify the viscosity of the fluid at inlet and outlet temperatures. If the
exchanger has a range of duties specify also the maximum viscosity case. For
fluids with very high viscosity, it may be necessary to increase the allowable
design pressure drop to ensure turbulent flow. (See also dew point/bubble point
discussion paragraph 2.18).

2.12 Thermal Conductivity (W/m0C)

Provide thermal conductivity data for both liquid and vapour components at
inlet and outlet conditions.

For vapour streams ensure that data is corrected for pressure.

2.13 Liquid and Vapour Density (kg/m3)

Provide density of liquid components (vapour density follows from


temp/press/MW/compressibility data).

2.14 Vapour Compressibility

Provide compressibility factor for the mixed vapour stream at inlet and outlet
(including steam and non-condensables).

2.15 Liquid Surface Tension (mN/rn)

Provide liquid surface tension at inlet and outlet. This is only required for
exchangers in which vaporisation or condensation takes place. (Note that 1
dyne/cm = 1 mN/in)

R2 2.16 Critical Press/Temp. (bar abs/0C)

Provide critical pressure and temperature values for liquid and vapour mixtures.

R2 2.17 Hydrate/ Pour Point/ Freezing Point (0C)

Specify a hydrate formation point, pour point or freezing point if the exchanger
operates at or near this temperature.

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ATTACHMENT 7 – HEAT EXCHANGERS (cont)

2.18 Dew Point/Bubble Point (0C)

If the exchanger acts as a condenser or evaporator and handles superheated


vapour or subcooled liquid, quote the dew point and/or bubble point of the fluid
as appropriate.

If subcooling is required, then the exchanger will need a control scheme or seal
capable of back flooding the bundle. Details of this should be shown by a
sketch on sheet 2.

R2
Provide physical properties of the liquid and vapour at the bubble point and/or dew point on a
separate sheet of the specification. Dew point and bubble points are optional
if heat curves are provided. However, for phase changes that result in unusual
heat curve patterns (e.g. kink resulting from water dew point in hydrocarbon
& water system), then dew point and/or bubble points are to be provided.

2.19 Latent Heat (kJ/kg) (For condensing/vaporising duties only)

Supply latent heat data at condensing conditions or provide a heating/cooling


curve if latent heat varies through the condensing range.
R2 2.20 Heating Curve Attached Yes/No

Delete as applicable.

For phase change duties a heating/cooling curve must be given (for both sides
of the exchanger if applicable) unless involving only isothermal streams such as
steam.

The heat curve data generated by the process simulator should normally be
used directly by cutting and pasting the simulation output to provide a paper
attachment to the hard copy datasheet.

The heat curve data should also be made available to Engineering electronically
to enable them to directly import the information into the exchanger thermal
design program. This should be done in the form of an Excel spreadsheet table
for each isobaric (constant pressure) curve laid out as shown below.

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ATTACHMENT 7 – HEAT EXCHANGERS (cont)

Pressure (bara)
Temperature Entire Entire Vapour Vapour Vapour Vapour
(deg C) Stream Stream Density Viscosity Therm. Spec. Heat
Enthalpy Mass (kg/m3) (cP) Cond. (kJ/kgC)
(MW) Vapour (W/mC)
(%)
Point 1
Point 2
Point 3
Point 4
Point 5
Point 6
Point 7
Point 8
Point 9
Point 10

Temperature Liquid Liquid Liquid Liquid


(deg C) Density Viscosity Therm. Spec. Heat
(kg/m3) (cP) Cond. (kJ/kgC)
(W/mC)
Point 1
Point 2
Point 3
Point 4
Point 5
Point 6
Point 7
Point 8
Point 9
Point 10

Up to 3 isobaric curves, each with up to 10 temperature points can be input


into the thermal design program. Ideally at least 2 isobaric curves should be
provided spanning the full operating pressures of (each side of) the exchanger.

For condensing and boiling cases with high inlet pressures, say above 15bar,
and where the pressure drop is less than approximately 1bar, then one non-
isobaric curve may can be provided based on the inlet pressure and allowable
pressure drop to the exchanger. Intermediate points should be based on
intermediate temperatures and pressures.

For kettles one isobaric curve should be provided at the pressure of the vapour
space above the liquid in the kettle and another curve at an additional 0.15bar
(approx) to enable static head effects to be taken into account. For operating
pressures above 15 bara, a single isobaric curve should be sufficient as the
effect of the static head will be negligible.

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ATTACHMENT 7 – HEAT EXCVHANGERS (cont)

2.20 Heating Curve Attached Yes/No (cont)

For thermosyphon reboilers two isobaric curves are required, one at the column
pressure and the other at the column pressure plus static head (approx 0.35 bar) to
enable the actual heat curve within the thermosyphon loop to be determined.

2.21 Velocity Allowable (m/sec)

Specify any limitations on velocities. To minimise fouling, minimum velocities


are specified where the process fluids contain solids such as catalyst, or where
the process fluid is water (for these services the velocity is generally not less
than 0.9 m/sec). In addition maximum velocities are sometimes specified to
prevent erosion.

2.22 Fouling Factor (W/m2oC)-1

Refer to TEMA Standards for Typical SheIl & Tube Fouling Factors.

Fouling factors are influenced by type of exchanger (e.g. generally lower for
plate types).

Consult technical literature/Suppliers brochures for specific data.

2.23 Heat Exchanged (kW)

Heat exchanged should be consistent with temperatures and physical


properties listed above.

Heat loss to the atmosphere is ignored here, as insulation should reduce this to
a very small level (maybe 3% of heat load). However remember to allow for a
heat loss such as this when uprating steam/fuel usage rates for guarantee
purposes.

R2 2.24 Margin Required on Duty & Flow

Refer to Attachment 2, Section 2.1.23

2.25 Design Pressure/Temperature

These conditions should be consistent with the Design Pressure and


Temperature Diagram.

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ATTACHMENT 7 – HEAT EXCHANGERS (cont)

2.26 Short Term Maximum Temperature/Pressure

Give maximum temperature and coincident pressure that is likely to occur as


the result of maloperation or a failure condition. Also give the anticipated
duration for such conditions.

HED will design exchangers so that either side can withstand its design
pressure with atmospheric pressure (or full vacuum if specified) on the other
side. In some cases a cost saving may result if the design differential pressure
between hot and cold side is reduced. If the Process Engineer considers that
advantage of such a situation can safely be taken then this should be clarified
by means of notes.

R2 2.27 Minimum Temperature During Atmospheric Venting

If venting of the exchanger can result in temperatures below 00C, the minimum
temperature that will be experienced should be specified. This will normally be
the atmospheric boiling point of the fluid handled. Refer to Technical Work
Practice GEN/DTA/31-08 Design Temperatures and Pressures.

2.28 Mechanical Cleaning Requirements

Indicate whether the fouling nature of the fluid requires mechanical cleaning.
Engineering/HED will determine the effect on the hardware.

2.29 Cyclic Service

Indicate if the service is cyclic and give details of frequency by means of notes.

2.30 Materials of Construction

Different types of heat exchanger may require different materials of


construction for the same process duty.

(E.g. plate and spiral types are not made in carbon steel and can have no
corrosion allowance).

The minimum material suitable for process duty should be stated here as
primary materials selection. The corrosion allowance consistent with this
material choice, and any stress relief for process reasons should also be noted.

Specify any materials, which must definitely be excluded (e.g. No Copper) in a


note.

N.B. The materials finally chosen may be higher grade than shown on sheet 1.

The primary requirement should be consistent with the Materials Selection


Diagram.
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ATTACHMENT 7 – HEAT EXCHANGERS (cont)

2.31 Line Size In/Out

Supply if known (HED compare their calculated nozzle sizes to the line size to
ensure a reasonable match, but they are not necessarily the same).

2.32 lnsulation

Indicate only process requirements for insulation e.g. tracing, jacketing, heat
conservation, cold conservation.

Do not indicate personnel protection or acoustic protection, which are


Engineering responsibility.

R2 2.33 Fluid Composition

Provide the fluid composition on a separate sheet.

Indicate also, whether the service is Sour, Hydrogen or Lethal. The definition of
these terms is usually driven by the client. Hydrogen service is typically if the
H2 partial pressure is above 7 bar. According to API 617, sour service is
classified under NACE MR 0175. In many applications, small amount of H2S are
sufficient to require materials resistant to sulphide stress corrosion cracking.
When trace quantities of wet H2S known to be present or there is uncertainty
about the quantity of wet H2S present, consideration should be given to use of
materials that are resistant to sulphide stress corrosion cracking.

Lethal service should be in accordance with client or local legislation


requirements. Where lethal service is identified, this must be checked with the
Client in view of the likely cost implications.

2.34 Equipment Selection

Data in this section is optional, and should only be completed if:

a) Process Department or Licensor have specific requirements on a


contract, or

b) Process Department are making equipment selection themselves for a


proposal.

The blank process specification sheet 2068/21 may be used for continuation if
no information is included in this section.

2.35 Sketch

Provide a sketch if relevant to understanding of the heat exchanger duty, this


is particularly important for reboilers and other special designs.

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ATTACHMENT 7 – HEAT EXCHANGERS (cont)

3. PROCESS SPECIFICATION SHEETS

R2 A copy of each Heat Exchanger Process Specification Sheet (Ref. 2068/5-1/2)


is included overleaf.

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ATTACHMENT 7 – HEAT EXCHANGERS (cont)

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ATTACHMENT 7 – HEAT EXCHANGERS (cont)

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ATTACHMENT 8 – INSTRUMENTS

1. GENERAL

This Technical Work Practice supersedes FWEC Design Bulletin No.10 (revised
issue August 7th 1975).

Section 2. outlines the way to complete the Instrument Process Specification


Sheet (2068/18). For special instruments e.g. on line analysers additional
information must be given on the blank Process Specification Sheet (2068/21).

The Instrument Process Specification Sheet shall also be used for globe valves
where some degree of control is required.

On certain projects, process data for instruments may be transferred to


Instrument Engineers electronically using the PC-based Process Instrument
Database.

Local pressure and temperature instruments and remotely operated ball valves
are not normally specified by the Process Engineer. The Instrument Engineer
will obtain the required information from the Line Classification List.

2. COMPLETION OF PROCESS SPECIFICATION

Use one set of sequentially numbered Specification Sheets for each EFD and
put only one type of instrument on each sheet (but see 2.1 below). The
headings used are as on the Specification Sheet.

2.1 Instrument Type

Group instruments by types on the Specification Sheet e.g. temperature


instruments, flow instruments, control valves, etc. Critical instruments such as
control valves, relief valves, and flowmeters should be issued by type of
instrument, first, across the project to minimise delay in issuing requisitions.

The only exception to this concerns flow transmitters and associated flow
control valves. These should preferably be shown on adjacent columns of data
sheets so that inconsistencies between orifice and associated flow control
valve are easily spotted. Head the sheet "Flow Transmitters and Control
Valves".

2.2 Engineering Flow Diagram No.

Each Instrument Process Specification Sheet should be specifically for one EFD
only, and its drawing number should be entered here accordingly.

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ATTACHMENT 8 – INSTRUMENTS (cont)

2.3 Process Data

Line Instructions
Number

R3 1 General: Item no, EFD no & Service

Data required for all items.

1. Show instrument symbol such as "TRC", "FRC", "FRCV", "LIC",


"PDI", etc. followed by the instrument number. For example:
TRC-401. Instruments are numbered by the Instrument Group
and frequently the numbers are not available when the process
Engineer fills out the Instrument Process Specification Sheet. In
this case, identification will be dependent on the Service
discipline. Instrument numbers should be added when available.

