Here are the design conditions I determined based on the provided process diagram and information:
Line 1 (Reactor to Exchanger):
Design Pressure: 1500 psig
Design Temperature: 400°F
Test Medium: Hydrostatic
Piping Material: Carbon Steel Sch. 80
Insulation Type: A
Insulation Thickness: 2"
Paint Class: B
Line 2 (Exchanger to Separator):
Design Pressure: 1000 psig
Design Temperature: 300°F
Test Medium: Hydrostatic
Piping Material: Carbon Steel Sch. 80
Insulation Type: A
Insulation Thickness: 1.5"
Paint Class: B
Line 3 (Separator to Storage):
Pressure relief devices are important safety components that protect process equipment from overpressure. Standards like the ASME Boiler and Pressure Vessel Code provide guidelines for the proper design, installation, and sizing of relief valves, rupture disks, and other pressure relief devices. These standards help ensure personnel safety and prevent equipment damage in the event excess pressure develops from sources like explosions, fires, or pump failures.
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The document describes the design of a pressure reducing and desuperheater station (PRDS) by a group of mechanical engineering students. It includes the objectives, methodology, design calculations, layout, and components of the PRDS. The group analyzed steam properties, selected valves and layout, designed an inline multi-nozzle desuperheater, and installed and analyzed the PRDS. Calculations were shown for sizing the steam and water pipes, nozzle dimensions, and validating the design was safe. The layout included valves, strainers, gauges and the desuperheater. References were provided for standards and related research.
This internship report summarizes Ali Hassnain's internship at the Scientific & Engineering Services Directorate. The internship covered four departments: Design & Engineering, Fabrication/Production, PWI (Pakistan Welding Institute), and NCNDT (National Center for Non-Destructive Testing). Key activities included design and manufacturing of heat exchangers, pressure vessels, and conducting various welding and non-destructive testing techniques. The report provides an overview of processes used to design, fabricate, weld and test these industrial products.
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This document provides guidelines for determining the design temperature and pressure of equipment and piping for oil and chemical plants. It defines key terms like operating temperature, design temperature, minimum metal temperature, and design pressure. It outlines general criteria for setting design temperature, such as adding 30°C to the maximum operating temperature below 343°C. It also provides special considerations and guidelines for various equipment types. Minimum design metal temperature should be set to avoid material brittleness at low temperatures and pressures.
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This document summarizes a final presentation on four months of training in mechanical engineering. It includes topics on the mechanical department, static equipment, pressure vessels, material selection, failures, software used for calculations, and vessel calculation formulas. Diagrams are presented showing examples of horizontal and vertical pressure vessel design in 3D and 2D.
The document discusses various piping codes and standards. It provides an overview of different ASME B31 codes for different types of piping systems used in power generation, processing plants, transportation of liquids and gases, refrigeration, building services, and slurry transportation. It also summarizes some key aspects covered in ASME B31.3 code for process piping such as scope, exclusions, design pressure, temperature, fluid categories, thickness calculations for pipes, bends, flanges, and other components. The document further discusses welding related topics like preheating, heat treatment, and impact testing requirements.
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Pressure relief devices are important safety components that protect process equipment from overpressure. Standards like the ASME Boiler and Pressure Vessel Code provide guidelines for the proper design, installation, and sizing of relief valves, rupture disks, and other pressure relief devices. These standards help ensure personnel safety and prevent equipment damage in the event excess pressure develops from sources like explosions, fires, or pump failures.
Be project - PRDS (Pressure Reducing And Desuperheater Station)Nikhilesh Mane
The document describes the design of a pressure reducing and desuperheater station (PRDS) by a group of mechanical engineering students. It includes the objectives, methodology, design calculations, layout, and components of the PRDS. The group analyzed steam properties, selected valves and layout, designed an inline multi-nozzle desuperheater, and installed and analyzed the PRDS. Calculations were shown for sizing the steam and water pipes, nozzle dimensions, and validating the design was safe. The layout included valves, strainers, gauges and the desuperheater. References were provided for standards and related research.
This internship report summarizes Ali Hassnain's internship at the Scientific & Engineering Services Directorate. The internship covered four departments: Design & Engineering, Fabrication/Production, PWI (Pakistan Welding Institute), and NCNDT (National Center for Non-Destructive Testing). Key activities included design and manufacturing of heat exchangers, pressure vessels, and conducting various welding and non-destructive testing techniques. The report provides an overview of processes used to design, fabricate, weld and test these industrial products.
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The document discusses various piping codes and standards. It provides an overview of different ASME B31 codes for different types of piping systems used in power generation, processing plants, transportation of liquids and gases, refrigeration, building services, and slurry transportation. It also summarizes some key aspects covered in ASME B31.3 code for process piping such as scope, exclusions, design pressure, temperature, fluid categories, thickness calculations for pipes, bends, flanges, and other components. The document further discusses welding related topics like preheating, heat treatment, and impact testing requirements.
