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DESIGN GENERAL SPECIFICATION

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PROCESS DESIGN CRITERIA

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DGS 0000 020 Rev 2

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CONTROLLED INTRANET COPY

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The Intranet copy of this document is the only controlled document. Copies or extracts of this document,

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which have been downloaded from the Intranet, are uncontrolled copies and cannot be guaranteed to

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be the latest version.

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REV
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DATE NAMES SUMMARY OF CHANGES

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A June 2001 A. Kara/ Abdul Aziz Al Ameri Issued for Comments

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0 July 2001 A. Kara/ Abdul Aziz Al Ameri Issued for Implementation

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1 May 2010 Yasser Hassan / S. Sayegh/ Marwan Al Hammadi Issued for Implementation
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Rahul Mukherjee/ Eman Al Suwaidi/ Ayman Ghazaly/

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2 Apr 2019 Re-Issued for Implementation

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Ahmed Mohamed Al Abri

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AUTHORIZATION NAMES SIGNATURE DATE

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Prepared by SME: Rahul Mukherjee

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Reviewed by TL: Eman Al Suwaidi

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Endorsed by DM: Ayman Ghazaly

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Endorsed by TA: Ayman Ghazaly

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Approved by UTA: Ahmed Mohamed Al Abri

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TABLE OF CONTENTS

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1.0 GENERAL....................................................................................................................................................................... 4

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1.1 INTRODUCTION .................................................................................................................................................................4

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1.2 PURPOSE ...............................................................................................................................................................................4

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1.3 DEFINITIONS.........................................................................................................................................................................4

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1.4 SCOPE.....................................................................................................................................................................................5

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2.0 CODES AND STANDARDS ........................................................................................................................................ 6

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3.0 REFERENCE DOCUMENTS......................................................................................................................................... 6

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4.0 EQUIPMENT DESIGN PRESSURE .............................................................................................................................. 7
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4.1 DESIGN PRESSURE SELECTION ....................................................................................................................................... 7

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4.2 DESIGN PRESSURE PROFILE FOR COLUMNS AND REACTORS .............................................................................8

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4.3 DESIGN PRESSURE AT THE DISCHARGE OF A CENTRIFUGAL PUMP ..................................................................9

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4.4 COMPRESSOR SEPARATORS ......................................................................................................................................... 10

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4.5 TUBE RUPTURE PROTECTION OF HEAT EXCHANGERS ......................................................................................... 11

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4.6 STEAM CONTAINING EQUIPMENT............................................................................................................................... 11

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5.0 DESIGN TEMPERATURE ............................................................................................................................................ 11

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5.1 EQUIPMENT OPERATING AT TEMPERATURE ABOVE 0°C ..................................................................................... 11

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5.2 EQUIPMENT OPERATING AT TEMPERATURE BELOW 0°C ................................................................................... 12

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5.3 DISCONTINUOUS / CYCLIC PROCESSES.................................................................................................................... 13

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6.0 METALLURGICAL REQUIREMENTS ....................................................................................................................... 14

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7.0 OVERSIZING FACTORS ............................................................................................................................................ 14

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7.1 HEAT EXCHANGERS / AIR COOLERS .......................................................................................................................... 14

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7.2 PUMPS ................................................................................................................................................................................. 14

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7.3 COMPRESSORS .................................................................................................................................................................. 15

7.4 FIRED HEATERS .................................................................................................................................................................. 15

7.5 FRACTIONATION COLUMNS, ABSORBERS AND REGENERATORS .................................................................... 15

8.0 EXCHANGERS FOULING FACTORS ....................................................................................................................... 15

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9.0 REQUIREMENTS FOR EQUIPMENT........................................................................................................................ 17

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9.1 DIAMETER OF VESSELS ................................................................................................................................................... 17

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9.2 VALVE TRAY FLOODING ................................................................................................................................................. 17

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9.3 ELEVATION OF EQUIPMENT.......................................................................................................................................... 18

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9.4 DRUM TYPE SELECTION .................................................................................................................................................. 18

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10.0 SPECIFIC REQUIREMENTS FOR HEAT EXCHANGERS ........................................................................................ 18

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11.0 LIQUID RESIDENCE TIME AND LEVEL POSITIONS ............................................................................................. 19

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11.1 LIQUID HOLD-UP AND RESIDENCE TIME .................................................................................................................. 19

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11.2 LEVEL POSITIONS............................................................................................................................................................. 20
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12.0 NOZZLES PROCESS STANDARDS..........................................................................................................................20
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13.0 INSULATION AND TRACING ..................................................................................................................................22

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14.0 PIPING .........................................................................................................................................................................23

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14.1 LINE SIZING CRITERIA FOR LIQUID............................................................................................................................ 23

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14.2 LINE SIZING CRITERIA FOR GAS AND STEAM ......................................................................................................... 24

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14.3 LINE SIZING CRITERIA FOR MIXED PHASE FLUID................................................................................................... 26

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14.4 LINE SIZING CRITERIA FOR OFFSITE LINES .............................................................................................................. 27

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15.0 APPENDICES / ATTACHMENTS .............................................................................................................................. 27

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1.0 GENERAL

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1.1 INTRODUCTION

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This specification describes the process criteria for the design and construction of various

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facilities during the Engineering Design phase for ADNOC Gas Processing.