Service description should refer to the nearest


appropriate equipment item FIRST e.g. "E-401 OUT" or P-301
DISCHARGE PRESS".

2. As stated in 2.1, instruments should be grouped by type. Blank


columns should not be filled in with other types of instruments.
This leaves room for additional items.

R3 2 Analyser: Function, Type & Accuracy

Data required for Analysers.

Fill in the details of the Function, Type and Accuracy of the analyser.

R3 3 Prelim Line Size

Data required for all items.

This line need only be completed when the current issue of Engineering
Flow Diagrams does not contain this information. Instrument Group
will normally obtain line sizes from Flow Diagrams. Later issues of
Instrument Specifications should have this information deleted.

1. Indicate nominal line size.

2. Upstream and downstream line sizes should be shown if


different.

3. If the instrument is mounted on a vessel leave blank.

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ATTACHMENT 8 – INSTRUMENTS (cont)

R3 4 Fluid Type, State

Data required for all items.

Only normal case to be shown. Other fluids if present in


alternate operating cases, should be covered by additional
notes. Indicate Fluid Type number by reference to Engineering
Standard 67A1 (extract in Section 2.7 of this Technical Work Practice).
On some projects, hazardous and toxic service identification letters
have been ascribed too. Refer to Instrument Group at start of project
for advice on this matter.

Indicate fluid state e.g. VAP, LIQ or MIX (if 2-phase).

Provide an abbreviated description of the fluid e.g. "Bright


Stock"; "HC"; "Steam".

List compounds (as a note at foot of Specification Sheet), especially


trace components, which may give rise to corrosive or erosive
conditions at the instrument or valve.

R3 5 PED Fluid Type, State

Data required for all items, only if the equipment falls under the PED.

The Pressure Engineering Directive (PED) applies only to installations in


the European Union. For further information on the PED, please refer to
Technical Work Practice DTA/GEN 11-16 and FWEL Contract Execution
Procedure FWEL/44/E24.

R3 6 Fluid Composition

Data required for Analysers.

Fill in the components and % of the stream to be analysed from the


mass and energy balance.

R3 7 Normal Flow

Data required for Flow Instruments and Control Valves.

State material balance normal quantities. Do not include safety factors


for equipment design. Use additional columns for alternate cases
which have substantial variations in flow quantities from the normal
case.

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ATTACHMENT 8 – INSTRUMENTS (cont)

R3 8 Max Flow %

Data required for Flow Instruments and Control Valves.

Show the maximum flow variation expected in the design


material balance as a percentage of the normal flow. For example:
110%. This factor should take into account equipment design safety
factors. For example, on a column reflux an extra 20% might be
allowed for above the design flowrate. Remember that a single orifice
plate/transmitter normally has a usable maximum flow ratio of 3 to 1 (4
to 1 is the widest possible ratio). A wider ratio will require either two
transmitters or alternative measuring devices such as vortex shedding,
variable area or ultrasonic flow meters. The allowable pressure drop
may need to be increased if dual transmitters are used.

In control valve calculations, the normal operating temperature will be


used for maximum and minimum flows, unless otherwise noted.

R3 9 Min. Flow %

Data required for Flow Instrument and Control Valves

Show the percent of normal flow equivalent to the minimum normal. For
example: 50%. See remarks against Max Flow % (line 8) regarding flow
ratio.

R3 10 SG @15oC

Data required for all Liquid Flow and Level Instruments.

State the specific gravity of liquid at 150C.

R3 11 SG @ Flow Conditions

Data required for all Flow and Level Instruments, Specific Gravity
Meters, Analysers and Control Valves handling liquids.

State the specific gravity of liquid at operating temperature.

R3 12 Viscosity @ Flow Conditions

Data required for Flow Instruments, Analysers, pH meters and Control


Valves handling liquids.

Viscosity at flowing temperature should be given in centipoises.

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ATTACHMENT 8 – INSTRUMENTS (cont)

R3 13 Liquid Vapour Pressure

Data required for Flow Instruments and Control Valves handling Liquids.

Indicate vapour pressure of the stream in bar abs at flowing


temperature.

R3 14 Liquid Critical Pressure

Data required for Flow Instruments, Control Valves and Restriction


Orifices handling Liquids.

Give the critical pressure of liquid stream in bar absolute when


vapour pressure is greater than half the inlet pressure.

Approximate figures will generally be adequate. The data is used for


noise estimation.

R3 15 Liquid Electric Conductivity

Data required for Flow Instruments handling liquids.

Give the electric conductivity for the liquid stream.

R3 16 Liquid dielectric Constant

Data required for Level Instruments.

Give the dielectric constant for the liquid.

R3 17 Mol. Wt.

Data required for Level and Flow Instruments, Control Valves and
Analysers handling gas or vapour.

State the molecular weight of gases or vapours in the steam.

R3 18 Viscosity @ Flow Conditions

Data required for Flow Instruments, Analysers, pH meters and Control


Valves handling gases or vapour.

Viscosity at flowing temperature should be given in centipoises.

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ATTACHMENT 8 – INSTRUMENTS (cont)

R3 19 Vapour Cp/Cv @ Flow Conditions

Data required for Flow Instruments and Control Valves.

State specific heat ratio of gases or vapours at upstream conditions.


See API data book Chapter 7 for estimating methods.

R3 20 Vapour Compressibility (PV/RT = Z)

Data required for Flow, Level Instruments and Control Valves handling
gas or vapour.

State the compressibility factor for the gas or vapour of the stream.

R3 21 Vapour Density

Data required for Flow, Level Instruments and Control Valves handling
gas or vapour.

State the vapour density of the stream.

R3 22 Operating Temperature: Minimum, Normal & Maximum

Data required for all items.

Give minimum, normal and maximum operating temperature in °C.


(Note that maximum working temperature of soft seats is limited).

R3 23 Pressure @ Normal Flow: Upstream & Downstream

Data required for Control Valves, Restriction Orifices and Flow


Transmitters:

Give upstream and downstream pressures in bar g under normal flow


conditions. For flow instruments show downstream pressure whenever
assumption of maximum pressure drop has been made in hydraulic
calculations.

Data required for Temperature, Level and Pressure Instruments:

Give normal static upstream pressure in bar g.

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ATTACHMENT 8 – INSTRUMENTS (cont)

R3 24 Pressure @ Maximum Flow: Upstream & Downstream

Data required for Flow Instruments and Control Valves.

When the value given in line 8 is greater than 130% or if pressure drop
is outside ±15% of value given by lines 23 to 27 (i.e. If the pressure
drop cannot be derived by application of square law).

State upstream and downstream pressures in bar g at the


control valves at maximum flow conditions shown in line 8.

Data required for Pressure Instruments:

Give maximum static upstream pressure in bar g.

R3 25 Pressures @ Minimum Flow

Data required for Control Valves.

When the value given in line 9 is less than 50% or if pressure drop is
outside ±15% of value given by lines 23 to 27.

State upstream and downstream pressures in bar g at the control


valves at minimum flow conditions shown in line 9.

Data required for Pressure Instruments:

Give minimum static upstream pressure in bar g.

R3 26 Max Control Valve DP

Data required for Control Valves.

State the maximum possible DP across the closed control valve. This
will size the actuating device.

The upstream pressure is usually taken to be the design pressure of the


system. In some cases e.g. dual acting valves on heat exchanger and
bypass, this may be relaxed to avoid over sizing the actuator. Provide
the lower pressure as a note for Instrument Group to consider e.g.
"max deltaP for actuator sizing can be reduced to xxx bar".

R3 27 System DP @ Normal Flow

Data required for Control Valves.

This is the frictional loss in the system excluding the control


valve pressure drop. It can assist in selecting the correct control
valve trim.

Consider the case where fouling may increase pressure drop


during operation.
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ATTACHMENT 8 – INSTRUMENTS (cont)

R3 28 Downstream Flashing

Data required for Control Valves.

State 'yes' or 'no'. If yes see item 4 under line no. 38.

R3 29 Tight Shut Off

Data required for Control Valves

If tight shut-off is not required, then state 'No'. Otherwise the


TSO type is to be specified with reference to ANSI Standard
FCI/70-2/1976 (rev 1987).

TSO valves shall generally be type 4. Type 5 valves shall only be used
for clean service and require the use of PTFE seals (or similar). If a
control valve is in series with a shut off valve and it is necessary to call
for tight shut-off on the control valve, then type 3 should be specified.

The philosophy should be checked with Instrument Group on a Project-


specific basis.

R3 30 Air Failure

Data required for Control Valves

Indicate valve action on instrument air failure;


Open '0'
Close 'C'
Lock-in-Position 'L'

For lock-in-position, also state, in brackets ('0') or ('C') since the valve
will eventually move on expiry of its self contained air supply, i.e. L (0)
or L (C) means respectively lock (tend to open) and lock (tend to close).

R3 31 Time to Close

Data required for Control Valves.

State valve closure time where critical e.g. 120 seconds minimum (to
avoid pressure surges, say) or 3 seconds maximum (quick closing, say).
Entry should be in the form 120 min or 3 max.

R3 32 Instrument DP: Normal & Maximum

Data required for Pressure Instruments.

State the normal and maximum differential pressure the instrument will
be exposed to
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ATTACHMENT 8 – INSTRUMENTS (cont)

R3 33 Velocity

Data required for Temperature Instruments.

State the stream velocity the instrument will be exposed to.

R3 34 Instrument Range

Data required for Temperature, Level & Pressure Instruments.

State the range of the range of the instrument.

R3 35 High Alarm

Data required for All Instruments.

Unless noted otherwise, units or measurement shall be as per the basic


instrument. Level alarm set points shall be shown on the vessel
Process Specification.

R3 36 Low Alarm

As per High Alarm. Refer also to Section 2.8.

R3 37 Reference Point / Level

Data required for Level Instruments.

State the reference point or level for the values in line no.’s 35, 36 &
38.

R3 38 Remarks

This space and the "NOTES" section below, should be used for adding
supplementary process data, as appropriate, which are not covered in
1-37 above.

1. Indicate the value of a process variable (e.g. temperature, flow,


level, pressure, etc) at which alarm and/or shutdown should
occur. See Section 2.8 for guidance concerning flow alarms.

2. Show restrictions on level controller floats, special


gauge glasses, special ranges or protective stops for instruments
which are required to operate over narrow ranges (e.g.
suppressed range pressure instruments).

3. Indicate special purging, steam tracing, or any other


special treatment of control valves and instrument element in
contact with the process fluid. Indicate whether protective
diaphragms are required on pressure or level instruments when
Process Department have special knowledge of requirement.
Instrument Group normally detail instrument protection.

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ATTACHMENT 8 – INSTRUMENTS (cont)

R3 4. Show percent by weight of liquid flashed and molecular


weight of resulting vapour if "yes" is indicated in line 28.

5. Show liquid pour points higher than lowest average


design ambient temperature.

6. Note presence of slurries or fouling type materials.

7. For pressure indicators the blocked-in-pressure should be given


in case it may go beyond the normal operating scale. For
example, a refrigeration system with a range of full vacuum to 1
bar may go to 20 bar when the system is blocked in.

8. Pump shut-off pressure should be indicated for any control valve


which must handle extremely low flow under start-up
conditions.

