PROCEDURE

eni spa 10009.HTP.PRC.
SDS
Rev 03 – July 2015
Page 3 of 55
Consulted Distribution List
Date Addressee / Position Holder Company/Unit

D. Fernandez / TEPI eni/ITEM
E. Di Rienzo / TEPI eni/ITEM
S. Gree Babu / MECC eni/ITEM
D. Armstrong / PSD eee&p
D. Welch / FED eee&p
A. Amati / PROS Tecnomare
S. Edoro / PROS Tecnomare
E. Palumbo / COAM Tecnomare
C. Prati / PRDO eni/ITEM
P. Bove / ENTA eni/ITEM
P. Gatto / MACC Tecnomare
D. Russel / EMS eee&p
M. Negretti / TEIMA eni/ITEM
Informed Distribution List
Date Addressee / Position Holder Company/Unit

G. Colombo / ITEM eni/ITEM
M. Barbieri / ENTA eni/ITEM
I. Hashi / ENTA eni/ITEM
M. Monteleone / IMPI Tecnomare
P. Woolfall / EMS eee&p
A. Marceglia / MECC eni/ITEM
M. Gorlini / TEEL eni/ITEM
R. Scanferlini / TEEL eni/ITEM
B. Cook / EMS eee&p
A. Zanoni / TESA eni/ITEM
W. Manghisi / TESA eni/ITEM
F. Artuso / ENTA eni/ITEM
L. G. Ciccarelli / TEPIM eni/ITEM
L. Cavazzoni / PROS Tecnomare
T. Cheldi / TEMC eni/ITEM
A Di Lullo / TEFA eni/ITEM
S. Mollica / TEIMA eni/ITEM
S. Fasoli / IMEL Tecnomare
L. Malaguti / IMEL Tecnomare
M. Poggi / SMESIN eni/ITEM
M. Skelton / INS eee&p
F. Vailati / STAU Tecnomare
C. Patanè / STAU Tecnomare
F. Girardo / COAM Tecnomare
ENGINEERING COMPANY STANDARD

This document is property of eni spa. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
eni spa 10009.HTP.PRC.SDS
Rev 03 – July 2015
Page 4 of 55
REVISION TRACKING
Rev 03: Actual revision is of 55 pages.
Summary of main changes:
1. General rewording through the entire document.

2. Design criteria name changed from Process Minimum Requirement to Process
Design Minimum Requirements, maintaining the same Company number and
changing the type of document to Company Specification.
3. Change of document format as required by ENTA.
4. Introduction deleted.
5. Applicability and Exclusion chapter included.
6. Reference Standards and Documents chapter updated. Method of Request
Company Standard included.
7. Abbreviations and Acronyms chapter updated and extended.
8. Units of measurement chapter updated.
9. Standard and Normal Conditions sub-chapter included.
10. Terminology and Definitions chapter updated.
11. eni’s Energy Efficiency references included.
12. eni’s HSE design requirements references included.
13. Sparing Philosophy chapter updated and moved.
14. Overdesign Criteria chapter updated and moved.
15. Design Pressure and Design Temperature chapter updated.
16. Line Sizing Criteria chapter updated.
17. Equipment Design Criteria chapter updated.
July, 2015
Rev 01: This revision is of 57 pages.

1. General revision of the document.
February, 2011
INFORMATION REQUEST
eni personnel can access company standard repository at:

http://wwweandp.eni.it/TSServices/ITEM/Standards-/Normalizat/Documents-/index.asp
External user shall refer to the Project Engineer Manager.
For information about the content of this standard, please refer to responsible and
accountable person as per above RACIE table or to Technical Authority coordinator
(COETA).

Rev 03 – July 2015
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INDEX
1. SCOPE ............................................................................................................................. 7
2. APPLICABILITY AND EXCLUSIONS..................................................................... 7
3. REFERENCE STANDARDS AND DOCUMENTS ................................................... 8
4. ABBREVIATIONS AND ACRONYMS ................................................................... 10
5. UNITS OF MEASUREMENT .................................................................................... 12

5.1 STANDARD AND NORMAL CONDITIONS......................................................... 12
6. TERMINOLOGY AND DEFINITIONS................................................................... 13
7. DESIGN PRESSURE AND DESIGN TEMPERATURE ....................................... 15

7.1 DESIGN PRESSURE (DP) ....................................................................................... 15
7.1.1 MAXIMUM OPERATING PRESSURE .......................................................................... 15
7.1.2 SPECIFIC EQUIPMENT REQUIREMENTS ................................................................. 15
7.1.2.1 Pressure Vessels ............................................................................................. 16
7.1.2.2 Columns .............................................................................................................. 17
7.1.2.3 Tanks .................................................................................................................... 18
7.1.2.4 Heat Exchangers and Air coolers .............................................................. 18
7.1.2.5 Pumps .................................................................................................................. 19
7.1.2.6 Compressors ..................................................................................................... 20
7.1.2.7 Piping ................................................................................................................... 22
7.1.3 SPECIFIC CONSIDERATIONS .................................................................................... 22
7.2 DESIGN TEMPERATURE (DT) .............................................................................. 23
7.2.1 MAXIMUM OPERATING TEMPERATURE ................................................................... 23
7.2.2 MAXIMUM DESIGN TEMPERATURE .......................................................................... 23
7.2.3 MINIMUM OPERATING TEMPERATURE (MOT) ....................................................... 24
7.2.4 MINIMUM DESIGN METAL TEMPERATURE ............................................................. 24
7.2.5 SPECIFIC EQUIPMENT REQUIREMENTS ................................................................. 25
7.2.5.1 Heat Exchangers ............................................................................................. 25
7.2.5.2 Piping ................................................................................................................... 26
8. LINE SIZING CRITERIA ......................................................................................... 27

8.1 GENERAL ..................................................................................................................... 27
8.2 GAS/VAPOUR LINES ............................................................................................... 28
8.3 STEAM LINES ............................................................................................................. 29
8.4 LIQUID LINES ........................................................................................................... 29
8.5 MIXED PHASE LINES .............................................................................................. 33
8.6 FLARE & BLOWDOWN LINES ............................................................................... 34
8.6.1 PSV INLET LINES ......................................................................................................... 34
8.6.2 BDV INLET LINES ........................................................................................................ 35
8.6.3 PSV OUTLET LINES ..................................................................................................... 35
8.6.4 BDV OUTLET LINES ..................................................................................................... 36
8.6.5 FLARE HEADERS AND SUB-HEADERS ..................................................................... 36
8.7 VIBRATIONS AND NOISE LIMITS CRITERIA SUMMARY .......................... 37
8.8 NOZZLE SIZING CRITERIA SUMMARY ............................................................. 37
8.8.1 FEED INLET NOZZLES (MIXED PHASE) .................................................................. 37
8.8.2 GAS OUTLET NOZZLES .............................................................................................. 38
8.8.3 LIQUID OUTLET NOZZLES ......................................................................................... 38
8.8.4 FLARE KOD NOZZLES ................................................................................................. 39
8.8.5 VESSELS / COLUMNS CONNECTIONS..................................................................... 39
8.9 PIPING EQUIVALENT LENGTH ............................................................................ 40

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9. OVERDESIGN CRITERIA ........................................................................................ 41
10. SPARING PHILOSOPHY ......................................................................................... 42
11. EQUIPMENT DESIGN CRITERIA ......................................................................... 44

11.1 VESSELS AND SEPARATORS ................................................................................ 44
11.1.1 TYPE OF VESSELS AND CONFIGURATION ............................................................. 44
11.1.2 GAS/LIQUID SEPARATION CRITERIA: .................................................................... 44
11.1.3 LIQUID-LIQUID SEPARATION CRITERIA: .............................................................. 46
11.1.4 MINIMUM LIQUID HOLD-UP AND RESIDENCE TIME............................................ 47
11.2 SLUG CATCHERS ....................................................................................................... 47
11.3 COLUMNS AND TRAYS............................................................................................ 47
11.4 HEAT EXCHANGERS AND AIR COOLERS ......................................................... 48
11.4.1 HEAT EXCHANGERS TYPE AND ARRANGEMENT ................................................... 48
11.4.2 AIR COOLERS ............................................................................................................... 50
11.5 PUMPS .......................................................................................................................... 50
11.5.1 CENTRIFUGAL PUMPS................................................................................................. 50
11.5.2 POSITIVE DISPLACEMENT PUMPS ........................................................................... 51
11.5.3 GENERAL RECOMMENDATIONS................................................................................ 51
11.6 COMPRESSORS.......................................................................................................... 51
11.6.1 CENTRIFUGAL COMPRESSORS ................................................................................. 52
11.6.2 RECIPROCATING COMPRESSORS ............................................................................ 52
11.7 TANKS........................................................................................................................... 53
11.8 ELECTROSTATIC DESALTERS .............................................................................. 53
12. INSTRUMENTATION DESIGN CRITERIA ......................................................... 54

12.1 CONTROL VALVES .................................................................................................... 54
12.1.1 PRESSURE DROP ......................................................................................................... 54
12.1.2 FLOWRATE .................................................................................................................... 55
12.2 PSV & BDV .................................................................................................................. 55

Rev 03 – July 2015
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1. SCOPE
This standard covers the process engineering criteria to be used for the design of
upstream onshore and offshore oil & gas facilities and addresses the basic sizing criteria
of the main process items.
The intent is to cover the minimum requirements; it is anticipated that not all the topics
of process design can be exhaustively covered in one single standard. Engineers will
regularly refer to other Eni's or international standards.
2. APPLICABILITY AND EXCLUSIONS
This specification shall be applied to the design of upstream onshore and offshore
facilities. Midstream and downstream installations are out of the scope of this standard
as well as drilling and completion facilities, subsea systems and transport facilities
(pipelines).
The requirements of this standard shall be applied to all the eni S.p.A projects.

Rev 03 – July 2015
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3. REFERENCE STANDARDS AND DOCUMENTS
In the following, is the list of main standards to be taken into account in process design
activities. Reference to any standard or code shall mean the latest edition of them.
Company standards
[1] 20183.COO.GEN.FUN Units of Measurement

Process Plant Steady State Simulation.
[2] 10010.HTP.PRC.PRG Minimum Setting Requirements. Process
Reports
Energy Efficiency Engineering Technical
[3] 27984.DOC.GEN.RWP Guidelines for Oil and Gas Surface
Facilities
Eni Standard HSE Minimum
[4] Doc. 1.3.0.07
Requirements
[5] 06574.VAR.PRC.SDS Process Engineering Deliverables
Technical Documentation Required
[6] 27700.VAR.GEN.SDS During The Project Development Phases
- Detailed List & Requirements
Flow Assurance Guidelines Slug Catcher
[7] 27931.VAR.FLW.PRG
Dimensioning.
Company specification. Mechanical
[8] 27953.VAR.GEN.SDS
Isolation Philosophy And Procedures
[9] 28013.MAN.MNU.SDS RAM Analysis Methodology
[10] 28014.MAN.MNU.SDS RCM Approach

Emergency Shut-down Philosophy
[11] 28038.HTP.PRC.SDS
Preparation
International standards
Sizing, selection and installation of
[12] API Standard 520 Pressure-relieving Devices, parts 1 and
2
Pressure-relieving and Depressurizing
[13] API Standard 521
Systems
Design and Construction of Large,
Welded, Low-pressure Storage Tanks
Venting Atmospheric and Low-pressure
Storage Tanks
Petroleum and natural gas industries -
[16] ISO 13703: 2000 Design and installation of piping systems
on offshore production platforms
[17] ANSI/ASME B31.3 Code for Pressure Piping Process Piping
Pipeline Transportation Systems for
[18] ASME B31.4
Liquids and Slurries
[19] ASME Section VIII Div. 1 Boiler and Pressure Vessel Code
[20] ASME B16.5 Pipe Flanges and Flanged Fittings