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1.2 PURPOSE

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The purpose of this document is to define the rules and criteria which shall be followed to

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implement the process design of the various facilities during the Engineering Design phase

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of a PROJECT. 2)
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This document provides guidance to:

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 Establish and correlate a source of basic information of typically multi discipline interest
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agreed as a common reference of easy access.

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Define the minimum basic sizing criteria.

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1.3 DEFINITIONS
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Where used in this specification, the following terms shall have the meanings indicated below
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unless otherwise clearly indicated by context of their use.

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COMPANY - ADNOC Gas Processing

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CONTRACTOR - The party which carries out all or part of the design engineering,
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procurement, construction and commissioning or management of the PROJECT.

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CONCESSION REQUEST - A deviation requested by the CONTRACTOR or VENDOR, usually

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after receiving the contract package or purchase order. Often, it refers to an authorization to
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use, repair, recondition, reclaim, or release materials, components or equipment already in

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progress or completely manufactured but which does not meet or comply with COMPANY
requirements. A CONCESSION REQUEST is subject to COMPANY approval.

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LICENSOR - The party(s) which provides the technology and the basic design package for the

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engineering, procurement, construction, commissioning of the PROJECT.

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PROJECT - (To be defined)

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SHALL and SHOULD - The word ‘Shall’ is to be understood as a mandatory and the word

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‘Should’ as strongly recommended to comply with the requirements of this document.

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ENGINEER / FEED ENGINEER - An Engineering Company / firm appointed by COMPANY to

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perform The Front End Engineering Design (FEED) and / or Engineering Design for

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the PROJECT.

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1.4 SCOPE
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This document outlines the basic design / sizing process criteria to be applied as a minimum
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in the specification of equipment, piping and insulation. The CONTRACTOR shall be aware
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of “fit for purpose” design. If the CONTRACTOR can provide enough justification or
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demonstrate that even by not following any of the below minimum basic design / sizing
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process criteria, the design can be robust and “fit for purpose” and can meet the Project
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objectives, the same shall be presented to COMPANY for review. Subsequently, DGS
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Addendum to be issued by CONTRACTOR for any accepted change.

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For Licensed process/package, no change will be considered to the basic design data and
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specific design criteria given by the Process LICENSOR without prior approval from the
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LICENSOR and/or COMPANY.

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Request for any change in LICENSOR basic design data or criteria shall be submitted to the
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COMPANY for review and approval only in the event that the Process LICENSOR criteria are
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less stringent than that for non licensed process units. In all cases where the LICENSOR design
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criteria or basic data is less stringent than those given below, the FEED ENGINEER shall bring
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this to the notice of the COMPANY.

In the event that the Process LICENSOR proposes specific design criteria which is more
stringent than the one summarized in this document, that shall take precedence.

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The following process design criteria given below shall be applied to equipment, which is not

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specified by LICENSOR.

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2.0 CODES AND STANDARDS

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The following codes and standards, to the extent specified herein shall apply. Where a specific

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edition is not indicated, it shall be taken that the most current edition (including addenda)

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shall apply.

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API 12J Specification for Oil & Gas Separators

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API 521 American Petroleum Institute Standard ‘Pressure

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Relieving and Depressurizing Systems’
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API 650 Welded Tanks for Oil Storage

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ASME Section VIII, Division 1 ’Boilers and Pressure Vessels’

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Shell DEP 31.22.05.11 Gen Gas/Liquid Separators – Type Selection & Design Rule
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TEMA Tubular Exchangers Manufacturer’s Association

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3.0 REFERENCE DOCUMENTS

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The following reference documents, to the extent specified herein, form a part of this
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specification. When an edition date is not indicated for a document, the latest edition in force
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at the time of the project execution shall apply.

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Design General Specifications

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DGS 0000 021 P&ID Development

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DGS 0180 002 Flare System Design Basis

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DGS 6300-006 Material Selection & Corrosion Control Philosophy

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DGS 0810 002 Pressure vessel design basis

DGS 6500 010 Hot insulation for piping and equipment

DGS 6500 020 Cold insulation for piping and equipment

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DGS 6000 003 Acoustic insulation for pipes, valves and flanges

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4.0 EQUIPMENT DESIGN PRESSURE

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4.1 DESIGN PRESSURE SELECTION

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Except for specific items such as thin wall equipment (Vessels open to atmosphere, storage

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tanks, etc.), the following design criteria shall be applied defining PD according to:

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PD : minimum mechanical design pressure

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PSM : maximum continuous operating pressure

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PSM (BAR G) PD (BAR G)

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<0 Full vacuum (2) and 2.0 or 3.5 bar g (3)

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0-10 Full vacuum (2) and PSM + 1 (3) (4) (5)

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10-35 Full vacuum (2) and PSM x 1.1

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35-70 Full vacuum (2) and PSM + 3.5

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> 70 Full vacuum (2) and PSM x 1.05

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Notes:
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1. When applicable, maximum liquid density and maximum liquid height in vessel shall be
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specified on the process data sheet for use in mechanical thickness calculations.
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2. Full vacuum design conditions shall be applied to equipment that fulfill one of the
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following conditions :
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Normally operates under vacuum

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Is subject to vacuum during start-up, shut-down or regeneration

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 Normally operates full of liquid and can be blocked in and cooled down
 Can undergo vacuum through the loss of heat input.