9. Indicate if mechanical limit stops are required for control valves.

10. Specify thermocouple burnout scale direction e.g. "Up scale" for
temperature control of fired heaters and furnaces, when required
for safety reasons.

11. For analysers, pH meters and specific gravity meters, process


data such as operating range, stream components, corrosive
elements, catalyst contamination, sample disposal and accuracy
required, should be given.

R3 12. Instrument Group will normally allocate hand wheels or block


and by-pass valves to each control valve
according to Engineering Standards. (FW Standards
specify hand wheels for control valves 2" and larger).

Process Engineers should indicate special requirements,


e.g. block and by-pass on larger valves for operability
and corrosive/erosive service. Process Engineers should mark all
block and by-pass valves required for such reasons on the first
issue of Engineering Flow Diagrams.

13. Indicate if a self actuating control valve is required.

14. Indicate if any special control valve action is required


e.g.
slow shutoff
quick open
on-off action

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ATTACHMENT 8 – INSTRUMENTS (cont)

15. For globe valves where some degree of control is required (e.g.
in series with a flow indicator) the following note should be
added "A hand control valve is not required. Instrument Group
to size as globe valve". Such valves are to be numbered as per
an HCV.

16. Show required range of variable to be covered by pressure and


temperature instruments if not shown elsewhere.

Note that level instrument range is normally shown on Vessel


Process Specification.

17. For complex control loops indicate operating requirements, e.g.


phased valve operation, split range valves.

18. Indicate whether any instrument reset should be automatic or


manual. It can be very inconvenient to have to go onto the plant
to manually reset a solenoid valve, conversely it may sometimes
be dangerous for solenoid valves to reset automatically.

19. Indicate whether any special features are required for


the instrument e.g. plastic instrument air tubing (fusible link) for
failsafe during fire.

20. State preferred vendor(s) if any for specialist items and give full
information.

21. Indicate when reverse flow is possible. Control valves,


flow instruments etc. are not able to handle reverse flow. Also
state maximum reverse flow, delta P etc. Include a check valve
to protect the instrument if necessary.

22. For certain types and sizes of thermowells, Instrument Group


require the velocity of the fluid (gas or vapour) in the pipe to
enable vibration checks to be made. Check with Instrument
Group on a project specific basis.

R3 39 Revision

The latest revision number should be indicated in this line when


data is changed. Use '0" for the initial issue.

2.4 Variation Limits for Alternative Conditions

If alternative process conditions exist which exceed the data variation limits
given below, then these conditions shall be shown on a separate column. The
item number is to be repeated in line 1, and the word "alternative" added.

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ATTACHMENT 8 – INSTRUMENTS (cont)

R3 Line Number Variation Limit

11 10% liquid specific gravity.


12 20% of the viscosity when the viscosity is greater than 40 cps.
17 10% of the molecular weight; gases and vapours.
23/24/25 10% of the absolute upstream pressure; gases and vapours.
23/24/25 15% of pressure drop across control valves.

2.5 Requisitions

The Process Engineer must review the instrument requisitions in the normal
way, mainly checking process data.

2.6 Control Valve Cv

If the control valve purchased has a high Cv, when wide open this valve could
pass a much higher flowrate than the Process Engineer originally envisaged.
This can affect relief valve sizing and other process aspects. The Process
Engineer should therefore specifically check the Cv of the control valve and its
by-pass valve which may have a greater capacity than the control valve.

2.7 Fluid Type

The following list of fluid types is taken from FW Engineering Standard 67 Al.
R3 The type number should be given in line 4 of the Process Specification Sheet.

Specification of fluid type number will assist the Instrument Engineer to provide
winterisation or other protection in accordance with Engineering Standard 67 Al.

Fluid Type Fluid Definition or Property

1 Water and water solution with freezing point approximately 0OC.

2 Liquids from which gravity separation of water could cause water to


accumulate in impulse lines (not because of steam out operations).

3 Corrosive liquids (only those corrosive to wetted parts of instruments


or instrument impulse lines).

4 Liquids whose pour points are above the minimum design (or lowest
average) ambient temperature.
5 Liquids which may change in chemical composition due to a decrease
in temperature from operating to minimum design or lowest average
ambient temperature. Specify minimum maintained temperature
(MMT).

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ATTACHMENT 8 – INSTRUMENTS (cont)

6 Liquids which could vaporise at an operating pressure and at ambient


temperature conditions.

7 Liquids which contain solids.

8 Steam

9 Corrosive vapours and gases.

10 Air, vapours and gases containing solids.

11 Wet gas

12 Dowtherm or other proprietary vapour heat transfer fluid.

13 Liquid heat transfer fluid.

14 No Protection Required. For fluids such as dry gas, (i.e. inert gases, dry
gases, non-corrosive fluids), hydrocarbon gas and clean air. The term
dry shall mean free from condensables at the minimum ambient design
temperature. [Note that liquids from distillation columns in which
water is present will be saturated with water (e.g. caustic washes,
amine treatment)].

15 Hygienic

16 Aseptic

17 Process fluids which require minimum maintained temperatures (MMT)


above –44OC other than 4 above.

18 Light hydrocarbons (C2-C5) which will be in a vapour state at


operating pressure and maximum ambient temperatures.

19 Light hydrocarbons (C2-C5) which will be in a liquid state at operating


pressure and all ambient temperatures.

20 Hydrocarbon vapours which can condense at operating pressure and


any ambient temperature

21 Pyrophoric substances e.g. DEAC/TEAL.

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ATTACHMENT 8 – INSTRUMENTS (cont)

2.8 Alarm Settings

The following guidance is given on low flow alarm settings in respect of flow
measurement based on differential pressure (e.g. orifice plates, venturi, nozzles,
Dall tubes, pilot tubes and Annubars).

The low flow alarm setting needs to fall within 3.5:1 turndown from ‘scale
maximum’ for flows measured.

The Instrument Group rule of thumb for setting an instrument “scale maximum”
is to take the greater of:
- Normal flow x 1.33
or, Maximum flow x 1 .1

For a 3.5:1 turndown on the instrument ‘scale maximum’, the resultant


minimum alarm setting is as shown below:

Examples

% %
Normal (design) 100 100
Maximum 110 125
Instrument Scale Maximum 133 137.5
Alarm Set Minimum (3.5:1 turndown) 38 39.3

R3 When a low flow alarm involves a turndown of greater than 3.5:1 from
instrument scale maximum the Instrument Group should be consulted as it may
require the use of multiple (or smart) transmitters.

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ATTACHMENT 8 – INSTRUMENTS (cont)

2.9. Summary of Data required

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ATTACHMENT 8 – INSTRUMENTS (cont)

3. Process Specification Sheet

R3 A copy of the Instrument Process Specification Sheets (Ref. 2068/18) are


included:

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ATTACHMENT 8 – INSTRUMENTS (cont)

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ATTACHMENT 8 – INSTRUMENTS (cont)

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ATTACHMENT 8 – INSTRUMENTS (cont)

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ATTACHMENT 8 – INSTRUMENTS (cont)

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ATTACHMENT 8 – INSTRUMENTS (cont)

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ATTACHMENT 8 – INSTRUMENTS (cont)

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ATTACHMENT 9 – MECHANICAL HANDLING EQUIPMENT

1. General

The Mechanical Handling Process Specification Sheet should be used for such
items as conveyors, (screw, drag, belt, pocket etc), elevators (bucket, pocket
etc), weighfeeders, weighbelts, grizzly screens etc. For other items e.g.
classifying screens or pneumatic conveying systems, this sheet can be used in
conjunction with the blank Process Specification Sheet (2068/21) to describe
the required system. Include a sketch whenever possible.

2. Completion of Process Specification

2.1 Material Handled

Specify the material handled.

2.2 Temperature and Pressure

The normal operating temperature and pressures should be completed in all


cases. The maximum operating conditions should also be completed except for
equipment under pressure, subject to explosions, autoignition etc. in which
case design conditions should be entered.

Note that for exposable dusts the I. Chem. E guide requires a minimum design
pressure of 0.2 barg. Higher design pressures may be more economic by
allowing reduced vent areas.

2.3 Density

Both solid and bulk densities are required.

2.4 Angle of Repose

This should be completed in all cases.

2.5 Size Distribution

The Process Engineer should provide all available data on size distribution.

2.6 Maximum Particle Size

This should be indicated in all cases. It may be important in setting clearances


of, for example, protective screens.

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ATTACHMENT 9 – MECHANICAL HANDLING EQUIPMENT (cont)

2.7 Material Characteristics

A multi choice system is used to specify properties of the material which


cannot be measured precisely. The Process Engineer should give his own best
estimate as to that property by ticking the appropriate box. Any supplementary
knowledge should be provided in the 'Notes' section.

2.8 Material Description

Describe material in as much detail as possible by reference to similar materials


if necessary. Use notes section of specification sheet as necessary.

2.9 Flowrate

Specify the required range of flowrates.

2.10 Distance Between Inlet/Outlet

This is usually a best estimate only and as such Note 1 (Distance is an estimate
only) has been added. If the distance is an accurate one Note 1 should be
deleted. Final dimensions will be confirmed by Project Engineer in conjunction
with the Drawing Office (layout).

2.11 Operation

State whether continuous or intermittent. Duration of each operating case


(hrs/yr) is required.

2.12 Angle of Incline

Estimate the angle of incline for the equipment. If a maximum allowable angle is
known, this should be stated. Leave for Engineering/ Layout if necessary.

2.13 Equipment Type

State the suitable equipment type for this duty e.g. bucket elevator, screw
conveyor, belt conveyor etc.

2.14 Drive

This is usually an electric motor but if more specific data is available e.g.
variable speed, reversible drive etc. then state this as well.

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ATTACHMENT 9 – MECHANICAL HANDLING EQUIPMENT (cont)

2.15 Miscellaneous Data

Data on the material(s) handled and equipment not covered in the specification
sheet should be added in the notes section. For example:

- Toxicity of material handled

- Possibility of dust explosions and required relief provisions, explosion panels


should be fitted with failure detection systems to shut down the plant.

- Flammability
- Dust control
- Define the performance guarantee criteria in detail. E.g. Capacity.

- If materials of construction or brand/ trade name is mandatory (e.g. client’s


requirement), then state this in the Notes section. If not mandatory, indicate as
‘xxxxx or equivalent’.

2.16 Process Sketch

Space is provided on the data sheet for a process sketch or additional notes if it
is required. Use the blank Process Specification Sheet (2068/21) if necessary.

3. Process Specification

A copy of the Mechanical Handling Process Specification Sheet (Ref. 2068/16)


is included overleaf.

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ATTACHMENT 9 – MECHANICAL HANDLING EQUIPMENT (cont)

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ATTACHMENT 10 – PACKING

1. General

The Packing Process Specification is divided into three principal sections as


follows:

• Contains basic data defining the points for which the hydraulic loading data
is given and establishing column size.

• Contains hydraulic loading data to permit the packing Supplier to confirm


column size and give performance guarantees.

• Covers materials of construction and other mechanical design features.

2. Completion of Process Specification

2.1 Operating Case

Independent data should be supplied for all operating cases which vary
significantly from the normal. Possible reasons for different operating cases
are:

Campaign Operation
Winter/Summer Operation
Different feedstocks or product specifications

Remember that low flow cases are important and may give rise to liquid
distribution problems.

2.2 Bed Number

Indicate the numbers of the beds over which one set of hydraulic data is
representative. Beds should be numbered from the top downwards.