This document provides an overview of key concepts in process design including block diagrams (BD), process flow diagrams (PFD), piping and instrumentation diagrams (PID), standards, distributed control systems (DCS), and icon conventions. It discusses how BDs are developed into more detailed PFDs and PIDs. Standards that are normative and informative for process design are outlined. The goals of PFDs to present process information clearly and concisely are described. Isolation, insulation, heat tracing, and control systems are also briefly covered.
General Air Products, Inc. - Air Compressor Selection and Design for Dry Pipe Fire Sprinkler Systems. This presentation is designed to educate fire sprinkler professionals, especially designers, engineers and technicians on the fundamentals of air compressor design, function and proper sizing and selection. For questions on this presentation please contact us at 800-345-8207 or visit our web site www.generalairproducts.com
1. The cooling load calculation of an auditorium is done using the CLTD method and duct design is carried out using the equal friction method.
2. The calculated frictional pressure drop is less than values typically used in industry, allowing for increased duct diameters and reduced losses of static and velocity pressure.
3. CFD software is used to analyze air flow in ducts and elbows, helping to identify eddies and optimize duct shapes and velocities to minimize pressure losses.
This document provides an overview of early sizing considerations for pressure safety valves (PSVs). It defines important terminology related to PSVs and describes the types and operating principles of conventional, balanced bellow, and pilot-operated PSVs. The document outlines the procedure for early PSV sizing, including identifying capacity requirements, applicable standards, and inter-discipline interfaces. It also notes lessons learned regarding material selection and potential failure modes of bellow-type PSVs.
This document provides an overview of early sizing considerations for pressure safety valves (PSVs). It discusses important terminologies, types of PSVs, sizing basis, applicable standards, and the early sizing procedure. The procedure involves selecting possible orifice areas to meet capacity requirements. The objectives of early sizing are to remove holds in piping and instrumentation diagrams and allow early release of piping designs. The document also discusses inter-discipline interfaces, lessons learned, and quality management system documents related to PSV sizing.
This document discusses fan concept and analysis in the cement industry. It provides information on static pressure, system resistance, gas properties, density correction factors, barometric pressure, and pitot tube measurements. It also discusses fan classifications, differences between fans and blowers/compressors, major process fans, system curves, fan laws, factors affecting fan performance, and calculations for fan efficiency, head, power savings, and damper losses. Case studies are presented on ESP exhaust fan retrofitting opportunities to increase efficiency.
This document discusses fan concept and analysis in the cement industry. It provides information on static pressure, system resistance, gas properties, density correction factors, barometric pressure, and pitot tube measurements. It also discusses fan classifications, differences between fans and blowers/compressors, major process fans, system curves, fan laws, factors affecting fan performance, and calculations for fan efficiency, head, power savings, and damper losses. Case studies are presented on ESP exhaust fan retrofitting opportunities to increase efficiency.
Generally Pumps classification done on the basis of its mechanical configurat...ShriPrakash33
Pumps simplify the transportation of water and other fluids, making them very useful in all types of buildings - residential, commercial, and industrial. For example, fire pumps provide a pressurized water supply for firefighters and automatic sprinklers, water booster pumps deliver potable water to upper floors in tall buildings, and hydronic pumps are used in HVAC systems that use water to deliver space heating and cooling.
TYPES OF PUMPS AND THEIR WORKING PRINCIPLES
Generally Pumps classification done on the basis of its mechanical configuration and their working principle. Classification of pumps mainly divided into two major categories:
Dynamic pumps / Kinetic pumps
Dynamic pumps impart velocity and pressure to the fluid as it moves past or through the pump impeller and, subsequently, convert some of that velocity into additional pressure. It is also called Kinetic pumps Kinetic pumps are subdivided into two major groups and they are centrifugal pumps and positive displacement pumps.
Classification of Dynamic Pumps
1.1 Centrifugal Pumps
A centrifugal pump is a rotating machine in which flow and pressure are generated dynamically. The energy changes occur by virtue of two main parts of the pump, the impeller and the volute or casing. The function of the casing is to collect the liquid discharged by the impeller and to convert some of the kinetic (velocity) energy into pressure energy.
1.2 Vertical Pumps
Vertical pumps were originally developed for well pumping. The bore size of the well limits the outside diameter of the pump and so controls the overall pump design.2.) Displacement Pumps / Positive displacement pumps
2. Displacement Pumps / Positive displacement pumps
Positive displacement pumps, the moving element (piston, plunger, rotor, lobe, or gear) displaces the liquid from the pump casing (or cylinder) and, at the same time, raises the pressure of the liquid. So displacement pump does not develop pressure; it only produces a flow of fluid.
Classification of Displacement Pumps
2.1 Reciprocating pumps
In a reciprocating pump, a piston or plunger moves up and down. During the suction stroke, the pump cylinder fills with fresh liquid, and the discharge stroke displaces it through a check valve into the discharge line. Reciprocating pumps can develop very high pressures. Plunger, piston and diaphragm pumps are under these type of pumps.
