Process Design Criteria
Process Design Criteria
화학플랜트공정설계기준
(SYSTEM PROCESS DESIGN CRITERIA)
2005. 5. 23
차 순 철 기술사
sc@charstech.com
TABLE OF CONTENTS
1. GENERAL
1.1 CRITERIA
1.2 RESPONSIBILITIES
1.3 CODES AND STANDARDS
3. EQUIPMENT DESIGN
3.1 PRESSURE VESSELS
3.2 TANKS
3.3 EXCHANGERS
3.4 EQUIPMENT IN PUMP DISCHARGE CIRCUIT
4. PIPING DESIGN
4.1 NORMAL OPERATING CONDITIONS
4.2 DESIGN TEMPERATURE AND PRESSURE
4.3 CODE ALLOWANCE
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6. UTILITIES
6.1 UTILITY STATIONS
6.2 SNUFFING STEAM
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1. GENERAL
1.3 CODES AND STANDARDS
Unless otherwise amended by CEC specifications, System Process Engineering Design
shall be in accordance with the latest edition for the following, unless otherwise
shown below.
Piping
Process Piping ANSI, B31.3
Boiler Piping ANSI, B31.3
Flanges ANSI, B16.5
Pressure Vessels
Unfired ASME, Sect. VIII, Div.1 & ASME, Sect. I
Unfired Steam Boilers ASME, Sect. I
Fired Steam Boilers ASME, Sect. I
Safety Relief Systems
Safety Valves API RP520 and API RP521
Header ASME, Sect. I and VIII
Pumps
Centrifugal API 610
Reciprocating API 674
Compressors
Centrifugal API 617
Reciprocating API 618
Air Compressor (centrifugal) API 672
Steam Turbines API Std 611 & 612
Exchangers ASME Section VIII & TEMA
Flammable and Combustible Liquid Storage NFPA Volume 1
Foam Extinguishing Systems NFPA Volume 7
Storage Tanks
Atmospheric Pressure API Std 620, 650, 2000
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2.6 PROCESS DATA FOR CONTROL VALVES, ORIFICES, AND METER RUNS
The System Process Engineer shall provide to the Project Instrument Engineer all the
process data for sizing control valves, orifices, and meter runs.
The control valve data shall be transmitted on Instrument Process Data Sheet.
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3. EQUIPMENT DESIGN
3.1 PRESSURE VESSELS
Complete systems within a process must be checked in addition to the following minimum
design pressure and temperature requirements of vessels :
For vessels with a pressure-relieving system to flare, consider 3.5 kg/cm2g minimum design
pressure to reduce flare size requirements.
Suction drums on reciprocating compressors are to be designed for vacuum conditions in
addition to operating conditions.
Mis-operation during steamout of vessels is not to be considered.
For liquified gas controlled under Korea High Pressure Gas Law, design pressure is saturation pressure
at design temperature.
Furnace and reactor sections may be subject to special considerations.
3.2 TANKS
The following shall be the minimum design pressure and temperature requirements of
tanks :
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Cone roof
up to design pressure .02 kg/cm2g
Dome roof
up to design pressure .035 kg/cm2g
up to design pressure 1.05 kg/cm2g
Notes :
Do not include liquid head. Design pressure is for the top of the tank.
Mis-opertion during steamout is not to be considered.
3.3 EXCHANGERS
Design pressure and temperature of exchangers are as follows :
3.3.1 Operating pressure - OP Min. Design press - DP
For air-cooled heat exchangers, the design temperature shall be the maximum fluid
temperature specified on the Process Equipment Specification or the Process Flow
Diagram.
If no maximum fluid temperature is specified by Process, the design
temperature shall be the normal operating temperature plus the applicable factor
specified above.
An upset condition may set the design temperature of certain exchanger.
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For shutoff pressure estimates on motor-driven centrifugal pumps, use the maximum
suction pressure plus 125% of the rated differential pressure of the pump. For steam
turbine-driven pumps, use 1.38 x maximum differential pump pressure at rated flow.
When pump-performance curves are obtained from pump vendors, the maximum pressure for
the purchased impeller shall be compared with the equipment design pressure.
Equipment design pressures must be increased if the pump shutoff discharge head is
greater than estimated.
For turbine-driven pumps, the certified shutoff head must multiplied by the square of
the ratio (turbine trip speed/pump rated speed).
4. PIPING DESIGN
4.1 NORMAL OPERATING CONDITIONS
The process conditions of the greatest severity expected during normal operation.
Conditions such as turndown, startup, dual-cycle, and regeneration shall be included,
when appropriate, as separate entries.
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Tag number
Equipment name as on the equipment list
DP:in kg/cm2g;DT:in Deg C (two values for shell and tube exchangers)
Exchanger of heater absorbed duty in kcal/h
Pump rated capacity in m3/hr or L/hr and differential pressure in kg/cm2
Pump rated power in kW
Vessel dimensions tangent to tangent and diameter
Insulated (when required)
Equipment with spares will be described once unless the spare is on a separate drawing.
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5.7 INSTRUMENTATION
5.7.1 Symbols and identification letters
Instrument symbols and identification letters will be in accordance with the
instrument society of American Standard ISA-S 5.1 “Instrumentation symbols and
Identification”, latest edition.
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5.9.2 Exceptions
Full-line size block and bypass valves are required for the following :
Vaporization or volume increase requires full-line capacity.
Use downstream line size to size downstream block valve from table.
Gravity flow with small control valve differential.
Requirement for future expansion.
High pressure drop where cavitation could occur.
Expansion will be used immediately at the control valve outlet.
5.10.2 If valve takeoff is made after the pump nozzle sizes are known, valves in suction
and discharge lines shall be sized as follows:
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5.10.2.1 If there is one size difference between pump nozzle and pipe.
pump suction valve shall be line size or suction nozzle size, whichever is greater.
