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GENERAL SPECIFICATIONS FOR

LINESIZING DESIGN BASIS.

1.0 GENERAL INFORMATION.

These specifications cover guidelines for Line sizing for Process Plants and Offsite and Utilities.

2.0 Piping Engineering Hydraulics

· Liquid Hydraulics.

· Vapour Hydraulics.

· Mixed Phase Hydraulics.

2.01 LIQUID HYDRAULICS.

Piping systems should be designed taking into consideration capital cost versus operating costs and with
due allowance for noise erosion and corrosion limitations.

The following tables are to be used as a guide for the sizing of pipe lines in liquid service. Line sizing
should satisfy both the pressure drop and the velocity criteria.

Recommended Velocity and Maximum D P for Carbon Steel Liquid Lines

Liquid Lines in Process and Equipment Service

Sr. Type of Service Velocity Maximum D P

No. ft/sec. m/sec. psi/100ft kg/cm2/100m

1. General recommendation 5-15 1.5-4.6 4 0.92

2. Laminar Flow 4-15 1.2-1.5

3. Turbulent Flow

Liquid density

100 lb/ft3 1602 5-8 1.5-2.4

kg/cm3

50 lb/ft3 801 kg/cm3 6-10 1.8-3.0

20 lb/ft3 320 kg/cm3 10-15 3.0-4.6

4. Pump Suction

Boiling Liquid 2-6 0.6-1.8 0.5 0.115

Non-boiling liquids 4-8 1.2-2.4 1 0.23

5. Pump Discharge

0 - 250 0 - 57 6-8 1.8-2.4 6 1.38

gpm m3/hr

250-700 57-159 8-10 2.4-3 4 0.92

gpm m3/hr

>700 gpm >159m3/hr 10-15 3-4.6 2 0.46

6. Bottoms Outlet 4-6 1.2-1.8 0.6 0.14

7. Reboiler Trapout 1-4 0.3-1.2 0.15 0.035

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8. Liquid from Condensor 3-6 0.9-1.8 0.5-0.11

9. Liquid to Chillers 4-6 1.2-1.8

10. Refrigerant Lines 2-4 0.6-1.2 0.4 0.09

11. Gravity Run LInes 3-8 0.9-2.4 0.4 0.09

12. Liquid Feed to Towers 4-6 1.2-1.8

WATER LINES

Sr. Type of Service Velocity Maximum D P

No. ft/sec. m/sec. psi/100ft kg/cm2/100m

1. General Service 2-16 0.6-4.9 2 0.46

Diameter, inches

1 2-3 0.6-0.9

2 3-4.5 0.9-1.4

4 5-7 1.5-2.1

6 7-9 2.1-2.7

8 8-10 2.4-3.0

10 10-12 3.0-3.7

12 10-14 3.0-4.3

16 10-15 3.0-4.6

20 and up 10-16 3.0-4.9

2. Pump Suction and Drain 4-7 1.2-2.1

3. Pump Discharge 5-10 1.5-3.0

4. Boiler Feed 8-15 2.4-4.6

5. Refinery Water Lines 2-5 0.6-1.5 2.5 0.58

6. Cooling Water 12-16 3.7-4.9 2 0.46

7. From Condensor 3-5 0.9-1.5

RECOMMENDED VELOCITY AND MAXIMUM D P FOR CARBON STEEL VAPOR LINES

VAPOR LINES IN PROCESS AND EQUIPMENT SERVICE

Sr. Type of Service Velocity Maximum D P

No. ft/sec. m/sec. psi/100ft kg/cm2/

100m

1. General Recommendation

Pressure Level

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psig kg/cm2

P > 500 P > 35.1 2.0 0.46

200<P<=500 14.1<P<=35.1 1.5 0.35

150<P<=200 10.5<P<=14.1 0.6 0.14

50 <P<=150 3.5 <P<=10.5 0.3 0.069

0 < P <=50 0< P <=3.5 0.15 0.034

Subatmospheric 0.1 0.023

2. Gas Lines within Battery 0.5 0.12

Limits

3. Compressor Piping Suction 0.5 0.12

4. Compressor Piping 1.0 0.23

discharge

5. Refrigerant Suction Lines 15-35 4.6-11

6. Refrigerant Discharge Lines 35-60 11-18

7. Tower Overhead

Pressure (P > 150 psia) 40-50 12-15 0.2-0.5 0.046-

0.12

Atmospheric 60-100 18-30

Vacuum (P < 10 psia) 125-200 38-61 0.05-0.1 0.012-

0.02

STEAM LINES

Sr. Type of Service Velocity Maximum D P

No. ft/sec. m/sec. psi/100ft kg/cm2/

100m

1. General Recommendation

Maximum :

Saturated 200 61

Superheated 250 76

Steam Pressure :

psig kg/cm2

0 - 50 3.5

50 - 150 3.5 - 10.5

150 - 300 10.5 - 21

>300 >21

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2. High Pressure Steam Lines

Short (L<600 ft) 1.0 0.23

Long (L>600 ft) 0.5 0.165

Short Leads 2.5 0.577

3. Exhaust Steam Lines 0.5 0.165

(P > 1 atm)

Leads to Exhaust Header 1.5 0.346

4. Feed Lines to Pumps and 12.5-15 3.8-4.6

Reciprocating Engines

5. Power House Equipment 100-170 30.5-52

and Process Piping
(Saturated at P >=25 psig)

6. Boiler and Turbine Leads 115-330 35-100 3 0.69

(Superheated to P >= 200
psig)

LIQUID SERVICE SINGLE PHASE :

TYPE OF MAXIMUM MAXIMUM VEL. REMARKS

SERVICE FRICTION LOSS M/SEC.
DP KG/CM2 / 100
MT.