2.2 Rotary Type Pumps
The pump rotor of rotary pumps displaces the liquid either by rotating or by a rotating and orbiting motion. The rotary pump mechanisms consisting of a casing with closely fitted cams, lobes, or vanes, that provide a means for conveying a fluid. Vane, gear, and lobe pumps are positive displacement rotary pumps.
2.3 Pneumatic Pumps
Compressed air is used to move the liquid in pneumatic pumps. In pneumatic ejectors, compressed air displaces the liquid from a gravity-fed pressure vessel through a check valve into the discharge line in a series of surges spaced by the time required.
The document summarizes modifications made to a two-stage centrifugal compressor to convert it into a single-stage compressor suitable for laboratory testing. Key modifications included replacing the refrigerant fluid with air, installing an external drive motor instead of the internal hermetic motor, and adding static pressure taps to the vaneless diffuser and volute casing. Experimental results showed the compressor was operating off-design, with the vaneless diffuser and volute being too large for the mass flow rates tested. Pressure maps revealed distortion in the diffuser and volute due to the tongue region, reducing stage performance.
1. Ducts are sized using pressure drop and velocity criteria. The duct diameter is selected based on the air volume and desired constant pressure drop. Duct velocities are limited based on building type to control noise.
2. Elbows, T-branches, Y-branches, and reducers (transitions) are examples of duct fittings.
3. Volume dampers and fire dampers are examples of duct accessories.
4. Allowable duct velocities vary from 2-12 m/s depending on the building type, with typical office spaces around 6 m/s.
5. Supply ducts deliver conditioned air to spaces, return ducts remove air from spaces, and exhaust ducts remove
Ai Ch E Overpressure Protection Trainingernestvictor
The document provides an overview of overpressure protection and relief system design. It discusses key concepts such as causes of overpressure, applicable codes and standards, the relief system design process, relief device terminology, and methods for determining relief loads from scenarios such as blocked outlets, thermal expansion, external fires, and automatic control failures. The document is intended to educate engineers on important considerations for properly sizing and designing pressure relief systems.
The document discusses seismic qualification of pressure vessels and strainers according to ASME and PNAE codes. It provides an overview of typical workflows for seismic qualification, including creating CAD and FE models. Load cases like dead weight, pressure, thermal loads, operational basis earthquake and safe shutdown earthquake are considered. Allowable stress intensities and acceptable limits for different service levels are compared between the codes. A case study demonstrates seismic analysis of a tank for various load combinations and service levels. Results are shown to comply with allowable limits from both ASME and PNAE codes.
Pressure piping thickness and flange rating calculation 2Thành Lý Phạm
Using a simple script and Generic 4D chart combination in Flownex, process engineers can now account for pressure piping wall thickness requirements and flange ratings during thermo-fluid design. This extends Flownex's design capability and may reduce rework by ensuring the correct pipe schedules and flange ratings are used early in design. The script implements international piping standards to calculate thickness and ratings, sources material property data from Generic 4D charts, and reports warnings to users.
Design and Analysis of Pressure Vessel Using Finite Element MethodIJLT EMAS
Pressure vessel is used to carry liquids such as petrol,
kerosene, aviation fuel etc and these fuel tanks are used to
transport fuel. Finite element method is a mathematical
technique used to design a fuel carrying vessel and performing
the stress analysis. In this the geometrical model is created and
the model is sub divided into smaller elements. It is subjected to
internal pressure and these Boundary conditions are applied at
specified points. The aim of this paper is to design a model and
analysis of fuel carrying tank using finite element analysis
software and also select a proper material composition for
pressure vessel.
Designing is validated according to maximum principal stress
theory and Distortion theory by taking design factor or factor of
safety. The comparisons also made between the calculation
results and software results.
This document provides a description of the air compressed network for a concrete factory. It will include one screw compressor to supply air to internal vibrators and cleaning works at a maximum consumption of 8,100 liters per minute at 6 bar pressure. The network will consist of distribution lines from a 3,000 liter storage tank to manifolds and supply points along pillar rows. It must be installed according to safety standards and include a two-year warranty covering manufacturing defects and maintenance of the compressor, dryer, and filters. The supplier must provide assembly details, delivery timeline, and payment terms in their offer.
This document discusses the design of piping and instrumentation diagrams (P&IDs) for chemical processes. It provides guidance on:
1. The components that should be included on a P&ID such as equipment, pipes, valves, instruments, and their identification numbers.
2. Standard symbols used to represent these components on P&IDs according to British and other standards.
3. Selection criteria and examples of pump, valve, and pipe fitting types that are important to consider for the piping design.
4. Equations and charts for calculating pressure drops in pipelines due to friction and other factors.
This presentation discusses key considerations for designing production casing that will maintain well integrity and optimize costs while allowing for hydraulic fracturing. It outlines factors to consider like mud weights, formation pressures and fracture gradients. It also covers casing design loads, pipe performance metrics, material selection standards, connection types, and stimulation design requirements. Proper casing design requires selecting pipe that meets minimum design safety factors for loads like internal pressure and tension during fracturing when factors like fluid gradients, pipe ratings, and temperature effects are accounted for.