The valves on the discharge of a pump shall be the same size as the pump nozzle or
the piping, whichever is smaller.
5.10.2.2 If pump suction or discharge nozzle differs more than one size from the line size,
valves shall be one size smaller than the line size.
Where pump nozzles are smaller than the line size by two sizes or more, check the
line size for proper sizing and consider, from economic standpoint, a line-size
valve and a single swage versus two swages and a one size smaller valve.
Check line size if pump nozzles are two sizes larger than line size.
Both discharge check and block valves shall be the same size.
5.10.4 A minimum of three diameters of straight run of pipe shall be shown on compressor
suction piping.
Instrumentation or rotating equipment may have additional requirements.
5.10.7 Piping and valving around water cooled heat exchangers shall be shown as in sketch
below :
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5.11.2 Steamout connections are located at minimum distance above the bottom head steam of
vertical vessels and the side or head of horizontal drums. If vendor designed
vessels do not have steamout connection and client request the connection, they will
be located on connecting pipeline.
5.11.3 Purge connections follow the same rules as steamout connections, but differ in that
they are used when steam or water could be detrimental to the equipment or process
material. Nitrogen or some other inert gas is therefore used to purge these systems.
5.11.4 Steamout or nitrogen purge shall be permanently piped for sizes 2 inches and larger.
A double block, check, blind, and bleed in the purge piping shall be provided for
the connection to a process line. When piping purges into a vessel, a double block,
removable spool, and vent shall be provided in the purge line.
5.11.5 Vents are located on the top head of towers and vertical vessels. They are located
on the top of horizontal drums at the same end as the drain and at the end opposite
from the steamout or purge connection. All vents are valved and blinded or capped.
5.11.6 Vents, drains, and steamout and purge connection for columns and vessel shall be
sized as follows :
NOTE : Minimum size vents for vessels having only one personnel access way will be 4
in, for horizontal vessels and 2 in, for vertical vessels.
5.11.7 All drains from towers containing toxic fluid shall have some arrangement for being
double blocked.
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5.11.8 Operating vents and drains for piping systems shall be sized as follows :
Pipe Size, inches Vent size, inches Drain Size, inches
3/4-4 3/4 3/4
6 - 10 3/4 1
12 and over 1 1-1/2
Non-operating and hydrotest vents and drains will not be shown on the P&IDs.
5.11.9 All vents and drains smaller than 3 in. shall be capped. All vents and drains 3 in.
and larger shall be blinded.
5.12 INSULATION
Lines and equipment surfaces normally operating at 65 degrees C and above, not
insulated for heat conservation, shall be insulated for personnel protections.
Insulation thickness shall be as specified in the insulation specifications.
5.13 TRACING
Tracing shall be provided to maintain liquid viscosity at required levels, to keep
lines from freezing, and to prevent condensation. Select temperatures at least 6
degrees C above the liquid pour or freezing points, making sure it is below the
bubble point.
Electric tracing will be used for freeze protection, and steam tracing will be used
for process reasons.
Where operating temperature may exceed 215 ℃, electric tracing shall not be used.
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Permanent tie-ins of utility services to process equipment are not allowed. Install
all piping and connect drop-out spool each time.
Snuffing steam, steam out, and nitrogen purge may be excluded. (See above).
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5.17.2 The following shall be the criteria for header blocks for utilities (other than unit
header blocks) :
5.17.2.1 Steam
Provide block valves at header for all supply and user branches.
A turbine inlet and exhaust valve shall be located at the turbine and not at the
header.
5.17.2.2 Condensate
Provide header blocks.
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5.17.2.4 Nitrogen
Provide header blocks.
5.18 REDUCERS
Reducers will be shown where it is not obvious where a line has changed size.
Where pump, vessel, control valve or other equipment have sizes other than line size,
the flange or valve sizes shall be shown but the reducers will not.
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IDENTIFICATION
SP
032
The System Process Engineering Section shall issue to the Piping Material Section all
information necessary for the purchase of these specialty items.
All block valves in relief valves service shall be full port, unless the pressure drop
through the inlet piping including the block valve does not exceed 3% of set pressure
and the valve bore is larger than the relief valve inlet nozzle.
The relief valve shall be located at a high point and drain both to the vessel and to
the relief header.
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GATE
CHECK
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6. UTILITIES
6.1 UTILITY STATIONS
Utility stations for steam, service water, and air shall be provided at convenient
locations throughout the plant. At certain stations, as defined on the utility P&ID,
nitrogen shall be provided.
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Valves at control valve manifolds shall be sized in accordance with the following
table, unless otherwise shown on the piping and instrument diagrams : (All
dimensions are in inches)
Control Valve Size Line Size Block valve Size By-Pass Valve Size
3/4 3/4 3/4 3/4
3/4 1 1 1
3/4 1-1/2 1-1/2 1
3/4 2,3,4 2 1
1 1 1 1
1 1-1/2 1-1/2 1-1/2
1 2,3,4 2 1-1/2
1-1/2 1-1/2 1-1/2 1-1/2
1-1/2 2,3,4 2 2
2 2 2 2
2 3,4,6 3 3
2-1/2 3,4,6 3 3
3 3 3 3
3 4,6,8 4 4
4 4 4 4
4 6,8,10 6 6
5(6” flgs) 6,8,10,12 6 6
6 6 6 6
6 8,10,12 8 8
8 8 8 8
8 10,12 10 10
10 10 10 10
10 12,14 12 12
Where piping is expanded after a control valve assembly for flashing conditions,
the block valve downstream of the control valve shall be equal to or one size
smaller than the expanded downstream piping.
Where reducers are used, the maximum reduction shall not be greater than two nominal
line sizes per reducer.
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