1) Pump Suction

Boiling liquid 0.1 < 1.0

Non Boiling
liquid

Flooded 0.2 < 1.8 Note :1

Non Flooded 0.2 < 1.8

2) Pump Discharge 0.3 < 3.0

3) Gravity run Lines 0.1 0.9 - 2.4

4) Water Lines

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Main header 0.2 < 3.0

Sub header 0.3 < 3.0

5) Sea water Lines 0.3 < 3.0

(Concretelined/

Unlined Pipes)

2.02 VAPOUR HYDRAULICS

The following tables are to be used as a guide for the sizing of pipe lines in steam or vapour service. Line sizing
should satisfy both the pressure drop and the velocity criteria. Consider economic factors when and where applicable.

STEAM SERVICE :

TYPE OF MAXIMUM MAXIMUM REMARKS

SERVICE FRICTION LOSS VEL. M/SEC.
DP KG/CM2 / 100
MT.

1) Steam Lines

Saturated 61

Superheated 76

HP steam 0.25 < 20.0

>21 kg/cm2G

MP steam 0.12 < 20.0

10.5- 21 kg/cm2G

LP steam 0.08 < 20.0

3.5 - 10 kg/cm2 G

2) Exhaust Steam 0.15

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VAPOUR SERVICE

TYPE OF SERVICE MAXIMUM MAXIMUM REMARKS

FRICTION VEL. M/SEC.
LOSS DP
KG/CM2 / 100
MT.

1) General
Recommendation

Pressure levels

kg/cm2 G

P> 35.1 0.25

14.1 < P < 35.1 0.25

10.5 < P < 14.1 0.14

3.5 < P < 10.5 0.08

0 < P < 3.5 0.03

Subatmospheric 0.02

2) InstrumentAir/ Plant 0.1 <15

Air lines

3) Compressor

Piping Suction 0.12

Piping Discharge 0.23

4) Tower Overhead

Pressure

(P > 2.5 kg/cm2 G) 0.046 - 0.12 12 - 15

Atmospheric 18 - 30

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Vacuum 0.012 - 0.023 38 - 61

4.03 MIXED PHASE HYDRAULICS

The following basis shall be used as a guide for the sizing of pipe lines in mixed phase flow service. Line sizing
should satisfy both the pressure drop and velocity criteria. Consider economic factors when and where applicable.

Condensate Lines Velocity < Erosion Velocity

DP/100m < 0.2 kg/cm2 G

UNIT

The units and measurements to be used shall be those given below

MEASUREMENT UNIT

PRESSURE :(As guage) Kg/cm2

LOW PRESSURE : mmH2O

PRESSURE :(Draft or Vacuum) mmH2O

FLOW :

- Liquids m3/HR,l/HR

- Gas Nm3/HR

- Air Nm3/HR

- Steam Kg/HR

- Solids Kg/HR

TEMPERATURE : Deg.C

LEVEL :(Other than Tanks) %

VOLUME : m3

LEVEL : (Tanks) mm,cm or m

SPECIFIC GRAVITY:

-Water 1.0 at 4 Deg.C

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& 1013 millibar

VISCOSITY : CP

DENSITY : Kg/m3

DIFFERENTIAL PRESSURE IN mmH2O or

ORIFICE : Millibar

LENGTH : mm,cm or m

WEIGHT : Kg, ton

MEASUREMENT UNIT

ENERGY : Kcal

POWER : Kilo-Watt (KW)

CURRENT : Ampere

VOLTAGE : Volt

STRESS IN MATERIAL : Kg/cm2 or

Kg/mm2

THERMAL CONDUCTIVITY : Kcal/m.Hr.oC

HEAT TRANSFER Kcal/ m2.Hr.oC

COEFFICIENT:

LATENT HEAT : Kcal/Kg

SPECIFIC HEAT : Kcal/Kg .oC

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IMPACT VOLUME : Kg.m/cm2

SURFACE TENSION : Dynes/cm

MOMENT : Kg.m

AREA : m2

TIME : Sec,Min,Hr,Day

VELOCITY : m/sec

SPEED : RPM

FREQUENCY : Hz

SOUND LEVEL : db

CONVERSION UNITS

The conversion factors to be used shall be those as given below

QUANTITY TO CONVERT METRIC CONV. FACTOR

FROM UNIT

Length inch mm 25.4

Safety Distance feet m 0.3

Stress , Pressure psig Kg/cm2 .0703

Specific heat Btu/Lb °F K. cal/Kg °C 1.000

Surface Tension N/m dynes/cm 1000

Latent Heat Btu/lb Kcal/Kg .556

Flow rate lb/hr Kg/Hr .454

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Power Btu/hr K. cal/hr .252

6.0 EQUIPMENT DESIGN CONSIDERATIONS

6.01 DESIGN PRESSURE

GENERAL Equipment which are liquid filled and can be blocked into a pump discharge pressure shall be designed to
withstand the pumps shut-in pressure.