This document outlines the design of the HVAC system for the first floor of a science and technology hospital in Sana'a, Yemen. It discusses the building description, cooling load calculations using both manual and technical methods, duct design including duct sizing and selection of fans and accessories, and pipe design for the chilled water system. The technical method of load calculation in the REVIT program was found to be more accurate than the manual method. Ductwork was designed and fans were selected to meet the required air flows. A closed two-pipe direct return chilled water system was chosen for temperature control.
Pumps are widely used in process plants to transfer fluid from one point to the other and the Process Engineer is often required to specify the correct size of pumps that will optimize system performance. Though pump sizing can easily be performed using software such as Pipe-Flo®, understanding the basic principle will not only aid one to better interpret the results obtained by pump sizing software but also to better design pumps. Centrifugal pump sizing overview is presented in this tutorial.
1. The document provides guidelines for connecting a building's chilled water system to the campus's central district cooling system.
2. Key requirements include using plate and frame heat exchangers if pressure limits are exceeded, proper placement and control of temperature and flow sensors, and coordination with the Chilled Water Engineer for components like the bridge controller and return temperature control valve.
3. The designer must provide detailed tables with design parameters to ensure the bridge connection and controls will operate as intended over the full range of loads and pressure conditions.
Understanding Inductive Bias in Machine LearningSUTEJAS
This presentation explores the concept of inductive bias in machine learning. It explains how algorithms come with built-in assumptions and preferences that guide the learning process. You'll learn about the different types of inductive bias and how they can impact the performance and generalizability of machine learning models.
The presentation also covers the positive and negative aspects of inductive bias, along with strategies for mitigating potential drawbacks. We'll explore examples of how bias manifests in algorithms like neural networks and decision trees.
By understanding inductive bias, you can gain valuable insights into how machine learning models work and make informed decisions when building and deploying them.
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1. The cooling load calculation of an auditorium is done using the CLTD method and duct design is carried out using the equal friction method.
2. The calculated frictional pressure drop is less than values typically used in industry, allowing for increased duct diameters and reduced losses of static and velocity pressure.
3. CFD software is used to analyze air flow in ducts and elbows, helping to identify eddies and optimize duct shapes and velocities to minimize pressure losses.
This document provides an overview of early sizing considerations for pressure safety valves (PSVs). It defines important terminology related to PSVs and describes the types and operating principles of conventional, balanced bellow, and pilot-operated PSVs. The document outlines the procedure for early PSV sizing, including identifying capacity requirements, applicable standards, and inter-discipline interfaces. It also notes lessons learned regarding material selection and potential failure modes of bellow-type PSVs.
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Generally Pumps classification done on the basis of its mechanical configurat...ShriPrakash33
Pumps simplify the transportation of water and other fluids, making them very useful in all types of buildings - residential, commercial, and industrial. For example, fire pumps provide a pressurized water supply for firefighters and automatic sprinklers, water booster pumps deliver potable water to upper floors in tall buildings, and hydronic pumps are used in HVAC systems that use water to deliver space heating and cooling.
TYPES OF PUMPS AND THEIR WORKING PRINCIPLES
Generally Pumps classification done on the basis of its mechanical configuration and their working principle. Classification of pumps mainly divided into two major categories:
Dynamic pumps / Kinetic pumps
Dynamic pumps impart velocity and pressure to the fluid as it moves past or through the pump impeller and, subsequently, convert some of that velocity into additional pressure. It is also called Kinetic pumps Kinetic pumps are subdivided into two major groups and they are centrifugal pumps and positive displacement pumps.
Classification of Dynamic Pumps
1.1 Centrifugal Pumps
A centrifugal pump is a rotating machine in which flow and pressure are generated dynamically. The energy changes occur by virtue of two main parts of the pump, the impeller and the volute or casing. The function of the casing is to collect the liquid discharged by the impeller and to convert some of the kinetic (velocity) energy into pressure energy.
1.2 Vertical Pumps
Vertical pumps were originally developed for well pumping. The bore size of the well limits the outside diameter of the pump and so controls the overall pump design.2.) Displacement Pumps / Positive displacement pumps
2. Displacement Pumps / Positive displacement pumps
Positive displacement pumps, the moving element (piston, plunger, rotor, lobe, or gear) displaces the liquid from the pump casing (or cylinder) and, at the same time, raises the pressure of the liquid. So displacement pump does not develop pressure; it only produces a flow of fluid.
Classification of Displacement Pumps
2.1 Reciprocating pumps
In a reciprocating pump, a piston or plunger moves up and down. During the suction stroke, the pump cylinder fills with fresh liquid, and the discharge stroke displaces it through a check valve into the discharge line. Reciprocating pumps can develop very high pressures. Plunger, piston and diaphragm pumps are under these type of pumps.