Partial vacuum design conditions are normally not considered, except for the following
cases:

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 When the sub-atmospheric pressure is determined by the vapor pressure of the vessel

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fluid. Then the vapor pressure corresponding to the minimum ambient temperature has

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to be considered.

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 When the thickness of equipment is determined by external pressure calculation instead

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of internal pressure. This has to be considered on a case by case basis.

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3. Based on the minimum set pressure of safety valves:

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 3.5 bar g for a safety valve discharging to flare

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 2.0 bar g for a safety valve discharging to atmosphere for non-hydrocarbon / sour

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service only. ]F
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(This rule is not applicable for thin wall equipment such as vessels open to
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atmosphere, storage tanks, where "full of liquid" may be the governing case).
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4. For equipment in equilibrium with flare the design pressure is the flare design pressure.
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5. For tanks open to atmosphere, atmospheric pressure + full of water or specified liquid (if
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specific gravity > 1.0). For minimum design pressure of atmospheric storage tanks, API
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650 shall be followed.

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4.2 DESIGN PRESSURE PROFILE FOR COLUMNS AND REACTORS

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The same design pressure shall be selected for the top of a fractionation column and
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associated condenser, reflux drum and interconnected piping.

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The design pressure at the bottom of a fractionation column shall be determined as follows:
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PDB = PDT + ∆P1 + h.ρ.g

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Where:
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PDB : Design pressure at the bottom including applicable pressure due to maximum operating
liquid level

PDT : Design pressure at the top in the vapor phase

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∆P1 : Column pressure drop

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h : Maximum operating height of liquid

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ρ : Density of liquid

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g : Acceleration due to gravity

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The maximum liquid flowing density and the maximum liquid height shall be indicated on the

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Process Data Sheet for use in the mechanical thickness calculations.

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4.3 DESIGN PRESSURE AT THE DISCHARGE OF A CENTRIFUGAL PUMP

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As a general rule the design pressure shall be the maximum of the values calculated by
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the two following formulas :

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Hmax x dmax
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PDD = PSM + 10.2

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Hc x dmax
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PDD = PDS +
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10.2
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Where:
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PDD : Design pressure at the discharge of the pump (bar g)

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PDS : Design pressure at the suction of the pump (bar g)

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PSM : Maximum operating pressure (bar g)

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Hmax : Maximum differential head of the pump, generally at no flow condition (m)
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HC : Rated differential head (m)

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dmax : Maximum flowing specific gravity.

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 In order to ensure above, at the early stage of the project development when the

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maximum differential head of the centrifugal pump is not available, the design pressure

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at the discharge of the pump shall then be set as follows:

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1.2 x Hc x dmax

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PDD = PDA +

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10.2

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PDA : Safety valve set pressure for the suction vessel (bar g)

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+ Pressure drop through the vessel (bar), if any

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dmax

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+ Maximum static head at pump suction (m) x

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At the detail engineering stage, after pump selection, it shall be checked that the
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design pressure calculated using above formula is in accordance with general criteria
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stated above.
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 In case of two pumps in series, the maximum differential head shall be the sum of the
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maximum differential head of each pump provided there is no pressure relief valve
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between the pumps.

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For variable speed pumps, to calculate the pump shut off pressure, CONTRACTOR shall
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ensure that the maximum speed of the pump is considered.

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 On cooling water, fire water, chilled water systems (large water networks), surge pressure
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due to water hammer / sudden closure / stoppage of valves / pumps shall be estimated
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through detailed analysis and that pressure shall be within system design pressures.
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Necessary pressure relieving systems shall be designed and incorporated if increasing

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system design pressures is not economically justified.

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4.4 COMPRESSOR SEPARATORS

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Settling-out pressure of compressors shall be considered for design pressure calculations of

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compressor suction separator. This settling out pressure shall be confirmed as soon as
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relevant detailed information becomes available from compressors suppliers and Detailed
Engineering Studies.

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Design pressure or maximum allowable working pressure (MAWP) of the separator drum to

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be calculated as 1.05 times the settling out pressure, as a minimum, per API 521 requirements,

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to provide adequate margin for a compressor shutdown contingency.

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4.5 TUBE RUPTURE PROTECTION OF HEAT EXCHANGERS

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This concerns TEMA and multi tube heat exchangers.

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 Tube rupture protection of heat exchangers rules shall follow API 521 (latest edition). This

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practice applies only to the heat exchanger itself and does not concern relevant piping

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and valves.

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 Double pipe type of heat exchangers are not concerned by tube rupture protection as
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per API 521 (latest edition)
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 It has to be pointed out that considerations for thermal relief device implementation have
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to be taken independently from any tube failure protection requirement.

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4.6 STEAM CONTAINING EQUIPMENT

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As a general rule, steam containing equipment shall be designed for full vacuum conditions,
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since vacuum may happen during cooling down of such equipment when not connected to
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atmosphere.
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Steam out operation equipment design pressure to be half vacuum at steam out temperature.
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Steam out for internally coated or lined vessels is not permitted.