Centrifugal Pumps for Petroleum,
[21] ISO 13709
Petrochemical and Gas Industries

Rev 03 – July 2015
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Recommended Practice for Design and

[22] API RP 14 E Installation of Offshore Production
Platform Piping System
Other Consulted Standards
[23] 04937.EQP.MEC.FUN Shell and Tube Heat Exchangers
[24] opi svi 007 - ANNEX B Golden Rules

Design Fabrication and Testing of
[25] 05490.MAT.MEC.SDS
Pressure Vessels under ASME BPV Code
Axial and Centrifugal Compressors and
Expander Compressors
Standard on Explosion Prevention
[27] NFPA 69
Systems
[28] API Standard 650 Welded Steel Tanks for Oil Storage
Centrifugal Pumps for Petroleum,
[29] API Standard 610 Petrochemical and Natural Gas
Industries

Rev 03 – July 2015
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4. ABBREVIATIONS AND ACRONYMS
ANSI American National Standards Institute

API American Petroleum Institute
ASME American Society of Mechanical Engineers
BDV Blowdown valve
BFW Boiler Feed Water
BHP Break Horse Power
BS&W Basic Sediment & Water
C Empirical Constant for erosional velocity calculation
CAPEX Capital expenditure
CRP Compressor Rated Point
CS Carbon Steel
CV Valve Flow Coefficient
∆P Pressure drop
DCS Distributed Control System
DP Design Pressure
DT Design Temperature
ESD Emergency Shut Down
FEED Front End Engineering Design
Fr Froude Number
FV Full Vacuum
GRP Glass Reinforced Pipe
H&MB Heat and Material Balance
HHLL High High Liquid Level
HIPPS High Integrity Pressure Protection System
HLL High Liquid Level
HP High Pressure
HSE Health Safety and Environment
ID Inside Diameter
ISO International Organization for Standardization
K Coefficient for critical velocity calculation
KOD Knock-out Drum
LAH Level Alarm High
LAHH Level Alarm High High
LAL Level Alarm Low
LALL Level Alarm Low Low
LLL Low Liquid Level
LLLL Low Low Liquid Level
LNG Liquefied Natural Gas
LP Low Pressure
LPG Liquefied Petroleum Gases
Ma Mach Number
MAWP Maximum Allowable Working Pressure
MDMT Minimum Design Metal Temperature
MDT Maximum Design Temperature
MOP Maximum Operating Pressure
MOT Maximum Operating Temperature
mOT Minimum Operating Temperature
NLL Normal Liquid Level
NPSH Net Positive Suction Head
NPSHa Net Positive Suction Head Available
NPSHr Net Positive Suction Head Required
OP Operating Pressure
OPEX Operational Expenditure
OT Operating Temperature

Rev 03 – July 2015
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P Pressure
P&ID Piping and Instrumentation Diagram
PFD Process Flow Diagram
PSA Pressure Swing Adsorption
PSV Pressure Safety Valve
RAM Reliability, Availability and Maintainability analysis
RCM Reliability Centered Maintenance
ρ Density
SDV Shut-down valve
SI Système Intérnational d’Unités
STD Standard wall pipe schedule
T Temperature
TL Tangent Line
TVP True Vapour Pressure
UOM Unit(s) of Measurement
v Velocity
Ve Erosional Velocity
VSD Variable Speed Drive
W Mass Flowrate
XS Extra Strong wall pipe schedule
Z Compressibility Factor

Rev 03 – July 2015
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5. UNITS OF MEASUREMENT
The units of measurement to be used for process design criteria application should be
generally based on SI system. For a detailed and complete list of eni S.p.A units of
measurement for technical documentation see the Functional Specification
20183.COO.GEN.FUN, Ref.[1].
5.1 STANDARD AND NORMAL CONDITIONS
Standard conditions
Standard conditions are defined as those relevant to ideal gas (Z=1) at predefined
pressure (almost always atmospheric pressure i.e. 1.01325 bara, 14.69 psia) and
temperature.
The standard temperature often refers to 60°F (about 15.56°C) even though 15°C is not
uncommon and sometimes other values. For this reason it is always mandatory to
clearly define the standard temperature condition used within a project.
Normal conditions
Normal conditions are those referred to ideal gas (Z=1), 0 °C and atmospheric pressure
(1.01325 bara, 14.69 psia).
Stock-Tank Oil
Stock-tank conditions are those prevailing in a storage tank foreseen for the oil product
after the reservoir fluid has been separated from the associated gas.
It is normal practice to consider atmospheric pressure and storage temperature (project

specific) for stock-tank definition, even though 60°F are often used. Stock tank
conditions, both temperature and pressure shall always be clearly defined. The stock-
tank oil at stock-tank pressure and temperature is the quantity of oil without dissolved
vapour (also defined 'dead oil' or 'black oil').

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6. TERMINOLOGY AND DEFINITIONS
For the purposes of this document, the following terms and definitions apply:
 The Company is the party which initiates and manage all the project parts.
eni S.p.A may also include an agent or consultant authorized to act for, and
on behalf of the Company.
 The Contractor is the party which carries out all or part of the engineering,
procurement, construction, commissioning or management of a project, or
operation and maintenance of a facility. The Company may undertake all or
part of the duties of the Contractor.
 The Supplier or Third Party (Manufacturer/Vendor) is the party which

manufactures or supplies equipment and/or services to perform the duties
specified by the Contractor.
 The Company Engineering Technical Authority is a function whose main

scope is the development of Company documents that constitute Company
minimum requirements and rules for all engineering hubs; to give technical
support to projects for endorsement of deviations to Company standards and
major technical changes; to carry out technical reviews to monitor
implementation of Company expectations and to capitalize the experiences
and lessons learnt.
 The word shall indicate that a provision is mandatory. Any deviation from a
sentence using this word must be submitted to the Company Technical
Authority for recommendations and/or approval.
 The word should is used to indicate that a provision is not mandatory, but
recommended as good practice.
 The word can is used to indicate that requirements are conditional and
indicates a possibility open to the user of the standard.
 The word may indicates a course of action that is permissible within the
limits of the standard (a permission).
Some terms of general use in the document are here defined.
 Gas Blow-by: process upset resulting in gas flowing through a control valve
designed to regulate flow of liquid.
 Blowdown: the act of emptying or depressurizing a pressurized system.
 Erosional velocity: the velocity of two-phase flow (gas and liquid) above
which pipe erosion may occur. It is used primarily to size flowlines,
production manifolds, process headers and other lines.
 Flowline: piping system conveying well fluid from wellhead to manifold or

first process vessel.
 HIPPS: High Integrity Pressure Protection System. Safety system used to

protect production assets from over-pressurization.
 Hold-up time: the time a flowing fluid takes to increase the liquid level of a
vessel from an “empty” condition to a “liquid-full” condition (usually referred

Rev 03 – July 2015
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to LAL / LAH or LALL / LAHH) at the design feed rate without any outlet flow
(or alternatively a decrease of level with an outlet design flow without any
feed flow).
 Hold-up volume: as per hold-up time but referred to the volume.
 Operating Pressure (OP): the pressure in the equipment or piping when the
plant operates at steady state conditions, subject to normal variations in
operating parameters. The OP normally corresponds to the value of Heat and
Material Balance.
 Operating Temperature (OT): the temperature in the equipment or piping

when the plant operates at steady state conditions, subject to normal
variations in operating parameters. The OT normally corresponds to the
value of the Heat and Material Balance.
 Pressure Safety-relief Valve (PSV): a pressure-relief device designed to open

to relieve excess pressure and to reclose and prevent further flow of fluid
after normal conditions have been restored.
 Shut-Off Head: is the maximum differential head developed by a centrifugal

pump under zero-flow conditions (i.e. blocked outlet).
 Settle-Out Pressure: is the equalized pressure reached when the fluid is

entrapped between interconnected equipment on both discharge and suction
side after a compressor shut-down.
 Steam-Out: operation of maintenance consisting in purging and/or cleaning

a piece of equipment by use of low pressure steam.

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7. DESIGN PRESSURE AND DESIGN TEMPERATURE
The requirements described in the following paragraphs shall be used to determine the
design pressure and design temperature of the equipment and connecting piping for
process and utility systems.
Design pressure is used, coupled with coincident design temperature, for mechanical
design purpose with the scope to ensure the required design life of the
equipment/piping system.
It is common that the realistic coincidence of temperature and pressure conditions gives
different alternate design conditions to be all considered for design unless one is clearly
the most severe.
7.1 DESIGN PRESSURE (DP)
The Design Pressure (DP) for equipment and pipes is the pressure to be used for
mechanical design. It is calculated from the Maximum Operating Pressure as explained
in the following.
The design pressure shall be determined for an individual equipment or group of

equipment and associated piping connected together as a system and remaining
connected under all operational conditions.
7.1.1 Maximum Operating Pressure
The Maximum Operating Pressure (MOP) is the maximum expected operating pressure
for equipment / piping envisaged during design life for any possible operating scenario
(e.g. production profile and the relevant possible future configurations) also taking into
account transient or upset conditions such as start-up, shut-down, pressure surge,
settling out for centrifugal compressors suction and interstage coolers and knock-out
drums, etc.
Design pressure shall be based on the MOP increased by a safety margin which takes
into account uncertainties on the design figures.
When not otherwise indicated the MOP and design pressure figures used for vessels are
intended at the top of the equipment. Any additional static head shall be properly
considered to get the design pressure applicable for bottom of equipment and connected
piping.
7.1.2 Specific equipment requirements
When deciding the DP of a system including vessels and other equipment (e.g. pump or
compressor connected to a vessel) the maximum value between Table 7.1. and other
more specific requirements shall govern.

Rev 03 – July 2015
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7.1.2.1 Pressure Vessels
Internal Pressure
The minimum requirements to set the design pressure for Pressure Vessels are shown in
Table 7.1. for pressures above atmospheric (internal pressure):
DP (bar g)
MOP (bar g)
(Notes 1, 2)
0–2 3.5
2 – 15 MOP + 1.5
15 - 70 MOP + 10%
70 - 80 MOP + 7 bar
80 - 115 MOP + 8.5%
115 - 200 MOP + 10 bar
>200 MOP + 5%
Table 7.1. Design Pressure Criteria for Vessel
In general, Table 7.1. is applicable to all equipment designed as pressure vessels

(vessels, drums, columns, filters, heat exchangers) except for specific considerations
given in the paragraphs below.
Note 1:
For vessels in equilibrium with a flare system, the design pressure shall be the flare
design pressure (min. 3.5 barg). NFPA 69 (Ref.[27]) provides design bases and
equations to calculate the design pressure of a flare KOD.
Note 2:
The design pressure shall also take into account vapour pressure of the contained liquid
at the maximum ambient temperature. If the set of the pressure relief device is below
such vapour pressure it will cause unnecessary losses of fluids to the flare through PSV.
External Pressure
Vessels subject to external pressure shall be designed to resist the maximum

differential pressure that is foreseen to occur in service.
The design pressure for equipment operating at pressure below atmospheric shall be
defined as per the following requirements (Table 7.2.):
MOP (bar g) DP (bar g)
<0 3.5 (min)/ Full Vacuum (FV)
Table 7.2. Design Pressure for Vessels operating below atmospheric pressure