2.2 Rotary Type Pumps
The pump rotor of rotary pumps displaces the liquid either by rotating or by a rotating and orbiting motion. The rotary pump mechanisms consisting of a casing with closely fitted cams, lobes, or vanes, that provide a means for conveying a fluid. Vane, gear, and lobe pumps are positive displacement rotary pumps.
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Compressed air is used to move the liquid in pneumatic pumps. In pneumatic ejectors, compressed air displaces the liquid from a gravity-fed pressure vessel through a check valve into the discharge line in a series of surges spaced by the time required.
The document summarizes modifications made to a two-stage centrifugal compressor to convert it into a single-stage compressor suitable for laboratory testing. Key modifications included replacing the refrigerant fluid with air, installing an external drive motor instead of the internal hermetic motor, and adding static pressure taps to the vaneless diffuser and volute casing. Experimental results showed the compressor was operating off-design, with the vaneless diffuser and volute being too large for the mass flow rates tested. Pressure maps revealed distortion in the diffuser and volute due to the tongue region, reducing stage performance.
1. Ducts are sized using pressure drop and velocity criteria. The duct diameter is selected based on the air volume and desired constant pressure drop. Duct velocities are limited based on building type to control noise.
2. Elbows, T-branches, Y-branches, and reducers (transitions) are examples of duct fittings.
3. Volume dampers and fire dampers are examples of duct accessories.
4. Allowable duct velocities vary from 2-12 m/s depending on the building type, with typical office spaces around 6 m/s.
5. Supply ducts deliver conditioned air to spaces, return ducts remove air from spaces, and exhaust ducts remove
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Pressure vessel is used to carry liquids such as petrol,
kerosene, aviation fuel etc and these fuel tanks are used to
transport fuel. Finite element method is a mathematical
technique used to design a fuel carrying vessel and performing
the stress analysis. In this the geometrical model is created and
the model is sub divided into smaller elements. It is subjected to
internal pressure and these Boundary conditions are applied at
specified points. The aim of this paper is to design a model and
analysis of fuel carrying tank using finite element analysis
software and also select a proper material composition for
pressure vessel.
Designing is validated according to maximum principal stress
theory and Distortion theory by taking design factor or factor of
safety. The comparisons also made between the calculation
results and software results.
This document provides a description of the air compressed network for a concrete factory. It will include one screw compressor to supply air to internal vibrators and cleaning works at a maximum consumption of 8,100 liters per minute at 6 bar pressure. The network will consist of distribution lines from a 3,000 liter storage tank to manifolds and supply points along pillar rows. It must be installed according to safety standards and include a two-year warranty covering manufacturing defects and maintenance of the compressor, dryer, and filters. The supplier must provide assembly details, delivery timeline, and payment terms in their offer.
This document discusses the design of piping and instrumentation diagrams (P&IDs) for chemical processes. It provides guidance on:
1. The components that should be included on a P&ID such as equipment, pipes, valves, instruments, and their identification numbers.
2. Standard symbols used to represent these components on P&IDs according to British and other standards.
3. Selection criteria and examples of pump, valve, and pipe fitting types that are important to consider for the piping design.
4. Equations and charts for calculating pressure drops in pipelines due to friction and other factors.
This presentation discusses key considerations for designing production casing that will maintain well integrity and optimize costs while allowing for hydraulic fracturing. It outlines factors to consider like mud weights, formation pressures and fracture gradients. It also covers casing design loads, pipe performance metrics, material selection standards, connection types, and stimulation design requirements. Proper casing design requires selecting pipe that meets minimum design safety factors for loads like internal pressure and tension during fracturing when factors like fluid gradients, pipe ratings, and temperature effects are accounted for.
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Pumps are widely used in process plants to transfer fluid from one point to the other and the Process Engineer is often required to specify the correct size of pumps that will optimize system performance. Though pump sizing can easily be performed using software such as Pipe-Flo®, understanding the basic principle will not only aid one to better interpret the results obtained by pump sizing software but also to better design pumps. Centrifugal pump sizing overview is presented in this tutorial.
1. The document provides guidelines for connecting a building's chilled water system to the campus's central district cooling system.
2. Key requirements include using plate and frame heat exchangers if pressure limits are exceeded, proper placement and control of temperature and flow sensors, and coordination with the Chilled Water Engineer for components like the bridge controller and return temperature control valve.
3. The designer must provide detailed tables with design parameters to ensure the bridge connection and controls will operate as intended over the full range of loads and pressure conditions.
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2. 2
Overview
Design Conditions Work Process
• Establish design conditions
philosophy
• Design pressure considerations
• Confirm DP/MOT margins for
equipment
• Create DP/MOT mark-up
• Hold Design Conditions meeting
• Set equipment design conditions
• Develop piping design conditions
– Design Codes
– Short term questions
• Set piping design conditions
Input Docs
PFD
Process
release
H&MB
Go-By Jobs
MOC/MSD/
Alloy mark-up
Index of Piping
Material
Classes
Deliverables
Equipment Design
Data/Connection
summaries. Mark
up analytical
sketches.