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5.0 DESIGN TEMPERATURE

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5.1 EQUIPMENT OPERATING AT TEMPERATURE ABOVE 0°C

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As a general rule the design temperature shall be:

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TD = TSM + 15°C or TD = TE, whichever is the greater

Where:

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TD : Design temperature (°C)

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TSM : Maximum continuous operating temperature (°C)

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TE : Exceptional operating temperature (°C) to be considered for operations duration

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exceeding a total of 100 hours per year.

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The minimum design temperature shall not be less than 85°C for any metallic equipment

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which normally operates at temperatures above 0°C.

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Notes:

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1. The exceptional temperature generated by a fire should not be considered for design
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temperature selection but shall be addressed as part of the depressurization studies.
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2. The accidental temperature which may occur in emergency situations such as loss of
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utilities, valve closure, air cooler failure or any abnormal operation and corresponding to
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a short duration are not to be taken into account as long as the temperature increase
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does not exceed the codes limits.

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However equipment containing parts which can be damaged by abnormal high

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temperature has to be designed for this temperature. This mainly concerns equipment
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internals.
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3. Steam out conditions shall be specified on process equipment data sheet when hard-
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pipe steams out connections are provided. For non permanent connections, steam out
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conditions should not supersede Process Design conditions.

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4. A specific design temperature shall be associated to specified vacuum design pressure.

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5.2 EQUIPMENT OPERATING AT TEMPERATURE BELOW 0°C

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As a general rule the design temperature shall be:

TD = TSM - 10°C

Where:
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TD : Design temperature (°C)

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TSM : Minimum continuous operating temperature (°C).

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Notes:

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1. Depending upon the depressurization philosophy of the plant, dynamic simulations of

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equipment may have to be performed using COMPANY approved commercial software

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to determine the relevant pressure and temperature profile conditions during

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depressurization.

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2. Temperature generated by depressurization of equipment or interconnected items
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system shall be indicated on the datasheet as well as the related residual pressure.
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3. Where depressurization in accordance with the above criteria results in temperatures

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lower than -46°C, datasheet shall indicate Minimum Design Metal Temperature (MDMT).
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4. Minimum Design Metal Temperature (MDMT) shall be specified as per DGS-0810-002

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(Pressure vessel design basis).

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5.3 DISCONTINUOUS / CYCLIC PROCESSES

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Various pressure and temperature conditions sets shall be specified for each phase of
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equipment operation.
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Mixing of extreme conditions of pressure and temperature shall not be considered.

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Typical example is related to molecular sieves vessel design conditions specification. The sets
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of conditions of each phase of the operating cycle shall all be specified, e.g. design conditions
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of the adsorption phase, of the regeneration phase, etc.

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6.0 METALLURGICAL REQUIREMENTS

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The metallurgical selection to be applied for equipment and piping process design are to be

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reported in the "Plant Corrosion Control and Material Selection Philosophy” and shall take

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into consideration all the requirements of DGS-6300-006 and shall be shown on Material

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Selection Diagrams developed for each Unit. Process datasheet shall indicate the complete

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composition including presence of chlorides if any.

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7.0 OVERSIZING FACTORS

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7.1 HEAT EXCHANGERS / AIR COOLERS

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2)
Irrespective of phase change, both Duty & Flowrate shall be increased by 10%. This constitutes
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a 10% margin.
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7.2 PUMPS
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The minimum margin between the normal flowrate and the rated flowrate shall be as follows:
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Reflux pumps and pump around pumps : 20%

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Other process pumps : 10%

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 Boiler feed water pumps : See applicable codes,

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but not less than 10%

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 Other utility pumps : 10%

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Notes:
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1. When an automatically controlled minimum flow protection is not installed, the

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recirculation permanent flow must be added to the net process flow.

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2. Normal and rated flow rates may be identical for specific service such as intermittent
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service, sump pumps, etc.

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3. The above margin is to be applied at pump normal head.

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7.3 COMPRESSORS

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The minimum margin between the normal case and the rated case shall be as follows:

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Centrifugal compressors: 10%

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 Instrument Air Compressors : instrument air demand (all consumers including

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intermittent users) +30 % margin

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 Other compressors: 10%

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Nitrogen generation systems shall be sized for normal continuous operating demand + 20%

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margin.

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On site liquid nitrogen storage shall be based on maximum of
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a. 1 week normal demand

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b. 24 hrs peak consumption

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7.4 FIRED HEATERS

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No over sizing shall be considered over and above the design case unless specifically
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identified. Design case shall be identified after checking different process flows and different
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possible fuel gas compositions for the Project.