2.3 Loading Point Top/Bottom

Indicate whether liquid and vapour flow data given below applies to top or
bottom of bed. If significantly different give data for top and bottom of bed in
separate columns.

2.4 Type of Packing

Include Supplier's name if packing performance is Supplier dependent.

2.5 Height of Bed and Tower Diameter

This is required to establish quantity of packing required and obtain Supplier's


confirmation of required performance.

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ATTACHMENT 10 – PACKING (cont)

2.6 Allowable Pressure Drop

Indicate maximum allowable pressure drop, for each section of packing, under
the hydraulic conditions specified below.

2.7 Vapour and Liquid Load

Give a consistent set of loading data at the loading point indicated above.
Complete all data requested.

2.8 Design Pressure Drop

Quote maximum pressure drop resulting from relief/emergencies. Include


pressure drop resulting from fire, as the supporting equipment must avoid
packing material blocking vessel exit nozzles during a fire. If the fire pressure
drop is high, consider repositioning relief valves. Quote pressure drop in
bar/bed.

2.9 Packing Material

Identify all acceptable alternatives of packing material. State preferred Supplier


where appropriate.

Exercise extreme caution when specifying plastic packing. Consider all


operations such as start-up, shut-down or emergency conditions which could
cause high temperature and damage packing.

2.10 Packing Size

Packing size should be established by reference to Suppliers' literature or


licensor data.

2.11 Particle Density

Quote the particle density of the packing.

2.12 Packed Density

Quote estimated density of packing when installed.

2.13 Voidage %

Quote voidage (% free space) in packing when installed in vessel.

This enables weight of vessel during hydrotest to be established by vessel


engineer.

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ATTACHMENT 10 – PACKING (cont)

2.14 Notes

Allowable percentage flood

This should preferably be based on Client's or Licensor's operating experience.


If appropriate discuss the value with the Suppliers.

Packing volume allowance

For small diameter columns, the volume of redundant nozzles, manways or


manholes can be significant. The volume of these should be included in the
calculation of required packing volume. Alternatively nozzle inserts can be
specified which have the additional advantage of smoothing the flow. Consider
also variable packing density. Packing volumes should be checked even when
defined by third parties e.g. Licensors.

If we have previous experience with breakage allowance, then Commissioning


Group may be able to give guidance. Alternatively allow Supplier to
recommend an allowance based on his experience, remember an additional
allowance may be necessary for some locations. In either case complete note 4
as appropriate.

3. Process Specification Sheet

A copy of the Packing Process Specification Sheet (Ref 2068/27) is included


overleaf.

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ATTACHMENT 10 – PACKING (cont)

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ATTACHMENT 11 – PROCESS SPECIFICATION - GENERAL

1. General

The Process Specification Sheet (2068/2 1) is to be used either as an


attachment to any of the specific Process Specification Sheets to supply
further information, or to fully define miscellaneous items of equipment and
process packages.

The following paragraphs refer only to the specification of package units.

2. Completion of Process Specification - Process Packages

In order to achieve a consistent layout of Process Specifications for Process


Packages the general format noted below should be followed.

1. General Description
2. Duty
3. Mechanical Requirements/Constructional Features
4. Utilities Available
5. Materials of Construction
6. Information required from Supplier
7. Performance Guarantees

Sections that are not relevant to a particular application should be omitted. On


contracts where Engineering Department prepare requisitions, ensure that the
Process Specification can be easily incorporated into the requisition. Omit data
which Engineering will include.

1. General Description

"A …. is required …… to …… to …… from ……. Supplier is required to supply


a …… complete with …… motors, control gear …… and all ancillary equipment
necessary for the safe and reliable operation of the package/unit".

This section should define the scope of supply. Include a sketch whenever
possible. If the package is split into sub-units with individual equipment
numbers note these.

2. Duty

"A …… type ……is required to perform the following duty:

State feed and product flows, temperatures, pressures, composition or


specification. Give normal and maximum flows and, if relevant, minimum flows.

State equipment design conditions or state how they may be determined, by


reference to Basic Engineering Design Data if appropriate.

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ATTACHMENT 11 – PROCESS SPECIFICATION - GENERAL (cont)

2. Duty (cont)

Give other relevant information such as particle size, corrosive, nature of fluids,
pilot plant data.

Include a sketch whenever possible.

3. Mechanical Requirements/Constructional Features

"The following features are required:

i) Instrumentation …… )
)
ii) Cleaning facilities …… ) not necessarily in this
) order i.e. in order of
iii) Noise …… ) importance/magnitude
85dBA at 1m …… )
)
iv) Motors - type by others, ) Omit (iii) and (iv) if this
put power supply details ) will be covered by
) requisition.
)
…………………… )
)
(v) Special Features )
)
………………….” )

4. Utilities Available

Supply details of the conditions of only those relevant e.g. dust


extractor Supplier does not need to know about Cooling Water etc., but does
need to know about Power, Air etc. If a Basic Engineering Design Data
document exists refer to this.

5. Materials of Construction

Give any specific requirements, and detail any materials not permitted.

6. Checklist of Information required from Supplier

i) Fully listed extent of supply including model numbers sizes etc., for all
equipment including control systems.

ii) *Fully dimensioned drawing giving weights, arrangements, foundation


details etc.

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ATTACHMENT 11 – PROCESS SPECIFICATION - GENERAL (cont)

6. Checklist of Information required from Supplier (cont)

iii) Utility consumptions/guarantees (minimum, maximum, average and


start-up).

iv) *Quotation for Supplier's standard package listing separately


non-standard items.

v) *Separate quotation for spares for two years operation and


commissioning.

vi) Description of the operation of the equipment.

vii) Flow diagrams, PFD, EFD etc.

vii) Supporting calculations e.g. safety relief.

ix) Experience List

*Delete these if they will be covered in Engineering Requisition.

7. Performance Guarantees

See Process Engineering Work Practice GEN/DO1/02 and previous


specifications for similar equipment for method of supplying
performance guarantees. Alternatively request Supplier to propose performance
guarantees.

Consideration must be given to how performance guarantees are to be


demonstrated e.g. Specific test run or as part of overall plant test run.

3. Process Specification

A copy of the Process Specification Sheet (Ref. 2068/21) is included overleaf.

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ATTACHMENT 11 – PROCESS SPECIFICATION - GENERAL (cont)

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ATTACHMENT 12 – PUMPS

1. General

Co-ordination between the Mechanical Equipment Group and the Process


Engineer is important at the start of a project to avoid recycling of information
(for example to ensure that pump type proposed by Process Engineer is a
suitable and economical choice before specifying it).

Reference should be made to Process Standards 400-1.0, 400-1.1, and


400-1.2 covering pumps.

The Process Engineer should also ensure that the extent of information
presented is suitable for the equipment described. See Mechanical Equipment
Engineering Procedure 111-2-3.027. (Division of Responsibility between
Mechanical Equipment and Process Design Engineers).

Before the Process Engineer completes the specification sheet, a pump


calculation sheet (FWL-456), or baled program / Zyqad equivalent must be
completed to define the hydraulic requirements of the system. Serial
terminology to be eliminated.

FWL-456 is not normally issued outside Process Department, although some


clients require a package of hydraulic data, including pump calculations, to be
issued at the end of a contract.

2. Completion of Process Specification

2.1 Pump Type

Indicate suitable pump type by ticking appropriate box. Centrifugal pumps are
preferred but they have limitations (e.g. above 450 m3/hr mixed flow/axial may
be more suitable; below 7 m3/hr and head above 100 m, regenerative/turbine
pumps may be more suitable). If in doubt check with the Mechanical
Equipment Group.

Rotary pumps may be used for high viscosity duties. Metering pumps are used
for accurate control of low flows using driver speed or stroke adjustment.

Other types to be considered are:

Axial
Regenerative/Turbine
Diaphragm
Sump (Vertical axis)
Rotary pumps may include gear, lobe, sliding vane and other Supplier
specialities e.g. Mono progressive cavity pump.

See Process Standard 400-1.0 p2.

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ATTACHMENT 12 – PUMPS (cont)

2.1 Pump Type (cont)

Note that some rotary pumps may require pulsation dampers. If in doubt
discuss with the Mechanical Equipment Engineer.

Note that "recip. steam" means an integral steam driven pump. Recip. power
means a recip. pump with power from a separate driver.

Tick the 'end suction preferred' box when it is known that the pump will take
suction from tank which is at similar elevation to the pump. If a top suction
pump were used in this situation there would be a high point in the pump
suction line.

2.2 Number of Pumps Required

Indicate the number of operating pumps and the number of installed spares (i.e.
standby). Uninstalled spares are not indicated here. The sparing philosophy
should have been established by the Process Co-ordinator before any
specifications are written. If more than one pump is operating, use notes to
state whether the operating pumps are operating in series, parallel or separate
streams. Parallel operation should be discussed in detail with the Mechanical
Equipment Engineer.

2.3 Type of Driver

Indicate whether electric motor, steam turbine, gas turbine, compressed air,
hand pump etc.

2.4 Duty

State whether continuous or intermittent. Duration of each operating case


(hrs/yr max) is requested below (2.5.2).

2.5 Process Requirements per Pump

Process data should be given for all cases which might determine some aspect
of the pump (e.g. casing size, motor size, spillback requirement). Remember
cases such as start-up, alternative campaigns, winter/summer operation etc.

2.5.1 Operating Case

Expected rating duty should be given under required flow case. Minimum flow
case should be given if the plant is required to operate at a turndown below
say 50%.

Maximum SG case should be given if the SG can increase above 105% of


normal.

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ATTACHMENT 12 – PUMPS (cont)

2.5.2 Approx. No. of Hrs/Yr (Max)

Indicate approximately the duration of the various operating cases.

2.5.3 Liquid

Describe the liquid being pumped. The identification should be as shown on


the Process Flow Diagram with additional information if required.

Use the corrosion/erosion section to define the presence and size of any solids
or presence of entrained vapours, trace components etc.

2.5.4 Pumping Temperature (Normal)

State the normal pumping temperature.

2.5.5 Pumping Temperature (Expected Max).

Indicate also the maximum operating temperature anticipated for the case in
question. Do not add on any design margin but make an allowance for
operational fluctuations. The rated minimum SG quoted below should be
consistent with this expected maximum temperature.

2.5.6 Sp.Gr @ PT

Rated (min) : state the min. specific gravity corresponding to the required flow
case, and or which the pump is to be rated.

Expected (min) : low specific gravity can influence pump configuration.

2.5.7 Vapour Pressure @ PT

State maximum vapour pressure at which the pump is required to operate at


design rate. This should be consistent with max. pumping temperature.

2.5.8 Viscosity @ PT

R2 State viscosity at normal operating temperature. State maximum viscosity if


dealing with highly viscous liquids.

2.5.9 Capacity @ PT

Normal capacity is developed from the material balance flow and normal SG.

Required capacity is the normal capacity plus a margin to allow for operating
fluctuations, pump code tolerances and wear of the impeller.

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ATTACHMENT 12 – PUMPS (cont)

2.5.9 Capacity @ PT (cont)

Margins are established by the process co-ordinator on a project, and can be


influenced by pump duty (i.e. process or utility) and method of pump control
(i.e. LC, FC or PC etc). Remember that margin may be influenced by the
frequency/importance of the case in question.

The capacity should include an allowance for any continuous spillback.

Remember that spillback will affect suction line losses and NPSH available; if in
doubt discuss with Mechanical Equipment group and add agreed flow margins
when sizing lines.