P&ID Mark-ups
Line list
Systems
comments on pipe
specs
4. 4
Design Pressure Philosophies
The design pressure basis is developed in conjunction with the
Overpressure Protection and Vent Philosophy for each job.
Standard Design Pressure Philosophy
When equipment is protected by a relief device, KBR’s standard
design pressure philosophy is to set the design pressure of the
equipment equal to the highest pressure expected during normal
operation plus the margin required for proper operation of the relief
device. The relief device is sized to protect the equipment during
all upset conditions.
Alternate Design Pressure Philosophy
When equipment is protected by a relief device, KBR’s alternate
design pressure philosophy it to set the design pressure of the
equipment equal to the highest pressure expected during normal
operation and non-fire upset conditions plus the margin required
for proper operation of the relief device. The relief device is sized
to protect the equipment for the fire emergency only.
5. 5
Specific Design Pressure Considerations
1. For Centrifugal pump circuits-
Equipment upstream of control valve or a block valve.
DP = Shut-off head (SEM 1-301)
Equipment downstream of control valve:
DP is determined based on operating factors
2. Refrigeration Systems-
Systems should consider the long term settling out
pressure
3. Equipment discharging to a closed relief system-
No official ‘minimum’ standard design pressure exists.
However, for typical closed discharge systems back
pressure problems usually occur if the minimum
design pressure is less than 50 psig.
6. 6
Specific Design Pressure Considerations
4. Pilot-Operated Relief Valve-
KBR standard practice is to maintain the same margins
as for a conventional PSV. Systems may reduce
margins only with approval of Systems CTE (SEM 1-301
3.2.1).
5. Historically, the low pressure side of heat exchangers
were often designed for a fraction (two-thirds originally,
subsequently modified to ten-thirteenths) of the high
pressure side to take advantage of API recommended
practice concerning a tube failure scenario.
However, KBR’s current interpretation of ASME code,
per SEM 1-303 Section 4.2.1, is that designing for this
fraction of the high side pressure does not alleviate the
need to evaluate the effects of tube rupture on the low
pressure side system. Usually, the tube failure scenario
is not controlling because of the ability to dissipate the
flow into the low pressure system without causing
overpressure.
7. 7
6. KBR normally does not design vessels to withstand vacuum
conditions resulting from improper operation of equipment.
The requirement to design equipment for full vacuum
caused by improper operation must be specified by the
owner. Sometimes protective devices such as vacuum
breakers may be provided to prevent the development of
excessive vacuum in a vessel.
8. 8
Design Pressure Margins
Pressure relief devices require some margin
between MNOP (maximum normal operating
pressure) and set pressure due to the
mechanical characteristics of the device.
Pressure relief valves also require a margin
above the MNOP to account for blowdown
which enables the device to reseat. This is to
prevent leakage or simmering/chattering of
the device.
9. 9
Design Pressure Margins
Vessels that operate at pressures greater than
atmospheric (Non-Boiler Code)(ASME VIII)
If protected by a pressure relief valve: MNOP =
Maximum Normal Operating Pressure
MNOP + 5 psi (DPmin < 50 psig)
MNOP * 1.1 (50 < DPmin < 1000 psig)
MNOP * 1.07 (DPmin > 1000 psig)
If protected by a pressure relieving device other than a
pressure relief valve (rupture disk, etc):
Minimum design pressure = Maximum value of
MNOP * 1.1
MNOP + 10 psi
MNOP * (margin recommended by vendor)
10. 10
Design Pressure Margins
Vessels that operate at atmospheric pressure up to
a maximum of 2.5 psig
- Design per API 650
- DP = MAWP calculated by Vessel Mechanical or
tank vendor (not set by Systems)
Large storage vessels that operate at pressures
greater than 2.5 psig but less than or equal to 15
psig
- Design per API 620
- If protected by a pilot operated relief valve:
DP = Maximum value of:
MNOP + 0.5 psi
MNOP * 1.1
11. 11
Design Pressure Margins
Surface condensers in steam service
DP = 15 psig and FV
Cooling water side of exchangers
DP = Maximum value of:
MNOP * 1.1
Cooling water pump shut-off pressure
Use 150 psig and full vacuum minimum design
pressure for exchanger sides in cooling water service
because of possible transient conditions.
12. 12
Design Pressure Margins
All other exchangers
If protected by a pressure relief valve, Design Pressure =
MNOP + 5 psi (DPmin ≤ 50 psig)
MNOP × 1.10 (50 DPmin ≤ 1000 psig)
MNOP × 1.07 (DPmin 1000 psig)
If protected by a pressure relieving device other than a PRV
(i.e. rupture disk), Design Pressure =
Maximum value of:
MNOP × (Margin recommended by vendor)
MNOP + 10 psi
MNOP × 1.1
13. 13
Design Pressure Margins
Machinery
Systems does not set design pressures for machinery.