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7.5 FRACTIONATION COLUMNS, ABSORBERS AND REGENERATORS

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No over sizing shall be considered over and above the design case unless specifically
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identified. However, the columns shall be designed to meet specification requirements when
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operated at turndown conditions. Tray design shall have 10% margin on tray loading.
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8.0 EXCHANGERS FOULING FACTORS

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The following fouling factor figures shall apply:

 Process fluids

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h.m2.°C/kcal m2.°C/W

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Sour natural gas 0.00020 0.00017

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AI
Sweet gas 0.00020 0.00017

TR
Liquid NGL 0.00020 0.00017

IN
S
Liquid LPG 0.00020 0.00017

ID
SK
Raw Feed Condensate 0.00040 0.00035

ER
Stabilized Condensate 0.00020 0.00017

ET
M
Process water 0.00040 0.00035

W
LO
Stripped water 0.00040 0.00035
]F
Glycol 0.00040 0.00035
2)
(C

Amine Service (1) 0.0005 0.000375

E
AN
TH

(1) Filter or strainer is required for Amine Services

[E
EO

 Licensed units fluid by by LICENSOR by LICENSOR

D
F
O
N

 Utilities
I O
AT
AD

Chilled water 0.00020 0.00017

R

Potable water 0.00020 0.00017

G
P-
-U

Saturated steam / LP condensate 0.00020 0.00017

S

BFW / Demineralized water 0.00020 0.00017

AI
W

Superheated steam 0.00010 0.00009

RU
0-

Nitrogen 0.00010 0.00009

75
00

Instrument air 0.00020 0.00017

05
1-

Fuel gas 0.00020 0.00017

02
/2

Diesel 0.00040 0.00035

ul
/J
27

Revision No.: 2 Apr 2019 Document ID: DGS 0000 020 Page 16 of 27
 III
9.0 REQUIREMENTS FOR EQUIPMENT

D
N
IA
9.1 DIAMETER OF VESSELS

,I
-I
N
AI
As a general rule, inside diameter shall be specified on process data sheets. The equipment

TR
outside diameter and thickness shall be calculated by relevant specialists.

IN
S
ID
When the required inside diameter of a vessel is lower than 800 mm, a note should be added

SK
ER
on process data sheets specifying that a pipe element may be considered.

ET
M
When the required inside diameter of a vessel is lower than 900 mm, flanged heads may be

W
LO
specified on process data sheets. 2)
]F
(C

In some applications proprietary separator design may have to be selected. This applies
E
AN

mainly to separators where gas/liquid separation is of utmost importance for downstream

TH

equipment.
[E
EO

Proprietary design items should however be checked with great care as size may be reduced
D
F
O

at the expense of performance and separation efficiency is very difficult to check.

N
I O
AT

All vessel internal elements shall be designed to withstand depressurization rate and
AD

temperatures.
R
G
P-
-U

For items not covered here, SHELL DEPs /API standards to be followed.
S
AI
W

9.2 VALVE TRAY FLOODING

RU
0-
75

The recommended flooding factor for valve trays should be as follows:

00
05
1-

0.82 for pressure columns and atmospheric column

02
/2
ul

0.65 to 0.75 for columns with diameter lower than 900 mm.
/J
27

Higher flooding factors may be considered in special cases subject to COMPANY approval.

Revision No.: 2 Apr 2019 Document ID: DGS 0000 020 Page 17 of 27
 III
The system factors to be applied vary depending upon each service. Refer to the relevant

D
N
documents (Unit design basis, Process Datasheets, etc.) for full detailed information. For

IA
,I
LICENSOR units, the tray design criteria shall be as recommended by LICENSOR.

-I
N
AI
TR
9.3 ELEVATION OF EQUIPMENT

IN
S
When no process constraint is involved, it should be indicated "minimum for piping" in place

ID
SK
of elevation. Elevation shall then be determined during EPC phase.

ER
ET
Equipment elevation shall be specified on process data sheets and P&ID's when required, i.e.,

M
W
pump NPSH requirements, fluid circulation in column side exchangers, etc.

LO
]F
2)
Equipment elevation, piping layout, equipment performances shall be checked and confirmed
(C

acceptable when detailed information is available from relevant disciplines.

E
AN
TH

9.4 DRUM TYPE SELECTION

[E
EO

Horizontal drums are preferred to vertical drums when the liquid handling requirements are
D
F
O

more stringent than those of the gas phase, as they lead to relatively smaller drums.
N
I O
AT

Vertical vessels are be preferred when the gas/liquid efficiency is of critical impact, since the
AD

efficiency of a vertical drum does not vary with liquid level.

R
G
P-
-U

Horizontal drums are preferred when a three-phase separation is required. Vertical drums
S
AI

may be considered when the gas/liquid separation is considered more critical for process
W
RU

operation than the liquid phase separation.

0-
75
00

Other considerations such as plot plan requirements, etc. shall also be taken into account.
05
1-
02

10.0 SPECIFIC REQUIREMENTS FOR HEAT EXCHANGERS

/2
ul
/J

 TEMA R should be generally used for all shell and tubes and hairpin type heat exchangers.
27

Fixed tube sheet exchangers are acceptable for non fouling service being on the shell
side. In this case, Licenser and/or Contractor shall define all exceptional operating

Revision No.: 2 Apr 2019 Document ID: DGS 0000 020 Page 18 of 27
 III
conditions (start-up, shutdown) to check the necessity to provide an expansion bellow on

D
N
the shell.

IA
,I
-I
For water coolers, the sizing of by-pass on water side shall be 3/4" for water pipes up to

N
AI
TR
3", 1" for water pipes up to 8" and 1 1/2" for water pipes more than 8".