Rev 03 – July 2015
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Equipment that could be subject to external pressures under abnormal conditions, such
as:
 Suction drums on reciprocating compressors
 Can be evacuated by an ejector
 Vacuum conditions during start-up, shutdown and/or regeneration

purges.
 Normally operated full of liquid but that can be blocked in and cooled
down.
 Containing condensable vapour, but that can be blocked in and cooled

down.
 Could undergo a vacuum condition through the loss of heat input.
shall be designed for full vacuum at the design temperature in addition to the design
conditions as given in Table 7.1.
Appropriate protective devices can be provided. If such protective devices are used in
place of vacuum design, these systems shall be as reliable as a safety relief device
(e.g., vacuum breaking valve etc.).
Partial Vacuum (in place of Full Vacuum) may be specified on a case by case basis and
shall be subject to Company approval. If for any reason partial vacuum is specified, a
vacuum breaker set at design vacuum must be provided to prevent the vacuum falling
below the design value.
Steam-Out Conditions
For equipment subject to steam out the following alternate (i.e. not coincidental with
other conditions) design conditions shall be specified:
FV @ MOT of Steam
7.1.2.2 Columns
Columns design pressure (at top of column) shall be set as per Table 7.1. valid for
pressure vessels. The following are some additional considerations for columns design
pressure definition:
 Equipment associated with the top of a column, such as, overhead

condenser, reflux drum, interconnecting piping and side drums, are usually
designed at least to the same design pressure as the column.
 The design pressure at the bottom of a column (vapour phase) is usually

determined by adding the column pressure drop at the column overhead
design pressure.
 Liquid density and maximum liquid height in the bottom will be specified on
the process data sheet to allow the vessel designer to calculate the bottom

Rev 03 – July 2015
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design pressure (including hydrostatic head). The bottom design pressure

shall be used for column bottom outlet piping system design.
 For kettle type reboilers, the design conditions of the shell side should be the
same as the design conditions of the column, and no isolation valves should
exist between them. In this case column PSV’s will provide overpressure
protection for reboiler.
7.1.2.3 Tanks
Typical design pressure for tanks are shown in Table 7.3.
type DP (bar g)
Atmospheric Tank (typically Cone Roof Type, API 650)

Tank NOT blanketed and vent to
Atmospheric
atmosphere
Tank blanketed and vent to atmosphere 200 mm H2O & -60 mm H2O vacuum
Tank blanketed and vent to flare (*) 500 mm H2O & -60 mm H2O vacuum
Low Pressure Tank (typically API 620)
Dome Roof 0.05 to 1.0 barg & - 60 mm H2O vacuum
Table 7.3. Design Pressure Criteria for Tank
(*) In this case, the flare system shall have a maximum backpressure lower than 300
mm H2O.
The design pressure shall be related to the vapour phase at top of the tank and
therefore shall not include any liquid head in the tank. Liquid density and the maximum
liquid height shall be specified to allow the mechanical calculation (full of water or full of
product, if product specific gravity > 1). A vacuum breaker shall be provided.
The maximum inbreathing and out breathing capacities of storage tanks are dependent
on relative fast ambient temperature changes which occur in some climatic conditions.
This shall be considered when the tank breathing and relief systems are specified in
accordance with the standard API 2000 (Ref.[15]).
7.1.2.4 Heat Exchangers and Air coolers
The minimum requirements to set the design pressure for heat exchangers (shell and
tube for both sides and air coolers for process side) are those shown in Table 7.1.:
 Shell & Tube heat exchangers: Special considerations shall be given to the
opportunity to design the LP side of a shell and tube heat exchanger for a
design pressure at least as high as 10/13 of the design pressure of the HP
side (the factor 10/13 is applicable in case the corrected hydrotest pressure
is 130% of the design pressure, reference shall be made to API Standard
521 (Ref.[13]) for the proper factor to be considered). In this case a PSV
for the LP side is not required to be sized for tube rupture scenario (but the
LP side circuit as a whole shall consider this scenario for all safety or

Rev 03 – July 2015
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operational impacts of such an event). For such application rupture disks are
recommended since they react faster.
If no other constraints dictate otherwise it is thus recommended to follow the
10/13th rule for shell and tube type heat exchangers.
 Air Coolers: Generally Air Coolers design pressure will be equal to the
associated equipment (e.g. overhead condenser with relevant column).
Special considerations shall be given to the possibility that an air cooler could
undergo a completely liquid-filled condition (as upset condition) in assessing
the design pressure due to the resulting hydrostatic head contribution.
7.1.2.5 Pumps
This section reports the minimum requirements to set the design pressure for systems
at Pumps’ discharge.
Centrifugal Pumps
In general, no PSVs are provided at the discharge of centrifugal pumps (if powered by
fixed speed drivers). Design Pressure of equipment/piping systems in a pump discharge
circuit shall be equal to the pump shut-off pressure up to the last block valve installed in
the discharge circuit (i.e. before the next system protected for overpressure). Suction
piping of pumps up to suction valve(s) (included) shall be designed at the same design
pressure. This is to allow for backflow through the pump during shutdown, without over
pressurizing the suction side.
When pump characteristic curves are not known/available, the design pressure for
motor-driven pumps shall be estimated conservatively with the following formula:
1.2 head  d
Pd  Ps max.  max
10.2
Where:
Pd = Design Pressure at pump discharge = Shut-off Pressure, barg.
Ps max = Suction Vessel Design Pressure(*) + Static Head at maximum

specific gravity of pumped fluid(s) evaluated at HHLL or HLL (**) whichever
is applicable, barg.
head = Pump head at design point, m.
dmax = Maximum Specific Gravity of the pumped fluid(s) at normal

operating conditions.
(*) When suction vessel is equipped with a PSV, the PSV set pressure shall be used in
the formula, otherwise the design pressure shall be used.
(**) Static head evaluation shall take into account bottom TL elevation of suction
vessel.
When pump curves are available, this design pressure has to be checked with the actual
head of the pump at shut-in (no flow) conditions with the maximum suction pressure
and the maximum specific gravity.

Rev 03 – July 2015
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The following factors shall be also taken into account:
 For vertical pumps installed in sump pit/underground vessel clear reference

of elevation level (suction nozzle, discharge nozzle, impeller level) shall be
indicated while specifying differential head at nominal/rated flowrate.
 Variable speed driven centrifugal pumps could have a differential head at no

flow higher than motor (fixed speed) driven. The designer Process Engineer
shall consult the machinery specialist to calculate its shut-off pressure, but
for preliminary estimation a value of 130-140% of rated head shall be used.
Positive Displacement Pumps
Positive displacement pumps are classified in reciprocating, metering and rotary pumps.
The design pressure on the discharge side should be specified with a margin compatible
with the downstream system and a full flow pressure relief valve must be provided to
protect downstream equipment/piping in case of blocked outlets. Typically higher
margins between MOP and DP are required at the discharge of volumetric pumps for
operational flexibility (in order to prevent potential opening of discharge PSV during
normal operation caused by pressure fluctuations).
The Design Pressure (and consequently the set pressure of the safety valve) of the
discharge side of Volumetric Pumps shall be defined as minimum as shown in Table
7.4.
MOP, bar g (*) DP (discharge side), bar g
Discharge Pressure < 10 barg MOP + 2 bar
Discharge Pressure ≥ 10 barg 1.2 * MOP
Table 7.4. Design Pressure Criteria for Volumetric Pump

(*) The shown MOP actually refers to the maximum operating pressure required at
pump discharge during normal operation.
7.1.2.6 Compressors
Compressor design shall take into account all the operating conditions (start-up
included) considering the maximum/minimum fluid molecular weights, the
highest/lowest temperatures of the process gas with the maximum/minimum upstream
pressure, etc. On the basis of such evaluations, Process Engineer (in conjunction with
Machinery Department) shall evaluate which operating cases could impact machine
design and determine the maximum operating pressure (MOP) at compressor discharge.
Consideration shall be also given to the compressor arrangement to determine the
settling pressure of the isolated system.
On fixed speed (motor driven) centrifugal compressor discharge, PSV’s may not be
installed. If this is not practical and for variable speed drivers, then full flow relief valves
or alternatively an HIPPS shall be provided to protect downstream equipment/system.
The design pressure (i.e. set pressure of PSV’s or HIPPS) shall be specified with a
suitable margin to ensure reliable operation without spurious shutdown or release
during system settle-out.

Rev 03 – July 2015
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For variable speed driven centrifugal compressors (turbines, engines, VSD) it is almost
certainly economical to install a PSV on the compressor discharge (avoiding a too high
design pressure of the discharge system). This will also help project development to set
discharge system design pressure without waiting for compressor Vendor data to define
the design pressure.
Full flow relief is always required for volumetric compressors. Additional margins may be
required to take into account the effects of pulsation in the case of reciprocating
compressors, or the dynamics of a particular compressor shutdown/trip event, or for the
inter-stage pressure on multi-stage compressors.
The design pressure of the equipment/piping at compressor suction (i.e. Compressor

suction Knock-Out drum and coolers) shall be above the maximum settle-out pressure.
The opportunity to setting the design pressure of the suction side equipment on a
compression stage equal to the discharge design pressure of the same stage shall be
evaluated especially where this may allow elimination of PSV’s and simplification of the
plant.
In order to estimate the compressor settle out pressure, the following equations should
be applied:
∗ ∗

where:
Psuction = Suction Pressure, barg
Vsuction = Compressor Suction system volume, m3
Pdischarge = Discharge Pressure, barg
Vdischarge = Compressor Discharge system volume, m3
Vtotal = Vsuction + Vdischarge = Total compressor system volume, m3
Suction/discharge volumes shall take into account also equipment/piping included in the
respective systems. Usually, the compressor internal volume is neglected. In absence of
real data a ratio 2/3 to 1/3 of suction/discharge volumes can be assumed i.e.:
P settle out = 2/3 P suction + 1/3 P discharge
Centrifugal Compressors
In the absence of compressor performance curves, the minimum design pressure

criteria for centrifugal compressors (at the compressor discharge) are shown in Table
7.5. below:
MOP, bar g DP (discharge side), bar g
MOP < 10 barg MOP + 1 bar
MOP ≥ 10 barg 1.1 *MOP
Table 7.5. Design Pressure Criteria for Centrifugal Compressor

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However it is recommended to check with compressor Vendor/Supplier or similar service

as the one being designed, the anticipated maximum head at surge point to get a better
estimate of the design pressure to be considered for the discharge system of the
centrifugal compressor, in order to avoid installation of unnecessary PSVs on the
discharge side.
Reciprocating Compressors
The minimum design pressure criteria of the discharge side for Reciprocating
Compressors are shown in Table 7.6. below:
MOP, bar g DP, bar g
MOP < 20 barg MOP + 2 bar
MOP ≥ 20 barg 1.1 * MOP
Table 7.6. Reciprocating Compressor Design Pressure Criteria
7.1.2.7 Piping
Piping design shall provide for the most severe condition of coincident pressure (internal
or external) and temperature expected in both normal operation and upset conditions
including temporary conditions, such as start-up, shutdown, steam-out and ambient.
In general design pressures of piping systems are equal to the associated equipment
design pressures, i.e. same requirements shall be considered for design pressure of
equipment and connecting piping, including considerations on pump shut-off conditions,
settle-out pressure, any blocked-in condition, hydrostatic head, etc.
With reference to Production Manifolds (piping systems downstream of wellhead),

design pressure requirement shall be defined in compliance with upstream system
design (wellhead, flowlines, etc.). Unless other evaluations/constraints dictate
otherwise, design pressure of such systems shall be at least equal to Well Head Shut-In
(static) Pressure.
The selection of design temperatures and pressures must recognise solar heat gain and
ambient temperatures (see paragraph 7.2.2.).
7.1.3 Specific considerations
During the definition of the design pressure for equipment/piping the following must be
considered:
 Hydraulic pressure due to relative elevation of the pressure relief device and
the equipment to be protected shall be taken into consideration. Relief
device set pressures should be lowered to account for this in liquid-filled
systems.
 For reactors, pressure and temperature conditions during the regeneration of

the catalyst shall also be taken into account.