Systems only provides the input information used by the
machinery group in determining the design pressure for
that equipment.
14. 14
Determine Equipment Design Conditions
The recommended method for developing design
pressures is to mark up a copy of the PFDs with
proposed pressure relief device locations and
equipment design pressures. Thus, an overall view
is developed of the potential relief scenarios, the way
equipment is protected from overpressure, and the
equipment design conditions.
15. 15
Effect of PRV Location on Design
Pressure
What is design pressure?
REACTOR
MNOP = 1200
MNOP(1.1)=1320
PROCESS
COOLER
MNOP=1100
MNOP(1.1)=1210
MIXER
MNOP=1000
MNOP(1.1)=1100
OXIDISER
MNOP=900
MNOP(1.1)=990
SURFACE
CONDENSER
MNOP=800
MNOP(1.1)=880
17. 17
Maximum & Minimum Temp at Design Pressure
• Systems is responsible for specifying the
maximum temperature [Tmax] coincident with
the design pressure for equipment design
– Equipment containing liquids at their bubble point:
• Maximum temperature will be the boiling point at
design pressure
– Maximum temperature must consider process
upsets and allowance for control variation.
– When specifying maximum temperature, be aware
of flange ratings (Tmax, DP cannot exceed flange
rating).
– Minimum operating temperature at design
pressure is provided if the lowest operating
temperature is below the minimum design ambient
temperature
18. 18
Depressuring Conditions
• Applicable in light hydrocarbon services
• Equipment can be depressurized and thereby auto
refrigerate to temperatures lower than the minimum
ambient design temperature
• Coincident temperatures and pressures from 80% of
design pressure down to atmospheric
• Used to determine MDMT ( minimum metal design
temperature)
19. 19
Design Data and Connection Summary
Systems is responsible for communicating equipment
design data and connecting line data to other work
groups. This information is normally provided on the
Design Data and Connection Summary.
Types of Equipment Connection Summaries
• Vessel Design Data and Connection Summary
• Exchanger Design Data and Connection Summary
• Furnace Connection Summary
20. 20
Purposes of Equipment Connection
Summaries
1. To advise piping design and vessel mechanical of
the sizes and specifications for piping connecting to
equipment.
2. Provide size and rating of utility nozzles (vents,
drains, steam out, etc.)
3. Convey mechanical design conditions to
mechanical groups
– Design Pressure
– Maximum operating temperature
– Minimum operating temperature (if required)
– Depressuring conditions (used for MDMT)
– Alternate design conditions (must be coincident)
23. 23
Determination of Design Pressure and
Temperature
• Design temperature
Fluid temperature during the most severe condition
expected during operation or upset (SEM 1-602,
Sections 3.2 and 4.0)
• Design pressure
Non pumped piping systems (SEM 1-602, Section
6.1)
Design pressure should be the design pressure of
the vessel to which the piping is attached plus the
static head of the liquid at the lowest point of the
piping.
24. 24
Determination of Design Pressure and
Temperature
Pumped piping systems
– Centrifugal pump ( SEM 1-602, Section 6.2.2)
The piping design pressure from the pump discharge through the
last downstream block valve should be the greater of (1) or (2) below:
(1) Dp = max suction pressure ( during pump shutoff)
+ max static head ( at pump nozzle)
+ shutoff differential
(2) Dp = max suction press (Suction vessel at its max. relieving
pressure)
+ max. static head ( at pump nozzle)
+ normal pump differential
– Positive displacement pump ( SEM 1-602, Section 6.2.3)
In general, discharge piping is protected by a relief valve. The relief valve
should be set with sufficient margin on top of the operating pressure of
the discharge pipe. Margin will vary based on the type of positive
displacement pump.
25. 25
Line List components
• Design Pressure and Temperature
– These are defined as the coincident conditions that
produce the highest stress in the pipe.
– Used by Piping Design (isometrics), Systems (wall
thickness calcs, pipe spec selection) and Piping
Mechanical (stress analysis).
26. 26
Line List components
• Test Medium / Test Pressure
– Almost always hydrostatic. Consult with the work group leader for lines
that may be pneumatically tested or for services where a leak test is
permissible. Test pressures are calculated by the line list program based
on the ASME code. Test pressure information is used by Piping Design
(isometrics), Piping Engineering, Civil (pipe support loads) and by
Construction and Plant Services groups (field pressure testing).
– Hydrotest Pressure
• ASME B31.3 (Per SEM 1-302, Section 5.1)
• ASME B31.1 (Per SEM 1-302, Section 4.2)
– Pneumatic Test
• ASME B31.3 (Per SEM 1-302, Section 5.3)
• ASME B31.1 – Not Allowed
27. 27
Line List components
• Piping Material
– The design conditions of the line shall be used in
selecting the piping material ( also called piping
class).
– The metallurgy section of the Chief engineer’s office
alloy mark-up determines the use of special or alloy
piping in respect to factors such as corrosion, erosion,
and hydrogen attack.