Some pumps, generally those with high suction specific speeds, cannot operate at
turndown to less than 70% of rated flow. In this case the use of a constant
spillback may be unsuitable; if in doubt discuss the problem with the Mechanical
Equipment Engineer. While checking the pump requisition ensure that the spillback
flow added
by the Supplier is reasonable. See also section 2.5.13 below for further
information on NPSH and suction specific speed.

The use of an (ARC) Automatic Recycle Valve or other spillback control valve
instead of a continuous spillback via a restriction orifice should be considered
for any pump with a BHP in excess of 100 kW. When specified, ARC valves
should be included in the scope of the pump Supplier and reference to this
requirement included in the Notes section on the Specification Sheet. When an
ARC valve or spillback control valve is used there is no continuous minimum
spillback.

2.5.10 Pressures

Discharge Pressure )

Suction Pressure ) These are obtained from the pump

Differential Pressure ) calculation sheet and should be a

Differential Head ) consistent set.

N.B. Differential head may not be relevant to certain positive displacement


pumps, but is of primary importance for centrifugal pumps (axial, radial etc).

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ATTACHMENT 12 – PUMPS (cont)

2.5.11 Suct. Pressure (Max. Possible)

State the maximum suction pressure which might occur. This should be based
on the relieving pressure of upstream equipment plus maximum static head (see
Pump Calculation Sheet).

This data is used by Mechanical Equipment Group to establish pump casing


design pressure.

2.5.12 NPSH Calculated

State the NPSH calculated without deducting any safety margin. This permits
Mechanical Equipment Group to check that suction pressure, vapour pressure
and NPSHA calculated are consistent.

2.5.13 NPSH Available

State the NPSH which the pump Supplier may use after deduction of Process
Design Department margin. The margin used should be standard throughout
the contract and should be agreed with the Process Co-ordinator. A deduction
of 600mm is normally made for bubble point fluids and may also be applied to
all pumps. The margins used should be stated in the Co-ordination Procedure.

The pump NPSHR and suction specific speed (Ss) are related by

Ss = RPM X O0.5
(NPSHR)0.75

Q = pump capacity (USGPM) per suction eye


RPM = pump speed, normally 3000 rpm
NPSHR is in feet.

Process Standard 400-1.1 page 18 shows a nomograph of this formula.

Thus high capacity pumps with low NPSH tend to have high suction specific
speeds. Recent studies have shown that pumps with high Ss tend to exhibit
high failure rates. This is attributed to recirculation within the impeller when
the pump is operated away from its best efficiency point. Problems
experienced include impeller and case erosion, additional shaft stresses
resulting in radial and thrust bearing failure, seal problems, vibration and noisy
operation.

Mechanical Equipment Group will therefore normally limit suction specific


speed to 11,000 maximum. In addition they will apply a limit of 10,000
maximum if pump capacity can fall to less than 30% of the best efficiency
point capacity.

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ATTACHMENT 12 – PUMPS (cont)

2.5.13 NPSH Available (cont)

Process Engineers should check that allowed NPSHA values are within the
limits given by the above formula with a suction specific speed of 11,000 or
10,000 as appropriate. In addition Process Engineers should identify on the
process specification turndown flows below 50% of the design capacity when
such flows are possible long-term operating conditions covered by guarantees
of plant performance.

Further information on NPSH and suction specific speed is given in:

- Hydrocarbon Processing April 1982 p 195


Chemical Engineering Vol 89 No.20 October 4th 1982
pp 84-106
The latter covers many other aspects of pump performance.

2.5.14 Corrosion/Erosion Due To

Indicate the presence of components/solids/dissolved gases etc. which might


cause corrosion, erosion or blockage etc.

Specify the content of each such component in the mixture.

2.6 Additional Pump Data

These are data used in establishing pump detail. Data should only be given if
Process Engineering have a definite request.

2.6.1 Flow Controlled by

Indicate the flow control method as given on the PFD. LC, TC, PC and FC refer
to control valves on the fluid piping (normally discharge). Possible other
methods are variable speed, variable stroke, etc.

2.6.2 Method of Starting Spare Pump

Indicate whether a spare pump requires autostart. This information is used by


Mechanical Equipment/Electrical groups to determine the details of the driver.

Auto starts should not be used in hot 'black oil' service except after discussion
with the client. They shall not be used at above 260°C. This is due to the
possibility of seal failure and fire due to autoignition on start of spare pump.
The safety implications of auto-starts should be considered for all other fluids.

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ATTACHMENT 12 – PUMPS (cont)

2.6.3 Materials Recommended

State the minimum requirements to suit the process fluids (as given on the
Materials Selection Diagram). Give recommendations for both the casing and
internals.

List any materials which must not be used under Notes below (e.g. copper in
ammonia containing streams).

R2 2.6.4 Pump Jacket Required

Indicate whether a pump heating or cooling jacket is required for process


reasons. e.g. if the fluid could solidify. If not tick "no process requirements".

Minimum and maximum temperatures permitted may be given here, but they
will also be given on the line list.

2.6.5 Pump Sealing Requirement

Indicate if Process Department have specific sealing requirements (from Client,


Licensor etc).

R2 State nature of sealing fluid and reasons for needing external seal (e.g. contents
are hazardous, toxic, solids purging etc).

Indicate requirement for canned (or magnetic coupled) drive here if appropriate.
State "No special process requirements" if applicable.

2.6.6 Notes

.For centrifugal and other rotating pumps (where pump discharge is not
protected by a relief valve) the Process Engineer should indicate the head rise to
shut-off used in establishing down-stream design pressures. Normal practice is
to use 125% for motor driven centrifugal pumps. In the case of turbine driven
centrifugal pumps it has been the practice to use 132% although figures as
high as 138% have been experienced (see TWP GEN/DTA/31-08). The Process
Coordinator should establish the percentage to be used with the Mechanical
Equipment Engineer for each Project".

R2 Note 2 relates to spillback allowance as discussed under pump capacity. Fill in


the flow rate of spillback required.

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ATTACHMENT 12 – PUMPS (cont)

2.6.6 Notes (cont)

Further notes as required.

e.g. Mechanical design temperature (see 4 below)


Excluded materials
Uninstalled spares
Parallel/Series operation
Supply of pulsation dampers
Supplier name and model no.

(This is already covered in 2.5.14)

Mechanical design temperature is the maximum operating temperature plus a


suitable design margin to be used for the mechanical design of the pump. It
should generally be consistent with the Design Pressure and Temperature
Diagram (refer to TWP GEN/DTA/31-08). A note of explanation should be
added to the Process Specification Sheet including the statement that it is not
an operating case.

3. Process Specification Sheet

R2 A copy of the Pump Process Specification Sheet (Ref. 2068/24) is included


overleaf.

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ATTACHMENT 12 – PUMPS (cont)

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ATTACHMENT 13 – PRESSURE RELIEF VALVES

1. General

Refer to Process Standard 602. The following are additional notes and
comments applicable to the FWEL Pressure Relief Valve Process Specification
Sheet. (2068/13)

Only the governing relief case is normally given. The Process Engineer is
therefore responsible for making the correct selection. If in doubt, all possible
governing cases should be given.

Additionally, advise Instrument Group of extremes of temperature which might


occur with non-governing cases (e.g. LPG with governing fire case, but cold
relief under other circumstances).

Use a separate series of specification sheets for the relief valves on each
Engineering Flow Diagram.

2. Completion of Process Specification

2.1 Number of Valves Required

State the process requirements for number of valves in regular use and as
spares.

2.2 Interlocks Required

State the process requirements paying particular attention to applicable codes

2.3 Governing Conditions

See also Section 1.

A basic factor in sizing a relief valve is flow rate at the "Governing Conditions".
This implies that the "Governing Condition" is the one which will produce the
maximum flow rate. This maximum flow rate will in turn determine the orifice
area required for the relief valve. However, the maximum flow rate may not
necessarily be the "Governing Condition" nor give the maximum orifice area.
For example, some codes allow a 21% accumulation above design pressure for
the valve to reach full flow rate for the condition of "fire" and 10%
accumulation above design pressure for all other "operating" failure. Since the
orifice area is directly proportional to flow rate and inversely proportional to
accumulation pressure, then a fire condition can have as much as 10% higher
flow rate than operating failure; nevertheless the operating failure condition will
govern producing the larger orifice. Consider this for all cases where the flow
rate for fire condition is 0 to 10% higher than the flow rate for operating
failure. Give alternatives where appropriate

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ATTACHMENT 13 – PRESSURE RELIEF VALVES (cont)

2.3 Governing Conditions (cont)

Where built-up back pressures vary for different cases then this may also have
an effect on determination of governing case.

Note that flame impingement on unwetted metal surfaces can cause vessel
failure before relieving pressure is reached. Refer to Attachment 16, page 5,
for guidance on when additional protection in the form of water sprays,
fireproof insulation or depressuring is required.

2.4 Pressure Relief Valve Type

This is normally not specified by the Process Engineer but may be given by a
licensor in which case it should be entered on the form.

State if valve is known to be of conventional or balanced type or there are


other special requirements.

The Process Engineer should be aware of the relative costs of balanced and
unbalanced types (frequently more than twice as expensive). Also balanced
type pressure-relief valves are not available in orifice sizes below F which may
lead to oversizing of small relief valves. Balanced type pressure relief valves
are generally specified for two reasons:

1. Factors affecting set pressures - e.g. fluctuating back pressure.

2. Corrosion problems.

Note that for corrosion protection of the smallest pressure relief valve sizes for
which balanced type valves are not available, bellows may be inserted in the
valve. Therefore if protection against corrosion is the reason for selecting
balanced type valves, note this on the specification sheet.

2.5 Minimum Orifice Area Required

This information is not normally supplied by the Process Engineer. However,


some licensors' process packages include this information which may then be
included on this form. All process data should be included to permit
Instrument Group to check valve size.

2.6 Relief Valve Size

This is not normally specified by the Process Engineer. Give the information, if
known.

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ATTACHMENT 13 – PRESSURE RELIEF VALVES (cont)

2.7 Fluid and State

Full information on the fluid should be given - refer to Attachment 8


(Instruments).

2.8 Corrosive Compounds

List compounds, especially trace components, which may give rise to corrosive
conditions at the pressure relief valve.

2.9 Flow at Relieving Conditions

State the total relief load calculated (normally in kg/h). If a relieving liquid
flashes across the valve the weight percent vaporised should be indicated.

2.10 Molecular Weight/Compressibility Factor/Vapour Cp/Cv

Compressibility factor and Cp/Cv must be stated at relief conditions for a


relieving vapour, together with its molecular weight. If the pressure drop
across the valve causes flashing then again this information must be provided.

2.11 Specific Gravity

State the SG of the relieving liquid at the relief conditions. If the relieving
liquid flashes across the valve, SG of the flashed liquid should also be supplied.

2.12 Viscosity

This should be stated when the Reynolds number in the line leading to the
pressure relief valve is below 20,000.

2.13 Normal Operating Temperature

The normal process fluid temperature at the location of the pressure relief
valve. Note that this is not always equal to the normal operating temperature
of the equipment protected.

2.14 Relieving Temperature

This is the fluid temperature when the valve is blowing. For vapour from a
boiling liquid this means vaporisation temperature at relieving pressure
(including accumulation).

2.15 Liquid Vapour Pressure

If a liquid is likely to flash across the pressure relief valve, vapour pressure
must be quoted at the relieving temperature.