Rev 03 – July 2015
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 For any equipment subject to operating cycles, pressure conditions during

any operating phase shall be also taken into account (e.g. Pressure Swing
Adsorption (PSA) Units).
 For flare systems (i.e. continuously connected to atmosphere) the

backpressure on the PSVs (and other loads) discharging in the flare network
is limited to a maximum design value based on which the design pressure of
the flare network is defined.
 For closed drain/open drain systems procedures are available preventing the
equipment/piping to be drained but during supervised operation, which are
carried out after depressurization of the equipment/piping. The minimum
design pressure value for such systems shall be 3.5 barg unless other
considerations dictate otherwise.
7.2 DESIGN TEMPERATURE (DT)
The Design Temperature (DT) for equipment and pipes is the temperature which is
used, coupled with coincident design pressure value, for mechanical design purpose with
the scope to ensure the required design life of the equipment/piping system.
In most cases two design temperatures are considered: the MDT as high value and the
MDMT as low value (basically valid with respect to brittle fracture). They are calculated
respectively from the Maximum Operating Temperature and the Minimum Operating
Temperature as explained in the following. It is common to found in some
documentation the form DT xxx/-yyy intending xxx is the MDT and -yyy is the MDMT.
7.2.1 Maximum Operating Temperature
Maximum Operating Temperature (MOT) shall be normally taken from H&MB developed
for the considered scenarios.
In many cases different temperatures may occur at unstable conditions (e.g. during
start-up, shutdown, drying, purging, catalyst regeneration, end of run conditions for a
reactor, etc.) and in such cases the MOT to be considered for Maximum Design
Temperature (MDT) definition shall be the highest between the one expected during
normal operation (in all the operating modes) and the special operations, unless this
would lead to a too high MDT selection, in which case an assessment shall be done to
check the frequency and excursions above design conditions admitted by the applicable
design code. For process upsets the corresponding MOT should always be considered on
a case by case basis to establish if it should be taken as the maximum operating
temperature to be used as a base for MDT definition and associated to which pressure.
Short terms excursions due to steam-out, flushing or similar controlled operations shall
be specified separately along with the maximum coincident pressures as alternate
design conditions (see below).
7.2.2 Maximum Design Temperature
As a general rule the Maximum Design Temperature shall be specified as the MOT
increased by a sufficient margin to cope with transients, unknowns and uncertainties.

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The MDT shall be specified at least as the highest of the following:
 Maximum Operating Temperature (MOT) + 30°C.
 Maximum Ambient Temperature.
 Saturation temperature @ design pressure (for boiling water service)
 Sun Bare Metal Temperature for above ground piping / equipment exposed
to solar radiation.
Maximum Ambient Temperature and Sun Bare Metal Temperature for a project are
usually contained in the Basis of Design document or in a more specific Environmental
Conditions document. For preliminary studies and in absence of project data, reference
can be made to similar projects or to other reliable sources of data. The most severe
assumption for Sun Bare Metal Temperature being the 'black bulb' temperature with
values as high as 80-85 °C in tropical countries, 90 °C in Sahara Algerian desert, etc.
For equipment subject to steam-out see above 7.1.2.1.
The exceptional temperature generated by external fire will not be considered to specify
the design temperature selection. The rationale being that after a fire the equipment will
be specifically verified or replaced.
7.2.3 Minimum Operating Temperature (mOT)
Minimum Operating Temperature (mOT) is the minimum temperature reached on the

different envisaged operating conditions, including plant operation at unstable
conditions such as start-up/shutdown and process upsets.
Emergency or sudden depressuring of systems is generally treated as a special design

consideration and will require further study on heat transfer between the metal walls
and the process fluid.
7.2.4 Minimum Design Metal Temperature
The Minimum Design Metal Temperature (MDMT) is the minimum temperature which
serves as a base for specifying the low temperature design characteristics to which
equipment and piping may be safely subjected at its design pressure with respect to
brittle fracture. This design parameter is known as Lower Design Temperature as well.
The Minimum Design Metal Temperature shall encompass the minimum operating
temperature.
MDMT is the lowest of the different envisaged operating conditions that equipment or
piping may reach and it shall be specified as the lowest of the following conditions:
 Minimum Operating Temperature (mOT) – 5°C.
 Minimum dry bulb ambient temperature.
 Minimum metal temperature for process reasons (usually as a result of auto-

refrigeration during depressurization).

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Minimum dry bulb ambient temperature is usually selected between the absolute
minimum temperature and the average temperature of the four (or five) coldest days in
the location where facilities are being installed. In general the absolute minimum
ambient temperature should be conservatively considered for MDMT specification as
minimum ambient temperature.
In general, as a conservative approach, the MDMT shall be coupled with the Design
Pressure, unless this approach will lead to too stringent requirements: if MDMT is
selected on the basis of equipment/piping depressurization or due to minimum ambient
temperature, the MDMT should be coupled with corresponding envisaged pressure as
alternate design conditions; a series of couples Temperature/Pressure or a chart can be
also used.
In case MDMT is due to depressurization, the entire system subject to depressurization

shall have the same MDMT resulting from calculations, including the piping system and
relevant Shut Down Valves (SDV’s) used to isolate the system under depressurization
and up to Blow Down Valve(s) (BDV’s) through which the depressurization is initiated.
If the hazard analysis determines that the possibility of gas blow-by may occur from one
system to an adjacent system, auto-refrigeration effects shall also be taken into account
for both the HP and LP systems to check for the minimum temperature reached during
this upset condition which could impact on MDMT and thus on material selection.
Details of depressurization philosophy can be consulted in the Company Specification:

Emergency Shutdown Philosophy Preparation, Ref.[11].
To address the possibility of low metal temperatures at start up (i.e. during equipment
pressurization phase), special considerations shall be made to provide facilities to warm
up the system and/or warm up pressuring fluids to temperatures above the minimum
permissible start temperature for depressurizing.
Different MDMTs for parts of the same equipment may be selected if justified (e.g. by
significant savings) but shall always get Company’s approval.
7.2.5 Specific equipment requirements
7.2.5.1 Heat Exchangers
The Maximum Design Temperatures of an air cooler, shell & tube or plate & frame
exchanger shall be set according to section 7.2.2., where MOT is the maximum inlet
temperature. The Maximum Design Temperatures of systems downstream of an air
cooler, shell & tube or plate & frame exchangers should be set at the greater of:
 The maximum inlet temperature to the exchanger (i.e. loss of cooling or

exchanger bypass) without any further margin.
 The maximum outlet temperature + 30°C.
For air coolers, credit may be taken for residual cooling due to natural convection
(usually set equal to at least 20% of the normal operating cooling duty) for the
calculation of maximum design temperature of the system downstream of the cooler in
case of loss of cooling (instead of setting MDT equal to the maximum inlet
temperature). In case the air flow is shut off by louvers or if the air cooler is provided
with an operating by-pass, the design temperature of downstream system should be
assessed case by case.

Rev 03 – July 2015
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In general, said DT should be taken down to the inlet of next vessel/equipment, the
rationale being that the upset should not last enough for the vessel to be heated.
7.2.5.2 Piping
The Design Temperature for Piping shall be consistent with the connecting equipment.
Excursions above design conditions may be admitted subject to the conditions set forth
in the applicable design code (which is ASME B31.3 for process plant piping, see
Ref.[15]).
With reference to Production Manifolds (piping system downstream of wellhead), design

temperature requirement shall be defined in compliance with upstream system design
(wellheads, flowlines, etc.).

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8. LINE SIZING CRITERIA
The criteria described in this chapter shall be used to size process and utilities piping
inside a processing facility plant. They are not to be applied to long transport systems
(flowlines/pipelines, sealines, etc.). The designer shall be careful that these criteria are
not necessarily appropriate for some critical services and long headers and therefore the
overall system pressure balance shall be verified. This chapter reports the minimum
requirements for piping sizing of the following services:
 Gas Lines (Vapour, Steam).
 Liquid Lines.
 Mixed Phase Lines.
 Flare, Blow down Lines.
The sizing criteria shall be based on high limits for the following main parameters:
 Pressure drop, bar/100m.
 Velocity, m/s.
 ρv2, kg/m/s2 (Pa).
 ρv3, kg/s3.
8.1 GENERAL
The following design criteria and design rules shall be taken into account during the
design phase:
 Sizing shall be carried out in accordance with the flowrate reported in the
Heat & Material Balance (design case for the specific line) and the
discontinuous operations (i.e. start-up, shut-down, etc.) when applicable.
 A design margin can be added according to the project decisions and the
degree of uncertainty of the material balance. It is important to avoid
accumulating margins on margins which can lead to undesired flow regimes.
No margin to be taken for discontinuous conditions.
 For detailed design stage, the designer shall make hydraulic calculations
based on inner diameter in accordance with the piping class. In very early
stages of a project (when piping classes are not identified yet) as a
preliminary estimation STD schedules should be used for hydraulic
calculations of 150# or 300# rated lines, while XS schedule should be used
for 600# or above rated lines. Process engineer shall use good engineering
judgment based on anticipated design conditions. The user shall also verify
the overall system pressure balance.

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 Except for tubing, the minimum piping size shall be limited as follows:
- 1” for pipe when located above ground (not on piperack).
- 2” for process/ utilities lines on pipe racks.
- 2” for underground steel pipe.
 The following non-standard line size shall not be used: 1¼”, 2½”, 5”, 7”, 9”.
 Unless specific data on roughness are available, following values should be

used for calculations:
typical roughness
material average (mm)
(mm)
commercial steel, wrought iron 0.0200 - 0.1000 0.060
asphalted cast iron 0.1000 - 1.0000 0.550
cast iron 0.2500 - 1.0000 0.625
galvanized iron 0.0250 - 0.1500 0.088
drawn brass, copper, stainless steel 0.0015 - 0.0100 0.006
Table 8.1. roughness suggested values
8.2 GAS/VAPOUR LINES
Pressure drop for gas lines has to be evaluated considering that gas/vapour are
compressible fluids, so the density is strictly affected by pressure and temperature,
therefore:
 For short lines, it is sufficient to perform the calculations considering the arrival
pressure.
 For long lines, such as headers, a more detailed calculation may be needed on
the basis of the available pressure drop.
For lines where film forming corrosion inhibitor is used, velocity shall be limited to 20
m/s. (to be verified with Vendor if possible).
High limits for sizing parameters for continuous operation are shown in Table 8.2. for
Gas/Vapour Lines whereas for Steam Lines reference shall be made to Table 8.3.
For gas/vapour lines, generally, both pressure drop (overall/specific) and ρv2
(momentum) criteria shall be met. Additionally, as reference figure, a maximum velocity
of 30 m/s is normally considered.
For steam lines, generally, both pressure drop (overall/specific) and velocity criteria
shall be met.

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ρv2 , Pa
DP (barg) / service ∆P, bar/100 m
(Note 1)
0 to 3.5 0.10 6500
3.5 to 20 0.15 6500
20 to 50 8000
50 to 100 10000
Pressure drop shall match the
required process
100 to 140 15000
>140 20000
Compressor Suction Lines
0.20 % Operating Pressure

Reciprocating
(max. 0.03 bar / 100m)
As per above
0.50 % Operating Pressure
Centrifugal
(max. 0.07 bar / 100m)
Columns
Inlet to Overhead
0.10 1500
Condenser
Table 8.2. Vapour Line Sizing Criteria (High Limits)
Note 1: ρv2 is calculated at operating conditions but the selection criteria is based on
the design pressure (e.g. if line operates at 60 barg but the design pressure is above
140 barg, ρv2 limit shall be 20000 Pa).
8.3 STEAM LINES
DP Range, barg ∆P, bar/100 m Velocity, m/s
0 to 3.5 3.3% Operating Pressure -
3.5 to 10 0.35 -
10 to 30 0.7 40
> 30 1.0 30
Table 8.3. Steam Line Sizing Criteria (High Limits)
8.4 LIQUID LINES
Minimum requirements as high limits for sizing parameters are shown in Tables 8.4.
and 8.5. (velocity for seawater):

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∆P, bar/100m Maximum Velocity,

SERVICE
Normal Maximum m/s
(Note 2) (Note 2)
Pump Suction (Note 3)
▪ Liquid @ bubble point or with dissolved gas
( ≤ 4") 0.05 0.08 1.0
(4 to 8") 0.07 0.1 1.5
( ≥8") 0.07 0.11 1.8
▪Subcooled Liquid (<8") 0.25 0.35 2.0
▪Subcooled Liquid (≥8") 0.25 0.35 3.0
Pump Discharge
▪Lines < 8" 0.7 4.0
▪Lines ≥ 8" 0.7 5.0
Liquid Transfer Lines
▪ Liquid @ bubble point or with dissolved gas − 0.15 2.0
▪ Subcooled Liquid − 0.3 3.0
or as required
by system
balance
Liquid from Total Overhead Column
Condenser 0.1 − 1.0 to 2.0
0.035 (Note 1) −
Liquid to Reboiler (Natural Convection)
Gravity Flow 0.03 0.05 0.6
Drains
▪ Sanitary Drains − − 0.8/3 (Min/Max)
▪ Open Drain (Oil Contaminated Water) − − 0.8/3 (Min/Max)
▪ Open Drain (Oil Free Water) − − 0.8/3 (Min/Max)
Cooling Water Lines
▪ Headers 0.15 0.20 3.0
▪ Unit lines 0.30 0.35 3.0
As required by Refer to
Seawater Lines
System Balance Table 8.5.
As required by
Steam Condensate Return Lines (Note 4) 1.0
System Balance
Table 8.4. Liquid Line Sizing Criteria
Note 1: to calculate the feed line ∆P of a Natural Convection Reboiler, the overall circuit
∆P must be considered (i.e. Thermosyphon effect).
Note 2: during engineering calculation, reference shall be made to normal value.