– The pipe class selected shall be based on using the
most economical piping material that will resist the
limiting conditions of the service.
28. 28
Line List components
• Schedule (wall thickness)
– Taken from the piping class, this is based on the
coincident pressure and temperature limits set for
the class
• Flexibility Temperature
– Defined as the extreme highest (or lowest) temp
the pipe will experience after installation. Not
necessarily coincident with design pressure; can
be induced by environmental considerations (e.g.
solar radiation temp). Used by Piping Mechanical
(stress analysis, thermal displacement)
29. 29
Line List components
• Insulation Temperature / Thickness & Paint Class
( SEM 1-602, Section 10)
– Insulation thickness is based on the operating
temperature and pipe size specified and reported
by the program as a look up feature.
– The paint class is also determined by the program
and based on the max. normal operating
temperature. Selection must also take into
account the flex temperature.( SEM 1-602, Section
3.6)
– Otherwise, they are taken from the V-Class
Summary (for paint codes and insulation codes
based on operating conditions and materials of
construction) or client specifications.
30. 30
Piping Line List Generation
• The following line data must be shown on
the P&IDs
– Line number (ID)
– Size
– Class (spec)
– Design Code
– Insulation Temperature
– Insulation Type
– Special Requirements (remarks - optional)
31. 31
Piping Line List Generation
Procedure to generate Line List Report:
• Engineer marks up P&ID with line list
information indicated above and gives to CAD
designer to incorporate.
• Engineer (usually P&ID Coordinator or the
dedicated CAD designer) enters the conditions
for the design codes into Design Code Manager.
32. 32
Piping Line List Generation
• After incorporating the mark-ups, the
designer propagates the P&ID. During
propagation, PDS stores the information into
the database and looks up the insulation
thickness from the tables.
.
• Calculation routines determine the test
pressure and paint code for each line and
also check that the specified design
conditions are within the allowable flange
ratings for the assigned pipe spec. The
routine also produces a Checker’s Report
that lists all problems, errors and warning
messages.
33. 33
Piping Line List Generation
• Once the above routine is complete, the Line
List Report is run. All relevant data from
P&IDs, including remarks, as well as results
from the calculation and look up routine, is
reported in a specified line list format and can
be printed.
35. 35
Design Codes
• Groups of 3 letters that serve as a reference tag
to data in the database. Each design code has
a defined set of data. Design codes are used as
a shorthand method of assigning the same
design conditions to a multiple set of pipes or
pipe segments.
36. 36
Design Codes
• A design code is defined by the following
components:
– Design Pressure
– Design Temperature
– Flex Temperature High
– Flex Temperature Low (if required)
– Fluid Phase
– Test Medium
– Percentage Full Vacuum (if required)
37. 37
Design Codes
• Usually the letters of a design code have no specific
meaning, with the exception of utility systems where it is
common practice to assign logical letters. Hence design
codes in utility services are assigned a “U” as a starting
letter, followed by a recognizable pair of letters based on
the service. Examples of these are:
– UHS - high pressure steam
– UCW - cooling water
– UPA - plant air
• A block of letters is normally assigned to each process or
utility area for allocation of design codes at the start of a
project.
38. 38
Design Codes
• Ground rules for design codes:
1. One design code cannot be assigned 2 sets of
conditions, however, 2 or more design codes can have
the same conditions.
2. A design code, once assigned, should not be deleted
(since it may have been used by others in a different
area and also because there are plentiful codes
available).
3. Once assigned, the conditions of a design code
should not be changed (for the same reasons indicated
in 2 above).
40. 40
Homework
Based upon the following portion of an annotated process
diagram, determine the design conditions.
Also complete a Pipeline Nomenclature, on the enclosed
forms, for all of the lines shown on the process diagram.
Consider these lines to be governed by ASME B31.3 and that
the piping material should be carbon steel.
For reference there is included a V Class Summary (pages 1-
10) which has the Insulation Type Codes defined, the
Insulation Thickness Tables, and the Piping Paint Codes.
Also for reference are two pages of Allowable Stresses from
ASME B31.3. Use the Piping Material Specifications given in
the class handouts.
This homework will be submitted to Instructor
41. 41
Annotated Process Diagram
101-E
101-F
101-J
M
P-106-4"
P-105-4"
102-C
TOWER
P:
3 PSI
P-101-18"
P-102-8"
NORMAL T = 110 F
104-C
P-107-4"
MAX NORMAL TEMP = 451 F
MAX NORMAL
TEMP = 190 F
MAX NORMAL TEMP:
110 F
STATIC
HEAD TO
MAX. LIQ.
LEVEL:
5 PSI
P-103-8"
P-104-6"
STATIC HEAD
TO INLET: 20 PSI
CALCULATED
PUMP SHUTOFF
PRESS: 610 PSIG
CALCULATED MAX.
SUCTION PRESS: 570 PSIG
MAX OPERATING
PRESS: 500 PSIG
@ 200 F
CW
PROCESS
FEED
MP STEAM