IN
S
 Induced draft is preferred for air coolers, except when inlet temperature of fluids above 175

ID
SK
°C, outlet temperature of fluid is above 85°C and air outlet over 77°C. Temperature control

ER
on air coolers shall be set by Process requirements (Bypass, variable speed motors, etc).

ET
M
Louvres should be avoided as they are prone to stick.

W
LO
]F
 In plants where sea water is available as a cooling medium, it shall be ensured maximum
2)
(C

skin temperature and maximum bulk temperature on the cooling water side does not
E
AN

exceed 54°C and 43°C respectively. (skin temperature is defined as the tubewall
TH

temperature (metal surface temperature) on the cooling water side, in clean condition).
[E
EO

One of the possible ways of ensuing the same could be installing an air cooler upstream
D

the sea cooling water exchanger.

F
O
N
O

11.0 LIQUID RESIDENCE TIME AND LEVEL POSITIONS

I
AT
AD
R

11.1 LIQUID HOLD-UP AND RESIDENCE TIME

G
P-
-U

The hold-up time is defined between Low Liquid Level (LLL) and High Liquid Level (HLL).
S
AI
W

As a general rule hold-up times shall be as follows:

RU
0-
75

SERVICE HOLD-UP TIME (MINIMUM)

00
05

Surge 20 minutes
1-

5 minutes
02

Reflux or 2 minutes if product is sent to storage

/2
ul

15 minutes if product feeds a column

/J

2 minutes if direct cooling

27

Product to storage 5 minutes if heat exchange with other

process streams
5 minutes if liquid level is controlled
Product to process 15 minutes if flowrate is controlled
kettle liquid hold-up may be taken into
Reboiling by kettle account when considering the fractionation
system liquid bottom product hold-up
Revision No.: 2 Apr 2019 Document ID: DGS 0000 020 Page 19 of 27
 III
The Normal Liquid Level (NLL) is generally set at 50% of the HLL-LLL range.

D
N
IA
11.2 LEVEL POSITIONS

,I
-I
N
AI
Unless otherwise specified by Process LICENSOR, the following alarm and cut-off setting shall

TR
be used:

IN
S
ID
HLL Defines the 100% point of the controllable range.

SK
HLA At 80% of the controllable range.

ER
ET
NLL At 50% of the controllable range.

M
LLA At 20% of the controllable range.

W
LO
LLL Defines the 0% point of the controllable range.
]F
2)

HHLA / HLCO At a few seconds / minutes above HLL

(C
E

LLLA / LLCO At a few seconds / minutes above LLL

AN
TH

Trip tappings, e.g. dedicated to HLCO or LLCO, shall be independent from other instrument
[E
EO

tappings.
D
F
O

12.0 NOZZLES PROCESS STANDARDS

N
I O
AT

 Manholes installation
AD
R

Vessels of 6 meters or longer (tangent to tangent length) shall be provided with a

G
P-
-U

minimum of two manholes or more depending upon vessel specific internal

S

arrangement.
AI
W
RU
0-
75

Specific COMPANY requirements for additional manholes should be incorporated when

00
05

manholes on vessel top are deemed necessary for proper equipment ventilation during
1-
02

internal inspection.
/2
ul
/J

In columns with trays, manholes should be provided at the top, below the bottom tray,
27

at the feed tray, at any other tray at which removable internals are located, and at
intermediate points so that the maximum spacing of manholes does not exceed 15 trays.
The minimum tray spacing with manhole in the internal shall not be less than 760 mm.

Revision No.: 2 Apr 2019 Document ID: DGS 0000 020 Page 20 of 27
 III
Minimum size of manholes shall be 24”. Size other than this, i.e. up to 20” requires

D
N
COMPANY approval. The handholes size is 8" minimum.

IA
,I
-I
N
AI
For vessels containing solid catalyst/chemicals the manhole size shall be 30 “.

TR
IN
Nozzle sizes

S


ID
SK
ER
ET
All nozzles shall be flanged and minimum nozzle diameter permitted is 2” (50.8 mm)

M
nominal.

W
LO
The following nozzle sizes shall not be used: 1:25", 2.5", 3.5", 5", 7", 9", 22" and 26".
]F
2)
(C

The minimum vessels vent and drain sizes shall be as follows:

E
AN
TH

VOLUME OR DIAMETER OF VENT DIAMETER DRAIN DIAMETER

[E

VESSEL (M3 OR MM)

EO
D

V < 75 or D < 4 500 2" 2"

F
O

75 < V < 220 or 3" 3"

N
O

4500 < D < 6 000

I
AT
AD

220 < V < 420 or 4" 4"

R
G

D > 6 000
P-
-U

V > 420 6" 4"

S
AI

Note: Vent and drain connections may not necessarily be located on vessels, however, drains
W
RU

should be connected at the lowest point to allow complete drainage of the vessel.
0-
75
00

The purge connections for vessels shall be sized as follows:

05
1-

Drums and heat exchangers (when applicable) 2"

02


/2

Column diameter (m)

ul


/J
27

o D < 4.5 2"

o 4.5 < D < 6 3"
o D>6 4"

Revision No.: 2 Apr 2019 Document ID: DGS 0000 020 Page 21 of 27
 III
The steam out connections shall be of 2" for standardization reasons.