Should the resulting value be borderline, reference to the maximum value shall be made
according to good engineering judgement.
Note 3: when isometrics are not available, pump suction line sizing shall be determined
according to the criteria reported in Table 8.4. but a preliminary NPSH calculation shall
be also performed assuming a minimum equivalent length equal to 60 meters.
Maximum Velocity indicated to be halved for reciprocating pumps suction.

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Note 4: Sizing of steam condensate lines can be a very complex undertaking. When
condensate lines are too large, then purchase, installation and operation costs increase
substantially. Undersized lines can create too much back pressure, lowering heat
transfer and terminal equipment efficiency or causing the trap to malfunction.
Undersized lines also increase the chance of water hammer. For steam condensate line
sizing it's recommended to refer to specialist methods also available as open source in
internet.
MATERIAL Pipe Bore, mm Velocity, m/s (max)
10 0.7
Cast Iron 50 2.9
≥100 5.0
10 0.7
70/30 Copper/Nickel/Iron 50 2.3
≥100 4.0
10 0.7
90/10 Copper/Nickel/Iron 50 2.2
≥100 3.3
10 0.7
Steel, galvanized steel, aluminium
50 2.0
brass
≥100 3.0
<200 3.0
GRP
≥200 6.0
Table 8.5. Maximum Seawater Velocities in Pipes
In addition to the above, the user shall take into account the following rules:
 Lines upstream a pressure let-down valve shall be sized to prevent vapour

flash ahead the control valve.
 Where the presence of suspended or other solids might occur, the flow
velocity should not be less than 1 m/s to minimize deposition; erosional
velocity shall be assessed as well. See section 8.5.
 For gravity flow, gas or vapour entrained in liquid flowing by gravity from a
vessel can decrease the capacity of the outlet pipe. This can be avoided by
designing the line “Self Venting” where any entrained vapour will be vented
back into the vessel and will not be carried through with the liquid. Sizing
base is Froude Number lower than 0.3. Froude number is calculated with the
following equation:

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.
where:
v = fluid velocity, m/s
l   g
gu = g , m/s2
l
ρl = liquid density, kg/m3
ρg = gas density, kg/m3
g = 9.81 m/s2
D = Hydraulic depth (cross sectional area of flow)
When:
Fr = 1, critical flow,
Fr > 1, supercritical flow (fast rapid flow),
Fr < 1, subcritical flow (slow / tranquil flow)
 Drainage headers (open and closed) shall not be less than 3”. The minimum
gradient for horizontal piping shall be in compliance with the following Table
8.6.:
Service Diameter Slope
2” ≤ D < 6” 1.25%
Onshore 6” ≤ D < 20” 0.4%
20” ≤ D 0.2%
Offshore Platforms 1%
FPSO 1% (note 1)
Table 8.6. Drain Slope Criteria Lower Limits
Note (1): Reported figure represent the actual (net) lower limit. Attention shall be paid
to ship trim (pitch and roll). Typical trim is about 1/100.
 For reciprocating pump suction lines, acceleration head shall be considered.

Due to pulsation and acceleration effects, lower flowing velocities are allowed
(compared to centrifugal pumps). The acceleration head effect is
proportional to pipe length, velocity, pump speed and a factor depending on
the number of plungers in the pump (the acceleration effect decreases as the
number of plungers increases). Installation of pulsation dampers on both the
suction and the discharge lines is to be considered and can potentially
eliminate suction acceleration head losses.

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8.5 MIXED PHASE LINES
The following minimum requirements shall be applied for calculation of mixed phase
lines:
A. Erosional velocity (Ve) method: Actual velocity shall be equal to 0.7 * Ve as

maximum. In case of an existing line verification or revamping of facilities, a
value of 1.0 * Ve can be accepted. Less conservative approach may also be
agreed if adequate line integrity monitoring is in place and relevant operating
procedures are implemented. To calculate the erosional velocity and to determine
the pipe size to avoid erosion, reference will be made to Table 8.7.
B. Verify that the pressure drop matches the required process condition.
C. Same criteria as gas/vapour lines (ρv2) by using the fluid apparent density (ρm)
calculated as expressed below.
D. Check the flow pattern in order to avoid slug flow type. Annular flow is preferred.
To this scope, if possible, velocity should be higher than 3 m/s. In case slug flow
cannot be avoided, a note shall be included on the relevant P&ID in order to
highlight that the line shall be properly supported.
Erosional Velocity is used when no specific information as to the erosive/corrosive

properties of the fluid is available; it is based on a simplified model which does not take
into account sand production and other factors (e.g. CO2, H2S and chloride levels).
Erosional velocity shall be calculated as follows:
where:
Ve = fluid erosional velocity, m/s.
C = empirical constant, kg1/2 m-1/2 s-1 (= 1.22 * C lb1/2 ft-1/2 s-1,

i.e. C=100 in imperial units => C=122 in metric)
ρm = gas/liquid mixture density at flowing pressure and temperature, kg/m3.
Gas/liquid mixture (apparent) density should be calculated as follows:

W
m 
Wl Wv

 l v
where:
W= Wl + Wv = Total Flow Rate, kg/h

Wl= Liquid Flow Rate, kg/h
Wv= Gas/Vapour Flow Rate, kg/h
ρl= liquid density, kg/m3
ρv= gas/vapour density, kg/m3

Rev 03 – July 2015
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Mixed fluid velocity inside the line has to be lower than “Erosional Velocity”. Erosional
velocity is conservatively calculated using the following values for constant C:
Service (Note 1) C, [kg1/2m-1/2s-1]
Carbon steel lines without solids but with corrosive

122
contaminants in continuous service
Carbon steel lines without solids but with corrosive

150
contaminants in intermittent service
Carbon steel lines without solids and/or corrosive

200
contaminants (or inhibited fluid) in continuous service
Duplex and stainless steel lines in continuous service 250
Duplex and stainless steel lines in intermittent service 450
Table 8.7. “C” Constant for Erosional Velocity determination
Note 1: For CS lines in presence of solids or other erosive material, fluid velocities
should be significantly reduced (say halved unless additional work is carried out to
provide better estimation).
When solids and/or corrosive contaminants are present or when C values higher than
122 for continuous service are used, periodic surveys to assess pipe wall thickness
should be considered.
As reference, the apparent fluid velocity (V) should be limited to less than 0.7 Ve:
V≤ 0.7 Ve
For further details on erosional velocity limitations refers also to recommendations of

API RP 14E, Ref.[22].
8.6 FLARE & BLOWDOWN LINES
Lines shall be calculated according to API STD 520, Ref.[12] and API STD 521,
Ref.[13]. In the following paragraph several recommendations are reported to assist
Process Engineer in preliminary evaluation of Flare and Blowdown lines sizing. For any
other sizing issues not reported in the present standard or in case of any conflicting
requirements between this standard and API STD 520/521, the API is the governing
document.
8.6.1 PSV Inlet Lines
The following design rules shall be applied for PSV inlet lines:
A) For PSV inlet line pressure loss calculation, the ∆P criterion of 3% of the set

Rev 03 – July 2015
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pressure (gauge) shall be applied calculated at rated flow (i.e. based on the
installed PSV area). When isometrics are not available yet an equivalent
length of 60 meters for onshore and 90 meters for offshore should be
assumed. When isometric drawings are made available, the detailed
calculation based on real length and fittings shall be performed to confirm
preliminary design.
B) When isometrics are not available to perform the inlet line calculation, the
following additional criteria should be followed:
line ρv2 , Pa
≤ 25,000
≤ 2”
≤ 30,000
> 2” when relieving P is ≤ 60 barg
≤ 45,000
> 2” when relieving P is > 60 barg
Table 8.8. Safety Valves Inlet Line
8.6.2 BDV Inlet Lines
Table 8.8 shall be applied also for BDV inlet lines.
8.6.3 PSV Outlet Lines
The following design rules shall be applied for PSV outlet lines (tail pipes):
A) The discharge piping system shall be designed so that the total back
pressure prevailing at PSV outlet does not reduce the capacity of the
relieving device. Limits are given as per API 520, Part 1, Ref.[12]. However
for preliminary calculation total backpressure (sum of maximum
superimposed and built-up backpressure) should be limited as reported in
the following:
 Conventional Valves: back-pressure at relief valve outlet < 10% of the set
pressure (gauge).
 Balanced-type Valves: back-pressure at relief valve outlet < 30% of the

set pressure (gauge).
 Pilot Operated Valves: back-pressure at relief valve outlet < 30% of the
set pressure (gauge), but possible extension to 50% provided that an
appropriate back pressure correction is considered in the calculation.
B) Mach number (Ma) shall be limited to 0.7 calculated at rated capacity i.e.
based on installed PSV area (applicable for conventional and balanced
bellows type). Mach number limitation criterion should generally be checked
at minimum superimposed backpressure (which is generally the governing
case).
C) Outlet line shall slope towards the blowdown header without any low point
(minimum slope 1:500)
D) Connections to headers/sub-headers shall be top-entry and connected

preferably at 45° towards flow direction
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When isometrics are not available an equivalent length of 50 m (min) and Ma 0.6 - 0.7
should be used for estimating tail pipe size. When isometrics are made available, a
detailed calculation shall be done including real length and fittings to confirm that above
criteria are met.
8.6.4 BDV Outlet Lines
The following design rules shall be applied for BDV outlet lines (downstream of the
restriction orifice):
A) The discharge piping system shall be designed so that the built-up back
pressure caused by depressurization does not reduce the capacity of the
relieving device (i.e. the restriction orifice design backpressure shall not be
exceeded).
B) Mach number shall be limited to 0.7 at required peak flow at the minimum
superimposed backpressure of the flare system into which depressurized
fluid is discharged.
Points 'C' and 'D' as per 8.6.3. (PSV Outlet)
8.6.5 Flare Headers and Sub-Headers
To perform the Flare Headers and Sub-Headers design, the following rules shall be
applied:
A) The discharge piping system shall be designed so that the built-up back
pressure does not reduce the capacity of the relieving devices. Since this
calculation implies that different scenarios have to be taken into account, the
use of specific software is recommended. The software typically used are
hereunder listed:
 Flarenet (Aspentech).
 Unisim Flare (Honeywell).
 Visual Flow (Invensys).
For Contractors, the applicable version shall be specified and agreed with the Company.
B) Mach number shall be limited to 0.5 for any cumulative or single case
scenarios considering the required capacity.
For very rough estimation of main flare headers, following guidelines can be used:
 1.5x max gas flow for combined blowdown
 1.5x inlet flow for blocked outlet on inlet separator
 1x gas throughput if HIPPS installed and sequential blowdown
Flare stack shall be sized in order to limit Mach number to 0.7. For sonic flares, tip
diameter may allow for Mach 1.0.