Pump shut-off pressure shall be defined as the maximum suction pressure plus shut-off delta P. Maximum suction
pressure is the sum of maximum operating pressure and static head.

After vendor information on pumps are received, the maximum shut-off pressures shall be checked in order to confirm
that they do not exceed the equipment design pressure.

PROCESS EQUIPMENT The design pressure for vessels,towers and heat exchanger shall be atleast 1 kg/cm2 or 10
% higher than the maximum expected operating pressure including hydraulic head or pump shut off
pressure,whichever is greater

UTILITY EQUIPMENT Use mechanical design pressure given in the utility conditions

6.02 DESIGN TEMPERATURE

PROCESS EQUIPMENT The design temperature shall be 25 oC above the maximum expected operating
temperature.When the operating temperature is 15 oC and below,the dessign temperature shall be the minimum
expected operating temperature.Vessel part in contact with two fluids having different temperatures, shall be
designed for the higher of the two. When the operating temperature are 15 oC or less, they shall be designed for the
lower temperature of the two.

UTILITY EQUIPMENT Use mechanical design temperature given in the utility conditions

6.03 FLARE KNOCK-OUT DRUM : They shall be designed in accordance with API-521.The choice of a horizontal or
a vertical drum shall be based on economic consideration,taking into account the required slope of the flare
header.When large liquid storage is desirednnad the vapour flow is high, a horizontal drum is often more
economical.The drum sizing shall be based on the separation of liquid droplets of 300 to 600 microns from the
vapour.

6.04 VAPOUR LIQUID SEPARATOR

Where carryover of entrained liquid mist 400 micron and smaller is not critical to process or process or operation of
the equipment, use knock-out drum to separate the vapour and liquid phases.

If removal of liquid mist particles within 400 to 60 micron in size is essential, use wire-mesh entrainment separators.

If it is essential to remove particles of liquid mist smaller than 60 micron, other types of mist eleminators must be
used.

6.05 SHELL AND TUBE HEAT EXCHANGERS

The design pressure for the process side of exchangers is based on the set pressure of the relief valve. If the system
relief valve is upstream, use the set pressure for the design pressure. If the relief valve is downstream, use the set
pressure plus the pressure drop from the inlet of the exchanger to the vessel, calculated at the maximum possible
flow rate. Use maximum pump shut-off pressure where applicable.

The design temperature for the shell and the tube sides of heat exchangers shall be based on the inlet temperature
for the hot side and the outlet temperature for the cold side.

From this basis, the same conditions shall apply for pressure vessels as given in 6.01 above.

For a utility side use the same design temperature given in the utility conditions.

Fouling factors used in the design shall be in accordance with TEMA recommendations unless otherwise specified.
The tube side shall be used for cooling water unless otherwise dictated by the process.

The process side of exchangers pressure that can be blocked against centrifugal pump discahrge pressure shall be
designed to withstand the pumps shut-off pressure.Pump shut-off pressure shall be defined as the maximum suction
pressure plus shut-off delta P. Maximum suction pressure is the sum of maximum operating pressure and static head.

After receiving vendors information on pumps, check all pumps to make sure that the maximum discharge conditions
do not exceed downstream vessel design pressure.

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For a utility side use the same design pressure given in the utility conditions.

6.06 DESIGN OF TANKS

The design of tanks shall be in accordance with API 620, 650 and latest addenda.

6.07 DESIGN OF PUMP

CENTRIFUGAL PUMPS

The differential head for pumps shall be the circulated head based on process flow design rate.

Manufacturer is to specify minimum by-pass flow rate, if required, and if so, the amount of this flow is to be specified.

The pump motor shall be designed to cover the entire pump curve for the impeller.

RECIPROCATING PUMPS

The design capacity and differential head for reciprocating pumps shall be determined on the same basis as for
centrifugal pumps.

6.08 DESIGN OF COMPRESSORS

CENTRIFUGAL COMPRESSORS

The compressors rated capacity shall correspond with the process design conditions. Compressors must be capable
of operating throughout the range from start of run to end of run conditions.

RECIPROCATING COMPRESSORS

The compressors design capacity shall correspond to the process design conditions, with no negative tolerance permitted. The differential
head shall be the calculated value based on the process design flow rate.

LUBE OIL AND SEAL OIL SYSTEMS

Main oil pumps shall be driven from the crank shaft and the auxiliary oil pumps shall be motor driven. The Oil reservoirs shall be sized to
supply oil for a period of 5 min.,during a power failure or stoppage of tube or seal oil pump

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