D
N
IA
For large vessels (D ≥ 4.5m and columns), 2 X 2" connections shall be provided.

,I
-I
N
AI
TR
Notes:

IN
S
ID
1. The purge and steam out connections, when specifically required, may not necessarily

SK
ER
be located on vessels (advantage may be taken of available connections such as drains

ET
for steam out service).

M
W
LO
2. Steam out connections should be distinct and independent from drains.
]F
2)
(C

13.0 INSULATION AND TRACING

E
AN

Thermal insulation for hot or cold services is required for:

TH
[E

Heat or cold conservation of equipment and piping. (For more details, refer to DGS-
EO


D

6500-010 & DGS-6500-020).

F
O
N

 Temperature control to avoid condensation, solidification or a too high viscosity.

I O
AT

Anti external condensation

AD


R
G

 Steam or electrical tracing provided to prevent freezing or to keep a gas above its dew
P-
-U

point.
S
AI
W

For personnel protection of equipment, refer to DGS-6500-010.

RU
0-
75

Depending on the type and composition of insulation, if found to be fire resistant certified,
00
05

then credit maybe taken for its ability to reduce the relief load during a fire in accordance
1-

with API 521.

02
/2
ul
/J

Acoustic Insulation shall be required where noise levels are predicted to exceed PROJECT
27

standards.

Revision No.: 2 Apr 2019 Document ID: DGS 0000 020 Page 22 of 27
 III
14.0 PIPING

D
N
IA
14.1 LINE SIZING CRITERIA FOR LIQUID

,I
-I
N
AI
The following line sizing criteria shall apply for liquid services. The following criteria are valid

TR
for onsite lines sizing. Refer to paragraph 14.4 for offsite and interconnecting lines.

IN
S
ID
MAXIMUM

SK
SERVICE LINE SIZE
VELOCITY PRESSURE DROP

ER
ET
(M/S) NORMAL MAX.

M
(BAR/KM) (BAR/KM)

W
LO
Pump suction, bubble ≤ 2” 0.6 ]F 0.6 0.9
2)

point (1)(3)
(C

3" - 10” 0.9 “ “

E
AN

12" - 18” 1.20 “ “

TH

≥ 20" 1.5 ” “
[E
EO
D
F

Pump suction, ≤ 2” 0.9 2.3 3.5

O
N
O

subcooled (3) 3" - 6” 1.2 “ “

I
AT
AD

8" - 18” 1.5 “ “

R
G

≥ 20" 1.8 ” “
P-
-U

Pump discharge, P < 50 1.5 to 6 3.5 4.5

S
AI
W

bar g
RU

1.5 to 6 7.0 9.0

0-

Pump discharge, P > 50

75
00

bar g
05
1-
02

Gravity flow 0.6 0.25 0.45

/2
ul

Side-stream draw-off ≤ 2” 0.6 0.6 0.9

/J
27

(2) ≥ 3" 0.9 ” “

Cooling water 3.0 2.3 3.5

BFW 6.0 3.5 4.5

Revision No.: 2 Apr 2019 Document ID: DGS 0000 020 Page 23 of 27
 III
Notes:

D
N
IA
1. Applicable to liquid to thermosiphon reboiler and liquid containing dissolved gas.

,I
-I
2. Provide a vertical run of 3 meters minimum from nozzle, at nozzle size, before reducing

N
AI
TR
the size of the line.

IN
3. For high pumping temperature, extra margins shall be considered to compensate for

S
ID
SK
piping expansion devices pressure drop.

ER
ET
4. For sizing lines in amine service, LICENSOR recommendations to be followed. However,

M
as a general guideline, the following can be followed: Amine solution maximum velocities

W
LO
in (i) exchangers = 1 m/s (ii) pipes (pump discharge) = 2m/s. Long radius elbows should
]F
2)
be utilized where practical in rich amine service.
(C
E
AN

14.2 LINE SIZING CRITERIA FOR GAS AND STEAM

TH
[E

The following line sizing criteria shall apply for gas and steam services. The following criteria
EO
D

are valid for onsite lines sizing. Refer to paragraph 14.4 for offsite and interconnecting lines.
F
O

MAXIMUM MAXIMUM
N
O

SERVICE PRESSURE LINE SIZE VELOCITY (m/s) ρV2

I
AT

(bar g) (kg.m-1.s-2)
AD

Gases; General (1),(7) P < 20 (5) 15 000

R

20 < P ≤ 50 (5) 15 000

G

50 < P ≤ 80 (5) 15 000

P-
-U

P > 80 (5) 15 000

S
AI

Compressor Suction (3)

W

Reciprocating (5) 3 000

RU

Centrifugal (5) 6 000

0-
75
00

Heat exchangers nozzle (5) 6 000

(in/out)
05
1-
02
/2
ul

Steam, saturated (3) ≤ 2" (5) 15 000

/J
27

3” - 8" (5) “
≥ 10” (5) ”

Revision No.: 2 Apr 2019 Document ID: DGS 0000 020 Page 24 of 27
 III
Steam, superheated (6)

D
N
IA
,I
-I
N
AI
TR
Notes:

IN
S
1. The above indicated line sizing criteria are valid for continuous operation. Pressure drop