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ATTACHMENT 13 – PRESSURE RELIEF VALVES (cont)

2.16 Normal Operating Pressure

The normal process fluid pressure at the location of the pressure relief valve.
Factors such as static head for liquid relief must be taken into account.

2.17 Set Pressure

This is the pressure at which the valve starts to lift.

2.18 Superimposed Back Pressure

Specify whether constant (as when discharging to atmosphere or variable (as


when relieving to a manifold serving several valves simultaneously). If
constant, specify value. If variable, specify range over which back pressure is
variable. Complete only one line.

2.19 Built-Up Back Pressure

This is a differential pressure corresponding to the increase in pressure in the


discharge pipework that develops as a result of flow after the pressure relief
valve opens.

2.20 Back Pressure

Back pressure is the sum of the superimposed back pressure and the built-up
back pressure. It is the total pressure which exists at the relief valve discharge
flange when the valve is relieving.

The level of back pressure determines whether a conventional relief valve is


satisfactory or whether a balanced relief valve is needed. Back pressure is also
used in calculating orifice area. Depending on relief valve type and the level of
back pressure it may be necessary to apply a back pressure correction factor in
calculating the area required.

2.21 Accumulation

The accumulation allowed on pressure-relief valves varies according to the


relief case and the applicable vessel design code. It is therefore essential to
refer to the design code.

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ATTACHMENT 13 – PRESSURE RELIEF VALVES (cont)

2.22 Additional Notes

1. Bursting Discs

A bursting disc may have been specified in the line upstream of the
relief valve. Design codes are not very specific in this area but bursting
discs may derate the pressure relief valve. For instance ASME VIII
derates pressure relief valve capacity by 20% unless a pressure relief
valve/bursting disc assembly has been flow tested.

Ensure bursting disc carrier, especially if it includes a vacuum support


does not cause excessive inlet line pressure drop.

Bursting discs are very susceptible to corrosion, therefore full data on


all fluids likely to be encountered is required.

2. Low Set Pressures

At lower set pressures, below 2 barg, pressure problems may arise due
to reduced capacity and other effects. It may, for example, be
necessary to mount the valve upside down to avoid the weight of
spring and trim affecting valve setting. For all low pressure cases
discuss the requirements with the Instrument Engineer before issuing
the specification.

On atmospheric storage tanks, the relieving device is usually provided


by the tank Supplier, a weighted rather than a sprung device being
supplied. Indicate this on the specification sheet, see Attachment 16,
section 2.2.

3. Process Specification Sheet

A copy of the Pressure Relief Valve Process Specification sheet (Ref


2068/1 3) is included overleaf.

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ATTACHMENT 13 – PRESSURE RELIEF VALVES (cont)

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ATTACHMENT 14 – TECHNICAL PROCESS SPECIFICATION

1. General

The Technical Process Specification Sheet is to be used, where appropriate, for


miscellaneous items of equipment. A copy of this sheet (Ref. 2068/1 5) is
included overleaf.

R2 When specifying cooling towers, tower basin requirements should also be


provided in ‘Notes’ Section.

R2 If materials of construction or brand/ trade name is mandatory (e.g. client’s


requirement), then state this in the Notes section. If not mandatory, indicate as
‘xxxxx or equivalent’.

Define any performance guarantee criteria in detail

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ATTACHMENT 14 – TECHNICAL PROCESS SPECIFICATION (cont)

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ATTACHMENT 15 – TRAYS

1. General

Refer to Process Standard 105A

The Trays Process Specification is divided into three principal sections as


follows:

1. Contains basic data defining the points for which the hydraulic loading
data is given and establishing column size.

2. Contains hydraulic loading data to permit the tray Supplier to confirm


column size, complete tray design and give performance guarantees.

3. Covers materials of construction and other mechanical design features.

The following sections give guidance on completion of the specification:

2. Completion of Process Specification

2.1 Operating Case

Independent data should be supplied for all operating cases which cannot be
satisfactorily covered by the operating range % data given below in Section
1.11. Possible reasons for different operating cases are:

Campaign Operation
Winter/Summer Operation
Different Feedstocks or Product Specifications

Remember that low flow cases are important to tray Suppliers (particularly for
sieve trays where turndown is difficult).

2.2 Tray Numbers

Indicate the numbers of trays over which one set of hydraulic data is
representative. Trays should be numbered from the top downwards
(condensers and reboilers should not be allocated tray numbers unlike some
computer programs).

This range of trays is referred to as a section, and every tray should appear in
one and only one section of the column.

Note that in some cases a section may only cover 1 tray (e.g. feed tray).

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ATTACHMENT 15 – TRAYS (cont)

2.3 Loading Point (Tray No)

Indicate which tray in the section experiences the loading data presented
below. This
tray should be the critical duty within the section.

2.4 Type & Number of Trays

The number of trays should be consistent with the section definition above.

The Process Engineer normally chooses a tray type to allow column diameter
and tray spacing to be calculated. Consider the following when choosing tray
type:

Operating Range
Materials of Construction
Pressure Drop
Blockage potential
Cost

If no specific process requirements liaise with Vessel group

2.5 Tower Diameter/Tray Spacing/Number of Passes

These should be established by reference to in-house design methods such as:-


(Refer also to FW Process Standard 105A)

Glitsch Ballast Manual


In-house Computer Program - e.g. P2912 TRADEZ which is computerized
version of the Glitsch procedure)
FRI Method
FW Process Standard 200

Contact a Supplier if in doubt. Tower diameter should be specified generally as


internal diameter. Vessel Group may wish to buy columns with standard
outside diameters in which 'recycle' of diameter information may occur. Check
this with vessel group before specifying an internal diameter. Ultimately the
tower diameter must be agreed with the tray Supplier.

When calculating tray spacing, check with vessel group where manways are
required and ensure that the tray spacing is sufficient for manway installation
(normally 1 manway every 10 trays).

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ATTACHMENT 15 – TRAYS (cont)

2.6 Allowable Pressure Drop

Indicate maximum allowable pressure drop per tray (or per section if more
suitable).

Process Standards lOSA (page 20) and 200 (page 22) give approximate tray
pressure drops, but the process engineer should also rely on past experience,
licensor's information and/or tray Supplier design procedures. Pressure drop
stated should be sufficient for maximum operating case.

The value should only be for the fractionating trays, the pressure drop for other
internals such as mist eliminators or packed sections should not be included
here.

2.7 Loading Data

Indicate consistent set of loading data to the loading point noted above.

Complete all the data requested for:

Vapour TO the tray

Liquid FROM the tray

(If on different basis, state clearly the basis used and delete standard basis). If
the process specification is to be used for direct procurement then loading data
need not be given but IN ALMOST ALL circumstances comment/guarantee from
a tray Supplier is required.

2.8 Downcomer Area (Minimum)

The process engineer may need to calculate this parameter to be able to


estimate column diameter.

However this parameter should normally be left blank, as the tray Supplier will
have his own requirements to meet the tray guarantees.

Only quote a value if FW/Licensor has a specific minimum.

2.9 System Factor

This must be given by the Process Engineer. This indicates the tendency of a
system to foam. Typical data can be obtained from the Glitsch Ballast Tray
Manual, licensor information or past experience. Qualitative expressions may
be acceptable, but should be avoided whenever possible.

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ATTACHMENT 15 – TRAYS (cont)

2.10 Operating Range Max % Min %

Indicate the operating range over which the trays in this section must operate
encountering hydraulic problems such as flooding; weeping etc. If no
overcapacity is envisaged, it is normally good practice to request 110%
maximum operation to allow flexibility

Turndown requirements should be stated (if known) as Min %.

Independent Data can be given for both vapour and liquid loadings but the
maxima and minima are assumed coincident. (Remark 3) should be used if FW
or licensor have any strong views on the maximum permissible % flood that is
allowed. Indicate whether this is applicable to 100% capacity or max %.

2.11 Mechanical Design

Materials of Construction

The materials of construction of the deck and valve assembly (if applicable)
should be obtained from the materials selection diagram. Unless Process
Engineering or the Process Licensor have specific requirements, do not indicate
the thickness of the deck or valves. The vessel group will determine
thicknesses themselves from consideration of the materials and corrosion
allowances on the shell and the materials of the internals.

Corrosion allowance for tray parts can be confusing and should not normally be
stated.

The tray and valves thickness does affect the pressure drop through the tray,
and if pressure drop is critical then process should ask Vessel Group for
estimates of thicknesses.

Owing to the possibility of rusting caused by residual water following


hydrotesting, or inadvertent admission during the life of the plant, great care
shall be exercised in the specification of carbon steel valve tray decks. In all
cases valves will be 11-13 chrome or other alloy.
Note the following:

1. Carbon steel trays shall not be specified for a unit of FW design i.e.
which is not a licensed process or for a proposal or contract with
reimbursable materials.

2. Carbon steel trays may be specified provided all the following criteria
are met:

a) It is a proposal or contract including lump sum materials.

b) The design is provided by a licensor.


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ATTACHMENT 15 – TRAYS (cont)

2.11 Mechanical Design (cont)

Materials of Construction

c) Materials handled in the tower are compatible with the use of carbon
steel.

d) Carbon steel trays are permitted by Client's specifications.

e) The sketch has a note stating that the


tower with trays cannot be hydrostatically tested with water.

f) The use of carbon steel trays is approved for each specific case by
the Chief Process Engineer.

g) There is no possibility that water can condense on the trays.

In any proposal where carbon steel trays are included, an alternative for alloy
trays shall be included in our bid, together with a recommendation that the
latter is selected.

Design Pressure Drop

It is usually necessary to ensure that trays are sufficiently strong and well
supported to withstand abnormal upward vapour flows. This information may
be supplied in the form of a tray design pressure drop or minimum tray
thickness based on previous experience. This data will cover situations where
it is not possible to predict abnormal vapour flows with certainty e.g. if slugs
of water enter with stripping steam.

Alternatively give information on peak vapour flows under relief conditions but
note that if liquid flow also ceases vapour flow up down-comers could occur.
Give simultaneous pressure, temperature and composition.

It is only necessary to consider relief cases where catastrophic failure of trays


is unacceptable. Fire relief should not be considered, as fire damage to trays is
acceptable.

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ATTACHMENT 15 – TRAYS (cont)

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ATTACHMENT 16 – VESSELS

1. General

This Attachment covers the process specification of all vessels e.g. drums,
towers, tanks etc.

Each vessel specification will be prepared on two Vessel Process Specification


Sheets.

Sheet 1 (Ref 2068/1) comprises the vessel sketch


Sheet 2 (Ref 2068/2) comprises the nozzle chart and additional design data.

Special requirements for tanks are covered in Section 1 .3.

In addition a Tankage Summary Sheet (2829) is available for tank details; it


may be used only for proposal/study preparation.

This Technical Work Practice supersedes Process Standard 101, pp 7.0 - 1 to


7.0 - 4 which is specific to the FWEC Process Specification Sheets.

2. Completion of Process Specification

2.1 Vessels

Vessel Sketch (Sheet 2068/1) is used for a dimensioned sketch of the vessel.
It does not need to be to scale, but should be a fair representation of the
specified equipment.

The following data should be included:

2.1.1 Orientation (i.e. horizontal, vertical or slanted, show slope for example as
follows).

Show only if critical.

2.1.2 Dimensions (Internal diameter, tan/tan length etc.)

Show if critical, (including boot if applicable). State type vessel heads assumed
as required. Otherwise state working volume required. If appropriate Process
Co-ordinator should agree standard head sizes with Vessel Group at start of the
job.