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8.7 VIBRATIONS AND NOISE LIMITS CRITERIA SUMMARY
When sized a line, a final check on vibration and noise parameter is advised, considering
limit figures reported in Table 8.9. In case these limits are exceeded there are still
practical corrective means like special supports, sound barriers, etc.
Both vibration and noise criteria are evaluated in terms of fluid density and velocity.
The term ρv2, equal to twice the kinetic energy per unit volume, is used to define
acceptable levels of vibration.
Noise limits for design are expressed in terms of ρv3
ρ is density in kg/m3 and v is velocity in m/s.
These criteria apply in addition to the others described. The following flow types apply:
Type 1
- gravity flow of liquids, or liquids at their bubble point
- vapour recovery
Type 2
- Pump suction lines
Type 3
- Offsite pump discharge lines
- Exchanger, column, drum inlet
- Offsite transfer line
Type 4
- Pump discharge in unit
- Transfer line in unit or line in intermittent use
flow type 1 2 3 4
ρv2 660 3000 6000 15000
ρv3 100000 100000 100000 200000
Table 8.9. Vibrations and noise limits
Use ρv3 100,000 also for gas/vapour lines for vacuum and MOP< 10 barg and 200,000
for gas/vapour lines MOP >= 10 barg.
8.8 NOZZLE SIZING CRITERIA SUMMARY
The sizing of the nozzles shall be based on the maximum flow rates, i.e. the maximum
flowrate expected during the asset life as per H&MB/simulations, increased by the
relevant overdesign factor defined for the selected Unit (if applicable).
8.8.1 Feed inlet nozzles (Mixed Phase)
For a preliminary calculation, the following momentum criterion shall be satisfied:

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EQUIPMENT FEED INLET NOZZLES
ρmv2 ,(Note 1)
Inlet Device
Maximum
Separator / Column with no Inlet Device ≤ 1400 Pa
Separator / Column with Half-Open Pipe ≤ 2100

Separator / Column with specially designed
≤ 8000
inlet device (like Schoepentoeter, etc.)
Shell & Tube Exchanger - Tube Side ≤ 5950
≤ 2200 (non corrosive, non

Shell & Tube Exchanger - Shell Side and all abrasive, single phase fluids)
other Heat Exchangers types (Note 2) ≤ 750 (corrosive, abrasive, multi
phase)
Table 8.10. Equipment Inlet Nozzle Criteria
Note 1: ρm is the apparent density of the mixture in the inlet pipe calculated as
reported in section 8.6.
Note 2: During detail engineering it could be necessary to decrease the shell side inlet
nozzle size in order to optimize the mechanical design of the heat exchanger. In that
case, if the maximum value of ρmv2 exceeds values shown in the Table 8.10.,
impingement plates on shell side inlet nozzles shall be foreseen to protect the bundle
against impingement by the incoming fluid. Anyhow, the inlet nozzle area should not
produce a value of ρmv2 greater than 5950 Pa.
8.8.2 Gas outlet nozzles
The diameter of the gas outlet nozzle should normally be taken equal to that of the
outlet pipe, but the following criteria shall be satisfied:
ρgv2  3750; ρg = density of the gas at outlet conditions.
In any case pressure drop at outlet nozzle can significantly increase by a reduction in
nozzle size (in particular for vacuum applications where pressure profile might be very
tight) so in order to meet pressure drop requirements the aforementioned value of 3750
Pa may end up to be reduced to match with system hydraulics.
8.8.3 Liquid outlet nozzles
The diameter of the liquid outlet nozzle shall be chosen following Table 8.4. (e.g.
velocity 1 m/s for connection to a pump in case of liquid at bubble point and checking
also for ∆P to avoid problems with cavitation).
The liquid outlet nozzle shall be provided with vortex breaker at least in the following
cases:
 if outlet line is connected to a pump suction

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 if outlet line is connected to a thermosyphon or kettle inlet

 if outlet line is connected to a letdown valve or other control device (e.g.
calibrated orifices, magnetic/ultrasound flow meters, etc.)
A maximum velocity of 2.5 m/s is required to ensure a vortex breaker is working.
8.8.4 Flare KOD nozzles
For flare knock-out drums considering the non-continuous flow, less stringent criteria
than the above may be used such as:
Feed nozzle
 No inlet device (Not Recommended): the ρmv2 limit can be relaxed from
1400 to (say) 2000 Pa.
 Half-open pipe: the ρmv2 limit can be relaxed from 2100 to (say) 5000 Pa.
Gas outlet Nozzle
The ρgv2 limit can be relaxed from 3750 to 10000 Pa.
8.8.5 Vessels / Columns connections
Manholes and Handholes
Refer also to Ref.[25]:
 Manways minimum size will be as follows:
- 24’’ for tank and vessel/column diameters larger than 1000 mm
- 20’’ for vessel/column diameters equal or lower than 1000 mm
 For diameters up to 900 mm, a flanged head may be specified if required for
the installation/maintenance of the internals. If removable head is not
necessary i.e. there are no removable internals, two inspection openings
(handholes) 8’’ size minimum shall be provided.
 For horizontal vessels, if possible, at least one manhole/handhole should be

located at the opposite side of the utility connection.
 For vessels with length/height less than 6 m a single manhole shall be

provided (better two to allow creating a natural air circulation during
personnel entry for maintenance). For other vessels (length/height ≥ 6 m),
at least two manholes shall be provided. If the vessel is equipped with
internals (i.e. baffles, packing, etc.), one manhole shall be provided on each
compartment. Typically for columns manways are located: * above top tray,
* below bottom tray, * at inlet distributors, * every maximum 20 trays, * in
between each packing bed.

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Vents and Drains
Vessels must have at least one piped vent and one to atmosphere.
Vessels must have at least one drain for each compartment separated by
weir (e.g. oil and water sections). Drains are connected to both open drain
and closed drain by means of isolation valves.
Drains minimum diameter 2'' for vessels less than 15m3 volume
3'' for 15m3 to 75 m3
4'' for more than 75 m3.
8.9 PIPING EQUIVALENT LENGTH
In addition to the piping linear length for distributed pressure drop calculation, the
concentrated pressure drop of fittings, elbows, tees, valves and other accessories shall
be considered when detailed information are available (Main items typical equivalent
lengths are listed in Table 8.11.).
Fitting Le/D ratio
Gate Valve 15
Globe Valve 400
Angle Valve 150
Check Valve 135
Butterfly Valve 40
Tee Branch 60
Tee Straight 20
90° Elbow 30
90° Elbow Long Radius 20
45° Elbow 16
Table 8.11. Main Equivalent Lengths
However, when isometric drawings are not available yet, hydraulic calculations shall be
done based on factors.
The total piping equivalent length can be estimated by multiplying the pipe length
determined from the facility plot plan by the following factors reported in Table 8.12.
Pipe Size Intra Unit Line Pipe Rack Line
≤ 3” 2.0 1.5
4” – 6” 2.5 1.5
≥ 8” 3.5 2.0
Table 8.12. Multiplying Factors for Equivalent Length

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9. OVERDESIGN CRITERIA
The following table summarizes the typical over-design factors to be included in the
design capacity for equipment.
Overdesign factors shall be applied to figures taken and/or derived from Heat and
Material Balances (sizing value, unless otherwise indicated) to get design value. When
several cases are calculated (e.g. summer / winter; max gas / max oil; etc.) the sizing
case among all can be selected for each piece of equipment.
It is important to avoid adding margins on margins. For this reason each margin taken
should be indicated in the data sheets and agreement sought with other specialists e.g.
machinery.
Equipment Over-Design Notes
Lines, Control valves 0% See Chapter 8
Separators 10% on each phase flowrate

on compressor sizing
Compressor K.O. Drums 15% flowrate (with NO
margins)
Columns 10% on flowrates
Filters 10% on flowrate

15% on surface area
Shell & tube, Plate&Frame and hairpin
or
heat exchangers (general service) (1)
10% on duty/flowrate
Shell & tube and hairpin heat 15% on surface area
exchangers (reboilers and or
condensers) (1) 15% on duty/flowrate
15% on surface area
Air-coolers (general service) (1) or
15% on surface area
Air-coolers (condensers) (1) or
Furnaces 10% on duty & flowrate
Compressors and expanders 10% on flowrate

on duty (based on
Compressor process coolers 10% compressor sizing flowrate
with NO margin)
Fans 10% on flowrate
Pumps (general service) (2) 10% on flowrate
Pumps (reflux, BFW) (2) 20% on flowrate
Gas / Steam Turbines (3) 10% on power output
Table 9.1. Over design factors

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Notes:
1. Alternate overdesign factors shall be applied separately and the greater

surface shall be considered for exchanger design.
2. For pumps, the indicated overdesign is applicable only in case of continuous

service. For intermittent service no overdesign factor shall be applied.
3. In general overdesign for turbines is not by process
10. SPARING PHILOSOPHY
Project sparing philosophy shall be defined on the basis of the main project critical
elements (plant capacity, location, risks, etc.), in order to ensure required plant
availability. As part of the Reliability Centered Maintenance approach (RCM) which shall
be developed for each production asset, a RAM analysis (Reliability, Availability,
Maintainability) is recommended to be carried out in order to properly set sparing
requirements. Ref.[9], [10].
When train’s installation is foreseen, the number of trains shall be defined considering
the aspects such as: production profile, the possibility of phasing the installation, the
availability and the size of the equipment and the absorbed power, under the RCM
model.
A detailed RAM analysis will finally confirm that the sparing philosophy adopted during
the process design stage is suitable to meet the required performance.
The following rules are to be considered as reference while defining the general sparing
philosophy for the main process and utility equipment. Consider that in particular for
process compressors and expanders many configurations are often possible involving
splitting, sparing and overdesign.
Spare items/equipment to be located in warehouse are not included in the general rules
reported here below and are dealt in a case by case basis.
In the following list “n” represents the number of operating items. The general rule is
n+1 i.e. one installed spare, and can be assumed for the items non included in the list.
 Vessels: no spare.
 Columns: no spare.
 Heat exchangers: spare heat exchangers are not necessary with the
exception of some applications (e.g. frequent maintenance on critical items
required due to fouling or corrosion, typically crude oil/stabilized oil
exchanger in oil trains or oil cooler in case de-waxing is foreseen).
Tube bundle sparing is an alternative or the sparing of the electrical element
in the case of electrical heaters.
The heat exchanger splitting shall be recommended when the fluid
composition and profile could be affected by important changes during
project cycle and/or during asset life.