ID
SK
in bar/km shall be less than 5% of the static absolute pressure for long headers and 10%

ER
for short headers. For intermittent operation, these limits may be relaxed on a case by

ET
case analysis. As far as steam let down stations are concerned, for example, where

M
W
sufficient pressure drop is available, the pressure drop limit of 10% for short headers may

LO
]F
be increased to 30% and the ρV2 limit of 15000 may be increased to 25000.
2)
(C

2. Allowable pressure drop between 0.2 and 0.7 bar/km

E
AN
TH

3. Allowable pressure drop between 0.5 and 1.2 bar/km.

[E

4. In addition, to these criterions, flowing velocity for a noise point of view has to be
EO
D

considered.
F
O
N

5. Maximum velocity shall be determined from ρν² based on vapor/steam density at that
I O
AT

condition.
AD
R

6. Superheated Steam systems between 22 barg and 68 barg

G
P-
-U

(i) 0.01*(P+140)≤∆ P≤0.01*(P+620)

S
AI

Where P in barg, ∆ P in bar/km.

W
RU
0-

Note: Off-plot steam lines should be designed with a pressure drop of 1 bar/km.
75
00

7. ρV2 of 25000 (kg.m-1.s-2) can be considered on a case by case basis for intermittent service,
05
1-

for revamp/adequacy check of existing piping.

02
/2
ul

For Hydraulic analysis of Pipelines, The following requirements shall apply:

/J
27

1) For Dry or non-condensing gas and solids free : Pipelines conveying gas should be sized
so that the normal range of flow velocities is 5 m/s – 10 m/s.

Revision No.: 2 Apr 2019 Document ID: DGS 0000 020 Page 25 of 27
 III
2) For Dry or non-condensing gas and solids free: Continuous operation of gas pipelines

D
N
above 20 m/s shall be avoided.

IA
,I
-I
3) Pipelines conveying a liquid should be sized so that the normal range of flow velocities

N
AI
is 1 m/s – 2 m/s.

TR
IN
4) Continuous operation above 4 m/s shall be avoided for pipelines conveying a liquid;

S
ID
SK
5) Incidental operation of liquid pipelines above 4 m/s shall be evaluated and documented

ER
(e.g., surge analysis);

ET
M
6) Unlined carbon steel pipelines transporting category B liquids containing a separate

W
LO
water phase, even in a small quantity (e.g., 1% water cut), shall not be operated at low
]F
velocities (below 1.5 m/s). This is to prevent water dropout, which may lead to a corrosive
2)
(C

environment:
E
AN

Approval by the COMPANY shall be obtained on the required minimum velocity or

TH
[E

alternative corrosion mitigation measures to be applied.

EO
D

When transporting HC condensate, a minimum velocity of 1.5 m/s (higher in lighter fluids)
F
O

may not be sufficient to prevent water dropout.

N
I O
AT

7) For intelligent pigging operations, a minimum velocity of 1 m/s is recommended unless

AD

stated otherwise by the intelligent pig Manufacturer/Supplier.

R
G
P-

Note: Category B liquid as defined in ISO 1363: Flammable and/or toxic fluids that are liquids
-U

at ambient temperature and at atmospheric pressure conditions. Typical examples are

S
AI
W

petroleum products.
RU
0-
75

14.3 LINE SIZING CRITERIA FOR MIXED PHASE FLUID

00
05

The following criteria are valid for onsite lines sizing. Refer to paragraph 14.4 for offsite and
1-
02

interconnecting lines.
/2
ul
/J
27

For preliminary mixed phase fluid line size calculations, the average density method shall be
used while considering the following criteria:

 vM : 10 to 23 m/s
 v M2 : 5000 to 10000 Pa
Revision No.: 2 Apr 2019 Document ID: DGS 0000 020 Page 26 of 27
 III
 v M3 : 100000 to 150000 kg/s3

D
N
Where vM is the average fluid velocity.

IA
,I
-I
Ultimate checking of flow patterns shall be made using appropriate published charts such as

N
AI
TR
those by G. A. GREGORY & M. FOGARISI.

IN
S
For horizontal and vertical flows, continuous flow patterns should be ensured such as:

ID
SK
 Stratified, annular, bubble, wavy flow patterns, etc. for horizontal lines or slightly sloped.

ER
ET
 Annular or bubble flow, etc. for the vertical lines

M
W
LO
14.4 LINE SIZING CRITERIA FOR OFFSITE LINES
]F
2)
The following criteria are typical and may have to be supported by economical appraisal.
(C
E
AN
TH

LINE TYPE ∆P(BAR/ KM) MAX. VELOCITY

[E

(M/S)
EO

Normal Max
D
F

Long carbon steel water 0.58 1.16 -

O
N

line
I O
AT
AD

- - 2.5 to 3
R
G

Reinforced Concrete
P-
-U

Cylinder Pipe (RCCP)

S
AI

0.2 to 0.3 - 9 to 20
W
RU

Steam condensate
0-
75

15.0 APPENDICES / ATTACHMENTS

(mixture)
00
05

None.
1-
02
/2
ul
/J
27

Revision No.: 2 Apr 2019 Document ID: DGS 0000 020 Page 27 of 27