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ATTACHMENT 16 – VESSELS (cont)

2.1.3 Internals.

Show the number, type, dimensions, - spacing etc., of internals such as trays,
mist eliminators, hold down grids, distributors, heating/cooling coils and vortex
breakers. Indicate any essential fabrication requirements e.g. bolted
construction to pass through manway.

Note that FW vessel standards require a 50mm wide support ring for mist
eliminators. On small vessels consider whether this is acceptable. Consider
increasing vessel diameter or agree a narrower support ring with Vessel Group.

2.1.4 Catalyst packing.

Show bed dimensions plus design pressure drop across beds for support design.
(Consider emergency relief conditions when calculating design DP; but
remember that collapse of internals may be acceptable in a fire as long as the
containing vessel and its relief route is unaffected).

The following additional data should be supplied for each bed of packing or
catalyst to ensure that Vessel Group can design the supporting equipment:

Particle Density
Bulk Density
Packing Height

See also: Packing Specification Sheet (Attachment 10)


Catalyst Specification Sheet (Attachment 3)

2.1.5 Liquid Levels

Show the actual liquid levels (operating and alarm) used in process design on
the sketch as follows:

(Show levels relative to bottom tan line)

HLL High Operating Liquid Level


NLL Normal Level (not essential)
LLL Low Liquid Level

LLL should be at least 200 mm above bottom tangent line to allow space for
instrument connection. (See Note 1 on specification FWL 2068). On small
vessels or if other process reasons dictate then the 200mm may be relaxed but
requirement for level measurement must be considered.

High and low liquid levels used for alarms should normally be within the HLL -
LLL range, unless specifically stated otherwise. Note that bottom bearings may
be required on large agitators and must usually remain covered during
operation.
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ATTACHMENT 16 – VESSELS (cont)

2.1.5 Liquid Levels (cont)

Extra high and extra low levels (LAHH and LALL) are usually outside the range
of HLL - LLL and should be dimensioned. If used for a trip function this should
be stated in remarks on nozzle list.

When specifying level range between HLL and LLL, bear in mind the normal
displacer ranges quoted in Process Standard 101 Appendix 13.

Ensure that the maximum liquid level stated here is no more than General Note
(1) on sheet 2.

2.1.6 Nozzles

Nozzles are shown and labelled by a tag. Actual nozzle connection type i.e.
flanged, screwed, welded etc., will be chosen by Vessel Group. Once a nozzle
number has been allocated never change or re-use it. Nozzle designation by
licensors should be retained whenever possible. Nozzles are classed below
into four categories. Nozzles should normally be numbered so that the
manway(s) and access openings appear first, followed by process connections,
then the auxiliary nozzles, and lastly the instrument connections. Nozzle
designation numbers should not be revised if the duty or size of a nozzle
changes. Before specifying any nozzle sizes check the minimum allowable
nozzle size for the job. Nozzle sizes are allocated on sheet 2 of the Vessel
Specification.

1. Access

This includes manways, headholes etc. State only those which are required for
process reasons, and give sizes only if specific requirements are known. In the
absence of specific requirements, Vessel Group will locate these access points
as best suited to detailed layout. (See also Process Standards 101 p 5.0-7 and
200 p 105).

Vessel Group will add extra access if codes require. On distillation columns the
codes may require a manway every 10 trays or so. Check with vessel group to
see whether manways could affect tray spacing. Nozzle 2 is for other access,
leave blank if there is no process requirement.

2. Process

List Process nozzles in order of decreasing size. If a preliminary issue of the


specification is necessary before line sizing is complete, estimate the size order.

Vents and drains are termed auxiliary nozzles (see below) unless essential to
the process.

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ATTACHMENT 16 – VESSELS (cont)

2. Process (cont)

Only indicate precise location where this is process critical for example.

i) Nozzle locations relative to trays.


ii) Location of water draw nozzles relative to feeds/hydrocarbon outlets to
ensure good separation.
iii) Location of nozzles relative to liquid level.
iv) Vent at opposite end from steam out nozzle.

Identify those nozzles where fluid is above auto-ignition temperature.

If no dimensions are given, Vessel Group will retain the location principles
indicated on the sketch (i.e. on top, on head, bottom of boot etc).

Don't forget nozzle requirements for pressure relief or safety depressuring. A


logic diagram for deciding when depressuring (or other fire protection facility) is
required is shown in figure A overleaf.

3. Auxiliary Nozzles

This covers vents, drains, steam out, blowdown etc. Indicate auxiliary
connections as required by Process Department. Engineering may need to add
extra nozzles to satisfy codes. Exact location should be left to Engineering, but
indicate important location principles such as: location of gas lines for
depressuring above HLL.

In many cases auxiliary connections can be located more economically on the


piping. This should form part of the project philosophy, the Process Co-
ordinator should agree a consistent approach with Engineering Dept. and Client.
Note that a vent must be located on the vessel so that it will be effective when
all nozzles are blinded.

Vessel Group will size and locate steam out nozzles, but process can indicate a
definite request for steam out facilities by completing steam out conditions on
sheet 2068/2. Steam out nozzles must be above vessel base to avoid water
hammer. On a vertical vessel location should be just above bottom tangent
line. Sheet 2068/2 has a note indicating that the Vessel Group determine steam
out details. If a process vent is suitable as a steam out vent then this should
be stated in the remarks on sheet 2068/2.

If necessary, minimum auxiliary nozzle sizes can be obtained from the Process
Standards 101 page 5.0 - 3. Normally, however, Vessel Group will size
auxiliary nozzles for which their is no definite process size requirement.

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ATTACHMENT 16 – VESSELS (cont)

4. Instrument Nozzles

Remember that it is cheaper to mount instruments on piping rather than the


vessel and that in some cases (e.g. pressure) this may be acceptable.

If vessel mounting is required do not specify exact locations unless there are
critical to Process Department (for instance as long as the liquid levels have
been given on the vessel sketch, the Process Engineer need only request a
certain level instrument function. The Instrument Engineer can then choose the
best location of nozzles to do the job). Unless told otherwise Instrument Group
will assume that LI and LG functions cover the range from HLL to LLL.

The Process Engineer should indicate the instrument feature required such as
LIC, TRC, LAH, and make a preliminary estimate of number of nozzles required.

Assume 2 nozzles per level instrument unless instructed otherwise.


Label pairs of nozzles A/B where A is lower and B upper.

Instrument Group will confirm exact number during detailed engineering, and
therefore Note 3 has been added to 2068/2.

"Number and size of instrument connections to be confirmed by Instrument


Group"

Process should normally leave instrument nozzle sizes blank, Vessel Group can
estimate nozzle sizes if required for enquiry requisitions. If essential, Process
Standard 101 p.5.0-6 gives representative nozzle sizes.

There are instances where Process must give more precise instrument nozzle
locations, normally using the remarks column, for example:

i) State or indicate whether instruments in fractionation columns are


required to measure the liquid or vapour conditions.

ii) Ensure that instrument readings are representative of bulk conditions,


e.g. level instruments should be in a calm location (distance from feed
inlet).

The following data, in addition to nozzle data, is requested on sheet 2 of the


Vessel Process Specification Sheet.

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2.1.7 Design Pressure Top/Bottom

The Design Pressure should be consistent with the Design Pressure and
Temperature Diagram (refer to TWP GEN/DTA/31-08).

Quote design pressure at top and bottom of any vessel containing internals
through which pressure drop is consumed (e.g. trays, packing). Note that
pressure drop should be same as specified on sketch 2068/1. If no pressure
drop, indicate top design pressure only. Indicate break point between top and
bottom design pressure regions. Design pressure should exclude liquid static
head. This will be calculated by Vessel Group using the liquid level and SG
specified on the Vessel Process Specification. (See Note 1)

In some cases (sulphur plants) lower design margins are customarily used to
give an economic design. This might apply to storage vessels and reactors
operating at very low pressures.

2.1.8 Design Temperature

The Design Temperature should be consistent with the Design Pressure and
Temperature Diagram.

2.1.9 Operating Pressure Top/Bottom - same as PFD

2.1.10 Operating Temperature Top/Bottom – same as PFD.

2.1.11 Vacuum Design Conditions

Quote the lowest absolute pressure possible under any foreseen circumstance
such as vapour condensing. If in doubt about exact number err on the safe
side. Vessels group will use this value for vacuum design. Note that vacuum
conditions may be protected against using PVV relief. If the Process Engineer
foresees steam out, he should quote full vacuum.

2.1.12 Steam Out Condition

Quote steam out conditions it steam out is known to be a process requirement.


Use 140°C; 1.5 bar g if no other data is available.

Even if no steam out conditions are given on process specification sheet, they
may be added by engineering groups if required for maintenance, codes etc.

If no process requirement state 'by engineering'. Actual number and location of


steam out connections will be added by engineering (see General Note 2) unless
stated otherwise.

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ATTACHMENT 16 – VESSELS (cont)

2.1.13 Stress Relieved (Process Reasons)

Indicate YES if stress relief shown on materials selection diagram, otherwise


leave blank. (Note that Engineering may add stress relief for strength reasons) It
is helpful to Vessel Group if reasons for this stress relief are indicated by a note
e.g. Caustic, H25 etc.

2.1.14 Corrosion Allowance : Shell : See Materials Selection Diagram

Internals: If internals are same material as shell then Vessel group will use
their standards to choose corrosion allowance. Process Engineer should state
'By Engineering'.

If internals are different material from shell then specify a 'Total Corrosion
Allowance' for the internals. (As given on Materials Selection Diagram)

2.1.15 Short Term Maximum Temperature/Coincident Pressure

During Process upsets the equipment temperature may exceed the design
temperature for short periods. For example:

failure of overhead condenser gives increased temperature in the downstream


accumulator

reflux failure will give increased tower top temperatures

fire case in liquid-containing vessels. Note that it is not considered realistic to


consider increased vessel temperatures during a fire when the vessel contains
vapour only. For duration of a fire, a suggested guideline is two hours.

However, do not show fire conditions unless the temperature is abnormally


high, i.e. greater than the boiling point of the contents under relief valve
accumulation pressure of 120% design pressure.

Vessel group may be able to achieve a more economic design if short term
excursions above design temperature are given separately rather than given as
design conditions. In particular the grade of material selected and extent of
testing may be affected.

Pipe Stress Group will also require the maximum temperature condition, this will
be transmitted to them on the sketch issued by Vessel Group.

Duration of short term maximum temperatures should be decided by Process


Co-ordinator at start of each project (they will be influenced by degree of back
up equipment; type of control instrumentation; operator experience etc). Refer
also to TWP GWN/DTA/31-08 Design Pressures and Temperatures.

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ATTACHMENT 16 – VESSELS (cont)

2.1.16 Minimum Temperature During Atmospheric Venting

Identify the possibility of auto-refrigeration effects which could occur if the


vessel is depressurised. State atmospheric boiling point if below 00C and show
intermediate temperatures and pressures below 0°C. Refer also to TWP
GEN/DTA/31-08 Design Pressures and Temperatures.

2.1.17 Insulation

Indicate whether the following typical types of insulation are necessary:

Heat Conservation
Cold Conservation
Fireproofed
Traced
Jacketed

Do not indicate any requirements for personnel protection or winterisation as


these will be established by engineering groups. (See General Note 4 on sheet
FWL 2068/2). However, check vessel requisitions to ensure that they
incorporate known requirements.