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 Fired Furnaces: no spare except in case of frequent maintenance expected

and unless RAM analysis dictates otherwise.
 Pumps: n+1 (*).
 Centrifugal Compressors: n+1 unless RAM analysis authorizes n.
 Volumetric Compressors and blowers: n+1
 Fans for air coolers: the performance of the bundle shall be at least 60%
with one fan off.
 Filters: n+1. No sparing is accepted in case the filter can be put off-line and
bypassed for the time necessary for any maintenance operation (i.e.
replacement of the filtering elements), without any appreciable loss of
availability of plant operation.
 PSV: n+1. Exceptions: a) when the protected equipment is 100% spared or

a spare train/line is present; b) if the protected equipment is operated
occasionally, (e.g. pig traps and test separators, etc., which can be isolated,
depressurized and drained without production loss); c) Thermal Relief Valves
are not generally spared (i.e, pipework thermal relief) unless maintenance or
operation activities can stop the production or lead to unsafe conditions.
 Expander: no spare. The expander shall be always installed in conjunction

with a Joule-Thomson valve designed for the same capacity.
(*) For closed drain/open drain drum pumps the spare can either be installed or located
in warehouse. For optimization purposes common spares (located in warehouse) may be
considered.
Specific assumptions about utilities (power supply, instrument air, steam supply etc.)
have to be done concerning the possible impact over the system availability to
determine the number of spare items. Typical sparing is:
 100% on Instrument Air compressors

 100% on Instrument Air Dryers
 No spare on PSA, membranes (nitrogen generation)
 Water treatments: same sparing as process for the single piece of equipment
 n+1 on power generation sets with n>=2 (i.e. excluding the solution 1+1,
Ref.[24])
 n+1 for steam boilers (one in cold stand-by if the temporary loss of steam is
acceptable while the stand-by is brought on line)
 No spare for flares, vents, incinerators

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11. EQUIPMENT DESIGN CRITERIA
11.1 VESSELS AND SEPARATORS
11.1.1 Type of vessels and configuration
There are many categories and types of separators (e.g. liquid or gas accumulators,
gas/liquid separators, liquid/liquid separators, three phase separators, etc.) depending
on the service.
Horizontal or vertical type selection depends on which is the best configuration for the
required service. As a general rule horizontal vessels should be preferred for services
with high liquid volumetric flowrate while vertical vessels should be preferred when
vapour phase prevails.
To define the best configuration and the kind of internals to be used, the following
aspects and factors should be considered:
 Required efficiency of separation and relevant required residence time.
 Characteristics of the fluids to be separated (and especially density and

viscosity).
 Flowrate and volumetric ratio of the phases to be separated.
 Fouling tendency of the handled fluids (scaling compounds or solid content).
Vertical separators are typically used if at least one of the following conditions is valid:
 when gas to liquid ratio of volumetric flowrates is high (low liquid flowrate)
 when an accurate control of the liquid level is required.
In any case vertical separators should not be used in the following case:
 when relatively high residence time for the liquid phase is required (e.g.
when high efficiency liquid-liquid separation is required).
 when the volumetric gas/liquid flowrate ratio is lower than about 50%.
Horizontal separators should be used in all cases when a vertical separator is not
convenient according to the above criteria for vertical separators. Typically three phase
separators are almost always horizontal ones.
Normally horizontal separation, from settling point of view, is more efficient that vertical
one.
11.1.2 Gas/Liquid Separation criteria:
The basis for sizing these vessels is to keep vapour velocity sufficiently low to allow
gas/liquid separation.

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In order to calculate the required vapour area suitable for gas/liquid separation, the
Critical Velocity shall be preliminary calculated as follows:
l   g
Vc  0.0478 *
g
where:
ρl= liquid density, kg/m3

ρg= gas/vapour density, kg/m3
Vc = critical velocity, m/s
The maximum gas velocity shall be determined on the basis of the critical velocity as
follows:
V max  K * Vc
where “K” is a coefficient depending on the service and/or the presence of internal
device on gas outlet (i.e. wire mesh or demister or vane pack).
Selection of “K” values shall be carefully carried out by designer, however preliminary
figures given in the table hereafter may be used:
Without Wire
Type of Vessel/Separator With Wire Mesh
Mesh
Horizontal 1 2
Vertical 1 2
Table 11.1. Preliminary K values for maximum allowable gas velocity
In addition to the above, the following gas-liquid separation performance (see Table
11.2. here below) should be guaranteed (as a minimum) for gas-liquid separation
design, unless otherwise specified.
Therefore, since the calculation method based on the critical velocity is not rigorous
because it doesn’t take into account directly the liquid droplet size, an alternative
method may be required to ensure the following performances:
Max. Droplet diameter of

Service
entrained liquid particles
General Gas-Liquid Separator (*) 300 µm
Compressor Suction K.O. Drum 150 µm
Fuel Gas K.O. Drum 200 µm
Flare K.O. Drum As per API STD 521, Ref.[12]
Table 11.2. Liquid particle diameters for gas-liquid separation calculations

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(*) Oil separators (any stage) belong to this category. For slug catcher, dedicated
design criteria shall be used, Ref.[7].
In order to guarantee an adequate gas/liquid separation (i.e. liquid droplet settling from
the vapour phase), the vapour phase resident time shall be higher than the liquid
droplet settling time in the vessel.
The area used to calculate the terminal settling velocity in a horizontal vessel is the area
of the vessel’s vertical section above the high liquid level, and in a vertical vessel, the
area of the vessel’s horizontal section.
In horizontal liquid-vapour separators, the vapour space (i.e. space above the maximum
liquid level), shall not be less than 20% of diameter.
Compressor K.O. drums and vessels with no liquid phase shall be designed as for
vapour/liquid separators, assuming that the characteristics of liquid are those of the
liquid in equilibrium with the vapour. When no liquid is found in heat & material
balances or no other data are available, a liquid mass flowrate of 1% wt of inlet vapour
mass flow rate or the minimum liquid volume for level control (whichever is larger)
should be assumed at least. Data for entrainment from upstream vessel can also be
used if available or predicted.
11.1.3 Liquid-Liquid Separation criteria:
These vessels shall be sized in such a way that the settling time for each liquid phase
from the other is less than its residence time in the vessel itself to allow bulk
separation. Where not otherwise specified, the following liquid-liquid separation
performance (i.e. liquid hydrocarbons - aqueous phase) shall be guaranteed (as a
minimum) for liquid-liquid separation design:
Light Phase Droplet Diameter
Density < 850 kg/m3 90 µm
Density ≥ 850 kg/m3 150 µm
Table 11.3. Liquid particle diameters for sizing liquid – liquid separators
A maximum settling value of 250 mm/minute shall be assumed for light hydrocarbons.

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11.1.4 Minimum Liquid Hold-up and Residence Time
Typical minimum liquid hold-up times are shown in Table 11.4.:
Min. liquid hold-up time (LLL-HLL),

Service
minutes
Reflux Drum 5
Product to Storage 2
Oil/Gas Separator or others Drums 5
Feed to Tower or to Process Unit 10
Feed to Furnace 15
Compressor K.O Drum / interstage
5
separator
Flare KOD As per API STD 520/521 (Ref.[11],[12])
Table 11.4. Typical liquid hold-up times between LLL and HLL.
In addition a typical hold-up time of 1 to 2 minutes shall be considered between

HLL/HHLL and LLL/LLLL, or 300 mm whichever is greater.
LLLL shall be at minimum 300 mm above bottom tangent line for vertical vessels and
150 mm minimum from the bottom line for horizontal vessels.
Alternate arrangements may be acceptable (e.g. clean services) where the lower
instrument nozzle may be located on the vessel bottom.
11.2 SLUG CATCHERS
Slug catchers work on the same separation principles of the other separators with the
main difference that they are specifically designed to deal with rapidly changing
flowrates of gas and liquid, with possible unstable regime of flow of the inlet stream
(e.g. streams of gas with sudden peaks of liquid, “slugs”, or periodical portion of gas
followed by pistons of liquid, “plug flow”).
The volume to be allocated shall be defined by a flow assurance study. The Company
Design criteria for slug catcher sizing is Ref.[7]).
11.3 COLUMNS AND TRAYS
Flexibility
 Required tray flexibility shall be between minimum project turndown and

110% of the nominal capacity unless otherwise specified.
 Required packed column flexibility shall be at least 50-110% of the nominal

capacity unless otherwise specified.

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Flooding Factors
 Tray/packing columns shall be specified considering flooding factors at max.

specified load unless otherwise specified.
 Tray/packing hydraulic calculations and hence column diameter confirmation

shall be performed by the vendor of column internals.
In preliminary project stages, tray columns may be specified with the following max.
flooding factors at max. specified load:
- 77% for vacuum distillation columns
- 82% for other services (general service)
- 70% for column diameter lower than 900 mm
Less stringent flooding factors may be adopted for packed columns to be evaluated on a
case by case basis (possibly with supplier of column internals feedback).
Foaming Factors
 Foaming factor to be used shall be defined case by case possibly with the
supplier of column internals.
The following foaming factors may be used as preliminary values:
Foaming Tendency Foaming Factor

Non-foaming (e.g. deC3, deC4, stabilizer
1.0
if water is absent)
Low (e.g. CO2 regeneration, deC1,
0.9
deC2)
Moderate (e.g. CO2 absorber, sour water
0.75
stripping, glycol regenerator)
High (e.g. Glycol absorber, caustic
0.6
regenerator)
Table 11.5. Recommended foaming factors
11.4 HEAT EXCHANGERS AND AIR COOLERS
11.4.1 Heat Exchangers Type and Arrangement
Special Recommendations
 U tube exchangers shall be used when tube side fouling factor is equal or
lower than 0.00035°C m²/W and/or when tube side mechanical cleaning is
not required.
 Floating head type exchangers will be specified for fouling services on both
sides.

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 Fixed tube sheet exchanger will be used for service when shell side fluid is
not fouling or when fouling can be removed by chemical cleaning.
For more indications on heat exchangers thermal design Ref.[23], 'Shell and Tube Heat
Exchangers' may be consulted.
Fouling Factors
The following table gives some fouling factors for process and utility fluids to be used for
Shell and Tube and hairpin heat exchangers design unless otherwise indicated.
Process °C m²/W
Acid gas 0.00020
Sweet gas 0.00017
Liquid LPG 0.00020
Raw feed condensate from slug catcher 0.00052
Raw feed condensate 0.00035
Stabilised condensate 0.00020
Process water 0.00035
Stripped water 0.00030
Glycol 0.00040
Refrigerant (propane) 0.00015
Licensed Units Fluids by Licensor
Utilities
Sea water 0.00050
Chilled water 0.00020
Potable water 0.00020
Saturated steam / LP condensate 0.00017
BFW / demineralised water 0.00017
Nitrogen 0.00017
Instrument air 0.00017
Fuel gas 0.00017
Diesel (light) 0.00030
Diesel (heavy) 0.00035
Table 11.6. Fouling factors for Shell and tube and Hairpin Heat
Exchangers.
For plate / frame heat exchangers, a general fouling factor of 0.00068 °C m²/W shall be
taken for all fluids (or process licenser recommendation). For plate or pin fin heat
exchangers, no fouling factor shall be applied.
For plate and spiral heat exchanger the fouling factor shall be finally selected according
to manufacturer experience.