2.1.18 Fireproofing

State 'yes' if the vessel requires fireproof thermal insulation.

The process requirement applies only to the need for fireproof insulation on a
vessel. Engineering Department will be responsible for structural fireproofing.
Where Process Engineering specify fireproof insulation this implies that relief rate
calculations have taken credit for such insulation.

The Process Engineer must ensure that Project Insulation Specification meets the
main requirements for:

- low thermal conductivity


- stability under fire
- resistance to hose stream impingement

as outlined in Process Standard 602 p. 4.0-3. Fireproof insulation is not generally


recommended owing to its vulnerability; the client must be advised of the need to
maintain insulation integrity at all times.

Guidelines on where fireproofing should be specified are included on Figure 1.

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ATTACHMENT 16 – VESSELS (cont)

2.1.19 Pressure/Temperature Cycling

Where vessels operate on a cycle, quote alternative conditions and frequency of


cycle. Typical examples are pressure swing absorbers, where regeneration can
occur every few minutes, and batch processes.

Quote any cycles in excess of 500 during total lifetime.

Note that more-than-normal shut-down frequency for example due to unreliable


power supply may cause fatigue problems in high-stress designs such as B.S.
5500.

2.1.20 Blanketing (applies to storage tanks only)

2.1.21 Materials

State the materials of construction of the shell and the internals, and any parts
of the vessel if these are specific process requirements. The materials should
be obtained from the Materials Selection Diagrams.

Indicate whether lining/cladding is required or an acceptable alternative to solid


construction.

Use the widest permissible specification, such as carbon steel rather than a
particular ASTM number, which is acceptable to Process Engineering.

However specific process requirements such as 'low carbon steel' should be


stated.

2.1.22 Operating Temperature Profile (Columns only)

To assist Stress Group, where tower top/bottom temperature differential


exceeds say 120°C, add a temperature profile at say 250C intervals including
drawoff and feed locations.

2.1.23 Tankage Venting Data

This data should be completed for atmospheric or near atmospheric storage


tanks. This enables the tank Supplier to supply the necessary venting
apparatus. See Tankage (Section 2.2.23).

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ATTACHMENT 16 – VESSELS (cont)

2.1.24 General Notes

Delete notes 1 to 4 if not required.

Under note 5 indicate if high relief loads are likely to be experienced. On some
columns the addition of a multiplicity of relief valves on top of a column has
resulted in late changes to column design. If Vessel Group is aware of a
requirement for mounting of heavy relief valves later problems can be
minimised.

2.2 Tanks

Process Standard, Section 102 provides guidelines for specifying atmospheric


or near atmospheric tanks.

However this standard refers to a Tankage Summary Sheet which FWEC


Process Department use for transmitting contractual information to Engineering
Groups. This is similar to the Process Tankage Summary (FWL 2829).

In Reading and Branch offices, the normal vessel specification sheets 2068/1
and 2068/2 should be used for specifying tankage on contracts. The Tankage
Summary Sheet should only be used for approximate data on proposals and
studies.

The following additional notes refer to the incorporation of tankage details onto
the standard Vessel Specification:-

2.2.1 Standard 102 refers to API Standard 620 and 650. In the UK BS 2654 provides
alternative data on tank design conditions and sizes; other standards exist. There
are specific appendices in API 620 for low temperature applications.

Vessel Group will ensure that the correct codes are followed, but the Process
Engineer should know which codes will be used, as they influence process
specification.

If a fixed roof design is chosen, note that there are different degrees of
'atmospheric design'.

For example BS 2654 defines tanks in the following categories (in increasing
order of cost):

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ATTACHMENT 16 – VESSELS (cont)

Design Pressure Design Vacuum


Non Pressure + 7.5 mbar - 2.5 mbar
Low Pressure +20 mbar - 6.0 mbar
High Pressure + 56 mbar - 6.0 mbar

Typical tank usages are as follows:-


Non Pressure ) : Tanks venting to atmosphere
Low Pressure ) : Tanks gas blanketed but venting to
High Pressure ) : atmosphere

API standards describe higher design pressure tanks (e.g. 2 psig) which may be
necessary if the tank vents through a scrubber/flare system.

It is important to consult Vessel Group to ensure that the design pressures


specified are sensible, thus avoiding recycle of work.

2.2.3 Although the Process Engineer should estimate actual dimensions, state the
required working volume and add note that 'other dimensions giving same
working volume may be used if more economical'.

Process Standard 102 explains the portion of the vessel which can be used as
working volume.

2.2.4 Sketch (Sheet 2068/I)

The sketch should indicate:

- Type of Roof (i.e. fixed, floating)


- Type of Bottom (cone up/down)
Special detail such as integral concrete bunds, double wall for low
temperature service, etc
- Nozzles
- Special internals, see section 2.2.6

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ATTACHMENT 16 – VESSELS (cont)

2.2.5 Nozzles

1. Access Nozzle

The number and location of manways should be left to the Vessel Group.

2. Process Nozzles

Typical process nozzles are listed in Process Standard lO2p.6.O - 11.

Process Department should indicate outline requirements for safety


connections, and should size any nozzles which are attached to piping.

Where safety devices (e.g. PVV, Relief manway) are connected directly to the
tank then do not allocate a size. Include the flow data in the Tankage Venting
Data section of the process specification. The tank Supplier normally supplies
such safety devices with the tank.

If specifying these devices in detail note the following:

Set pressure
The required value should be discussed with the client. While setting the final
safety device at the tank design pressure is acceptable, certain clients require
that the accumulated pressure should not exceed the tank design pressure.
(Minimum setting is typically 2 1/4 in. wg 5.6 mbar g)

Differentials
For low pressure tanks an adequate margin must be maintained between the
breather set pressure and any other relieving device (for Whessoe equipment
this is typically 5 mbar or 25% of set pressure minimum).

Accumulation
As noted in FW Process Standard 102, 6.0-22 for API tanks shall be sized to
allow an accumulation of 10% over the set pressure for normal out breathing
and 20 percent over the set for emergency relief. For tanks designed to British
codes, by comparison with the pressure vessel codes, it is recommended that
the valves should be sized to allow an accumulation of 10% over the set
pressure for normal out breathing and 10% for emergency relief.

Liquid Overflow
It should be noted that relieving manways are not specifically designed
for liquid relief. Methods of calculating the likely capacity are given in
API RP 2000 and certain Client Standards (e.g. ICI), but at undefined
overpressure. Care should therefore be taken in specifying them for this
type of duty.

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ATTACHMENT 16 – VESSELS (cont)

2. Process Nozzles (cont)

Examples of typical safety connections for tankage are as follows:

Tank with atmospheric venting 1 open vent


1 emergency relief (manway or
vent)

Blanketed tank with atmospheric 1 PVV (Pressure vent to


venting atmosphere)
1 Blanket connection
1 Emergency relief (manway or
PSV)
Blanketed tank venting to flare 1 Blanket connection
1 PVV/Pressure vent to flare
1 PSV Emergency relief to flare

The location of process nozzles should be approximately indicated on the


process sketch. The normal FW procedure is to locate inlet pipes in the
bottom of a vessel to avoid splashing, but specific requirements (such as
reduction of spill hazard) may necessitate top entry with dip tube and
anti-syphon hole.

Note: Always ensure that tank vents are adequately protected from
blockage e.g. by solidification of tank contents.

3. Auxiliary Nozzles

As for other vessels, see 2.1.6.

4. Instrument Nozzles

Process should list the instrument functions required, and estimate the
number of nozzles for each service using normal vessel procedure, see
2.1.6.

2.2.6 Internals

Show requirements for internals such as:

Piping Inserts
Mixing nozzles
Heating coils (indicate coil length, diameter, materials and design Conditions)
Baffles

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ATTACHMENT 16 – VESSELS (cont)

2.2.6 Internals (cont)

Show if a mixer is required; this will be detailed on an Agitator Process


Specification Sheet (2068/17). Give Agitator item number.

Always beware of static generation in tanks with combustible atmosphere.


Certain internals such as mixers may be prohibited where static risk is high.

Consider the need for syphon breakers on top entry pipes with dip legs.

2.2.7 Design Pressure : See 2.2.1/2 above. Agree design pressure with
Vessel Group in accordance with vessel code.
2.2.8 Design Temperature : Remember that so called ambient tanks may be
subject to solar heat gain.

Design temperature should consider maximum


rundown temperature, maximum ambient
temperature and solar gain.

Do not consider fire.

2.2.9 Operating Pressure

This depends on the tank breathing arrangement, and chosen design pressure,
but typical values may be:-

Non Pressure Tank Atmospheric

Low Pressure Tank For nitrogen blanketed tanks the pressure will normally
vary between the nitrogen make-up regulating valve
set pressure (say 5-10 mbarg) and that determined by
the discharge mechanism. (The discharge mechanism
can either be a modulating backpressure control valve
or the breather valve).

Unblanketed enclosed tanks will normally vary between


the vacuum and pressure values of the breather valve.

High Pressure Tank Depends on venting system (may be as high as say 70


mbar if tank design permits and vent goes through
scrubber)

Always ensure a margin between operating and design pressure to permit


design of safety relief equipment. Low operating pressures will lead to
excessive consumption of blanketing gas due to thermal breathing.

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ATTACHMENT 16 – VESSELS (cont)

2.2.10 Operating Temperature

State fluid rundown temperature or ambient, whichever is applicable.

2.2.11 Vacuum Conditions

State the vacuum design condition agreed with the Vessel Group.

2.2.12 Steam Out Conditions

Give steam out conditions if steam out is known to be a process requirement.


If no specific request state 'By Engineering'.

2.2.13 Stress Relieved (Process Reasons)

Indicate YES if stress relief shown on Materials Selection Diagram. (Note that
Engineering may add stress relief for strength reasons)

2.2.14 Corrosion Allowance

See Materials Selection Diagram

2.2.15 Short Term Maximum Temperature

Use similar approach to that for other vessels, including potential effect of
failure of upstream cooler. However if a tank has a continuous inventory, it may
be possible to take credit for the moderating effect of the cool contents on the
hot feed. Consider each case on its merit.
Do not consider fire case.

2.2.16 Minimum Temperature during Atmospheric Venting

Not applicable to an atmospheric tank.

2.2.17 Insulation

As for general vessels.

2.2.18 Fireproofing

As for general vessels.

2.2.19 Pressure/Temperature Cycling

As for general vessels although cycling is unlikely in storage tanks.

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ATTACHMENT 16 – VESSELS (cont)

2.2.20 Blanketing

Indicate gas used for blanketing if any.

2.2.21 Materials

As for general vessels.

2.2.22 Operating Temperature Profile

Not applicable.

2.2.23 Tankage Venting Data

Completed this data when the tank Supplier is required to supply safety
breathing and relief equipment.

Max In breathing rate State the sum of the thermal breathing (API
RP2000) + pump-out rate.

Max Out breathing rate State the sum of the thermal breathing (API
RP2000) + pump-in rate.

Emergency Relief Provide the requested data for the limiting relief
case. This will normally be fire, but could be
the result of excess flashing if say the rundown
is excessively hot.

API RP2000 incorporates two different


calculation procedures for fire relief rates,
depending on whether or not a frangible roof
weld is an acceptable means of emergency
venting in fire. Process Co-ordinator should
check this with Vessel Engineer.

3. Process Specification Sheets

Copies of the Vessel Process Specification Sheets (Ref 2068/1 and 2068/2) are
included overleaf.

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ATTACHMENT 16 – VESSELS (cont)

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