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Temperature approach for heat exchangers
The following values are the minimum temperature approach and shall be optimised on
a case by case basis according to service:
 3°C for kettle reboilers.
 5°C for other shell and tubes exchangers.
 case by case for plate type heat exchangers.
11.4.2 Air Coolers
Forced draft type air coolers will be preferred to induced type ones, in particular if inlet
process temperature is above 175°C or air outlet over 90°C.
Temperature approach for air coolers
 10°C for air coolers
11.5 PUMPS
First step to size a pump is the analysis of hydraulic circuit to determine its performance
(differential head) evaluating the process where the pump is inserted.
11.5.1 Centrifugal Pumps
The following process requirements shall be used for centrifugal pumps design.
 For available NPSH (NPSHa) calculation, the following criteria shall be

considered:
- Suction line pressure drop shall be calculated at the rated capacity of the
pump.
- The source pressure (pressure of the suction vessel) shall be the

minimum expected normal operating pressure.
- Static head shall be measured from the LLLL of the suction vessel to the
pump centreline for horizontal pumps or to the suction nozzle centreline
for vertical pumps (or to a different reference point, e.g. @ pump impeller
level).
- For horizontal centrifugal pumps a minimum value of 0.5 m above grade

shall be assumed as elevation of the pump centreline.
- If NPSHa is greater than 7 m, indication of > 7 m may be sufficient.
 From a process point of view the estimated available NPSH (shown as

NPSHa) shall be at least 1 m greater than the required NPSH (NPSHr) of the
selected pump at the rated point

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 The suction circuit should be preferably designed in order to guarantee a

NPSHa not lower than 2m.
 The pump should be generally capable of operating continuously within a

flow rate range of 30-120% of the rated flow rate with a sufficient margin
between NPSHa and NPSHr along the entire operating range.
 It is important that any margin between NPSHa and NPSHr be clearly

indicated to avoid different specialists (e.g. process and mechanic) to add
unnecessarily additional margins.
 Minimum stable flow is to be provided by pump Vendor. For preliminary

estimation a value of 40% of the rated capacity may be used for minimum
flow system design in absence of more accurate information (e.g. from
similar service pumps or when performance curves are available, etc.)
 Centrifugal pumps shall be designed for continuous operation without bypass

at minimum flow rates, unless technically justified. When a non-
automatically controlled minimum flow protection has been installed, the
permanent re-circulation flow (if required) must be added to the net process
flow.
11.5.2 Positive Displacement Pumps
The following requirements shall be used for positive displacement pumps design:
 When specifying positive displacement pumps NPSHa calculation shall take

into account liquid acceleration contribution.
 Positive displacement pumps should have strainer on the suction and safety
relief valve on the discharge. The safety relief valves should be installed
ahead of the discharge block.
 Reciprocating pumps should be equipped with pulsation dampeners on the

suction and discharge.
11.5.3 General Recommendations
 If a recycle line is required, it should be preferably connected back to suction

vessel.
 In case of continuous recirculation, the effect of the temperature increase

shall be evaluated.
11.6 COMPRESSORS
For the purposes of this document, only process minimum requirements for centrifugal
and reciprocating compressors design will be given. Final selection of type, arrangement
and configuration shall be carried out in conjunction with Machinery specialist.
As preliminary approach, the maximum predicted discharge temperature should not

exceed 150ºC, unless otherwise specified and agreed: as compressor technologies have
improved significantly, the definitive maximum discharge temperature shall be
consulted with the rotating equipment specialist, especially in the advanced project

Rev 03 – July 2015
Page 52 of 55
phases. This temperature limit applies to all specified operating and load conditions. In
case of Contractor, he shall provide the Company with both the predicted and adiabatic
discharge temperature rise.
11.6.1 Centrifugal Compressors
In this section, process minimum design requirements for centrifugal compressors are
listed.
 The “normal operating case” is defined as the capacity and operating

conditions at which usual operation is expected and optimum efficiency is
desired (GUARANTEED POINT). Different operating cases are usually
specified to cover different scenarios/production years to be verified by
compressor manufacturer.
 A suction knock out drum (also known as suction scrubber) shall be provided
for each compression stage to separate liquid phase in order to protect the
machine against liquid ingress.
 An after-cooler shall be normally provided for each compression stage.
 Methods of compressor control:
- Variable speed (preferred solution)
- Constant speed:
 Suction throttling.
 Variable inlet guide vanes – only in the case of dry, clean and non-
corrosive gas.
 Recycling (cooled bypass from discharge to suction).
 Variable diffuser vanes.
 Discharge throttling.
 For constant speed compressors, the compressor rated point (CRP)

corresponds to the design flowrate (see Chapter 9).
 For variable speed compressors, the compressor rated point (CRP) is the
point on the 100% speed line corresponding to the highest flow of any
operating point. 100% speed curve is determined from the operating point
requiring the highest head (as per API STD 617, Ref.[26]).
The head-capacity curve at 100% speed shall extend to at least 115% of the
capacity of the CRP. Head-capacity curves at other speeds shall be extended
to equivalent capacity at each speed.
11.6.2 Reciprocating Compressors
Process minimum design requirements for reciprocating compressors are:
 The normal operating point and all other applicable operating points such as
start-up, loading and unloading, etc. shall be specified.
Rev 03 – July 2015
Page 53 of 55
 The compressor can be controlled on the basis of inlet pressure, discharge

pressure, flow, or some combination of these parameters. This can be
accomplished by suction throttling, valve unloaders, clearance pockets,
speed variation, or a cooled bypass from discharge to suction.
 Flow rate control on reciprocating compressors shall have the following

points of reference: 0%, 50%, 100% or else in accordance with process
requirements and number of cylinders per stage.
11.7 TANKS
Storage of refrigerated products (such as LNG, commercial propane, commercial butane

and LPG) and Fire fighting tanks are out of the scope of this standard.
Atmospheric storage tanks are generally used for products having a maximum TVP of
about 0.9 bar abs (13 psia). TVP is dependent on the rundown temperature of the
product and on its composition and is affected by changes in temperature caused by
meteorology and by heating due to solar radiation.
Criteria for floating roof tanks is 11 psia TVP max in normal operation.
11.8 ELECTROSTATIC DESALTERS
Process minimum design requirements for electrostatic desalters are listed below:
 In the desalter unit the action of electrostatic field causes the separation of
liquid hydrocarbon from water in which the major part of the salts is
dissolved. The preference is for two stages (in series) with fresh (wash)
water introduction and mixing: first often takes the name of dehydrator and
second of desalter.
 The electrostatic desalter shall operate completely full of liquid to avoid the
segregation of hydrocarbon gases which could form explosive mixtures that
could be ignited by sparks produced by electrostatic field. Moreover, the
presence of bubbles of gas disturb the interface and hence reduce the
efficiency of the water-oil separation.
 The Desalter Unit shall be able to perform its duty with the specified wash
water type.
 The dimensions of the desalter are defined according to typical residence

time of separators (for both oil and water) keeping into consideration that
the water level will be kept at about centerline.
 Each Desalter Unit is normally furnished with a mixing valve with differential
pressure control across it. Typical pressure drop of the valve is 1-3 bar to
enhance the mixture.
Figure 1 shows the typical PFD of Desalting Unit.

Rev 03 – July 2015
Page 54 of 55
Figure 1. Typical PFD of Desalting Unit.
12. INSTRUMENTATION DESIGN CRITERIA
12.1 CONTROL VALVES
In this section general rules for sizing control valves are given. Valve flow coefficient
(CV) preliminary estimation is normally performed by Process Department while detailed
flow coefficient calculation is Instrumentation department’s responsibility (in
consultation with valve Supplier).
12.1.1 Pressure Drop
For process circuits where the pressures upstream and downstream of the control valve
are not interdependent, control valve minimum required pressure drop values shall be
normally as the greatest of the following two values:
 20% of circuit pressure drop, excluding the valve.
 10% of the static pressure of the system which the circuit discharges into,
for pressures up to 14 bar; 1.4 bar for pressures from 14 bar to 28 bar; 5%
for pressures over 28 bar.
However, the following minimum values shall be respected:
 0.7 bar (for liquid service), 0.2 bar (for gas/vapour service, butterfly valve
excluded), 0.05 bar (for butterfly valve in gas/vapour service).
For process circuits where the pressures upstream and downstream of the control valve
are interdependent (e.g. in a column reflux circuit), control valve minimum required
pressure drop values shall be defined as the greatest of the following two values:
 10% of circuit pressure drop, excluding the valve.

Rev 03 – July 2015
Page 55 of 55
 0.50 bar (for liquids), 0.2 bar (for gasses/vapours with non-butterfly valve),
0.05 bar (for gasses/vapours with butterfly valve).
These values shall be used for preliminary sizing. Final sizing will have to take into
account other specific aspects (circuit available pressure drop for optimization purposes,
real piping isometrics which could have been simply estimated in the first stage of
control valve specification, etc.).
12.1.2 Flowrate
As a general rule, in order to guarantee correct functioning at the extremes of the

operating range, control valves shall be usually specified for the following operating
conditions:
 Maximum flowrate: 110% of maximum operating flowrate (sizing case). This

value shall be taken from Heat and Material Balance unless established by
different process requirements.
 Minimum flowrate: minimum operating flowrate related to the process

turndown requirements or other anticipated minimum flow conditions (e.g.
start-up, warm-up, etc.).
 For preliminary estimation of installed CV the calculated max CV is normally

increased by 30%.
 As a general rule, it is preferred that:
CV calculated at maximum flowrate ≤ 80% installed CV

CV calculated at minimum flowrate ≥ 10% installed CV
 If the required rangeability of the control valve does not allow to select a
single valve covering the whole required operating range (i.e. very low
turndown on flowrate, or very high pressure or delta pressure variation in
the different operating cases), selection of two or more valves in parallel (i.e.
split range configuration) shall be considered.
 As a rule-of-thumb, the manual by-pass of a control valve (when installed)

should be selected one diameter less in order to avoid the manual by-pass to
have a higher CV than the control valve.
12.2 PSV & BDV
PSVs and BDVs discharge flowrates shall be calculated on the basis of API STD 520 and
API STD 521 (Ref.[12], [13]). API 2000 shall be followed to calculate discharge
flowrates to size pressure relief devices of atmospheric tanks (Ref.[15]).


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eni spa 10009.HTP.PRC.

Consulted Distribution List

Date Addressee / Position Holder Company/Unit

Informed Distribution List

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ENGINEERING COMPANY STANDARD

Rev 03: Actual revision is of 55 pages.

Summary of main changes:

1. General rewording through the entire document.

Rev 01: This revision is of 57 pages.

eni personnel can access company standard repository at:

External user shall refer to the Project Engineer Manager.

ENGINEERING COMPANY STANDARD

1. SCOPE ............................................................................................................................. 7

2. APPLICABILITY AND EXCLUSIONS..................................................................... 7

3. REFERENCE STANDARDS AND DOCUMENTS ................................................... 8

4. ABBREVIATIONS AND ACRONYMS ................................................................... 10

5. UNITS OF MEASUREMENT .................................................................................... 12

6. TERMINOLOGY AND DEFINITIONS................................................................... 13

7. DESIGN PRESSURE AND DESIGN TEMPERATURE ....................................... 15

8. LINE SIZING CRITERIA ......................................................................................... 27

ENGINEERING COMPANY STANDARD

9. OVERDESIGN CRITERIA ........................................................................................ 41

10. SPARING PHILOSOPHY ......................................................................................... 42

11. EQUIPMENT DESIGN CRITERIA ......................................................................... 44

12. INSTRUMENTATION DESIGN CRITERIA ......................................................... 54

ENGINEERING COMPANY STANDARD

2. APPLICABILITY AND EXCLUSIONS

ENGINEERING COMPANY STANDARD

3. REFERENCE STANDARDS AND DOCUMENTS

[1] 20183.COO.GEN.FUN Units of Measurement

[10] 28014.MAN.MNU.SDS RCM Approach

[20] ASME B16.5 Pipe Flanges and Flanged Fittings

ENGINEERING COMPANY STANDARD

Recommended Practice for Design and

[23] 04937.EQP.MEC.FUN Shell and Tube Heat Exchangers

[24] opi svi 007 - ANNEX B Golden Rules

ENGINEERING COMPANY STANDARD

4. ABBREVIATIONS AND ACRONYMS

ANSI American National Standards Institute

ENGINEERING COMPANY STANDARD

ENGINEERING COMPANY STANDARD

5.1 STANDARD AND NORMAL CONDITIONS

It is normal practice to consider atmospheric pressure and storage temperature (project

ENGINEERING COMPANY STANDARD

6. TERMINOLOGY AND DEFINITIONS

 The Supplier or Third Party (Manufacturer/Vendor) is the party which

 The Company Engineering Technical Authority is a function whose main

Some terms of general use in the document are here defined.

 Blowdown: the act of emptying or depressurizing a pressurized system.

 Flowline: piping system conveying well fluid from wellhead to manifold or

 HIPPS: High Integrity Pressure Protection System. Safety system used to

ENGINEERING COMPANY STANDARD

 Hold-up volume: as per hold-up time but referred to the volume.

 Operating Temperature (OT): the temperature in the equipment or piping

 Pressure Safety-relief Valve (PSV): a pressure-relief device designed to open

 Shut-Off Head: is the maximum differential head developed by a centrifugal

 Settle-Out Pressure: is the equalized pressure reached when the fluid is

 Steam-Out: operation of maintenance consisting in purging and/or cleaning