Process Design, CV, Line Size, Hazard, Safety Valve Guide

Conceptual Process
Design
An introduction at
www.cpcsimulation.com
Basic process steps

Basic Engineering package
FEED
Residual process engineering
Detail engineering
Basic core process documents
Process design basis, PFD, P &ID,

Datasheets, Line lists, Safety study
Agenda for this presentation

Workflow for conceptual process design
PFD Development
P & ID Development
Line sizing
Control Valve sizing
Pump Head calculations
PSV sizing
Area classification
Conceptual process design

DESIGN BASIS
Why to prepare a design basis?
Any guess on what this document consists of?
Can a P&ID be made without knowing basis?
Two different plants same product. Can P & IDs
be absolutely same?
Two different plants same product. Can control
valve and safety valves be exactly same?
If Yes why and if no why?
Same product with same capacity: plant in India
and plant in Russia- will it be exactly same?

DESIGN BASIS
P & IDs for same product are different

because.
Different licensor philosophies and design
specifications
Different Legends
Different plant capacity
Different climatic conditions
Different utility availability
Different logistics requirements
Different plot layouts
Different equipment/ Instrument manufacturers

DESIGN BASIS
Equipment design margins
Standard design philosophy
Controls and instrumentation levels
(DCS/PLC, SIL study)

Safety philosophy: (Fire, F&G, Flare)
Isolation and sparing philosophy
Battery limit conditions
Environmental norms
Conceptual process
engineering
Focus on process flow diagram
development (Example.reflash column)

Generate a mass and energy balance
Chemicals and catalyst summary
Development of conceptual P & IDs
Critical equipment sizing
Estimate utility requirements
Operating instructions
Conceptual process
engineering
Not part of conceptual engg..
Pump head checks
Control valve sizing
Safety valve sizing
Safety valve sizing
Vendor package information
Utility distribution drawings
HAZOP study
DOUGLAS METHODOLOGY
BATCH VS. CONTINUOUS

Production rate: > 45000 T/yr, use continuous
process
Product demand: seasonal products batch
Multiproduct plant Batch plant
Significant gas recycle continuous plant
Reaction behavior: High temperature or highly
exothermic reactions, continuous plant
Significant opportunities of heat integration
continuous plant
RECYCLE STRUCTURE
Decide reactants to be
recycled / purged
Decide purity / separation
feasibility
Check effect of recycle on
reaction chemistry e.g.
recycle of poisons etc
Check effect of compression
cost on feasibility
BLOCK FLOW DIAGRAM

Major equipments on block flow diagram
Evaluate cost based on major equipments and
approximate operating cost

Use ratio method for cost estimation
Shortlist alternatives for further evaluation
Process simulation will help fix process
conditions, utility loads etc
Pinch analysis for energy and area saving, but
keep operational issues in mind
Any Questions so far?

PFD developement
Show only process flow lines
Start up lines, pump recycle lines need
not be shown
Utility streams shown in short
Standby equipment and working
equipment depiction
Which streams to number?
Where to place stream number
diamond?
PFD Development
All equipments tagged
Equipment title block added
Exchanger symbol is generic and not as
per its TEMA type

Start/stop switches for motors not shown
All bays of air cooler are not shown
Local temperature and pressure guages
not shown
Control valve Selection and Sizing
COMPONENTS OF
CONTROL SYSTEM
Measuring element
(thermometer)
Controller
Final control
element (control
valve)
F (kg/hr)
Ti (oC)
To (oC)
Ms (kg/hr)
TS (oC)
Thermometer
Hand
Human
Brain
CONTROL SYSTEM BLOCK

DIAGRAM
V1
Controller
P
Kc {1+(1/ I)+ d}
Final Control
Element
Process
__1__
v + 1
__1__
p + 1
Measuring
Instrument
__1__
m + 1
CONTROL VALVE SYSTEM

Controller sends the output signal
of the order of 4 to 20 mA.
The i/p converter changes the
signal to 3 to 15 psi and sends to
Actuator.
The Actuator moves the plug
relative to the stationary valve seat.
POSITIONER
Measures valve stem
position and compares with

set point
Makes sure control valve
opening is as required by
controller
Corrects for effect of packing
friction due to dirt, lack of
lubrication etc
VALVE TYPES AND

SELECTION
Globe valve
Workhorse of industry
Multiple ports available
Large pressure drop
Size limited to about 12
Butterfly valves
Low pressure drop
Large sizes available
Ball valves
Low leakage
Quarter-turn
CONTROL VALVE SIZING

- 1
Need to fix following:
Minimum, normal and maximum flow
Corresponding pressure drop
Required flow characteristics i.e. linear or quick
acting etc
Control valve flow coefficient Cv used as sizing
parameter
Cv is flow of water in m3/hr through valve at 1 bar
pressure difference across valve

HOW TO ASSIGN PRESSURE

DROPS?
For pump systems:
50-60% of total frictional loss excluding control valve
OR
15% of pump differential head OR
0.7 kg/cm2
For process systems
Difference of pressure between upstream and
downstream system
Should give better controllability
Smaller the pressure drop, bigger the valve
FLOW CHARACTERISTICS
Inherent characteristics
Quick acting / linear / equal percentage
Quick opening
Linear
Equal %
SELECTING CHARACTERISTICS:
LEVEL
Level control: very slow response (remember
tanks in series experiment)

Mostly linear
SELECTING CHARACTERISTICS: FLOW

Whenever in doubt, use equal percentage
CAVITATION AND FLASHING

Cavitation is collapse of
bubbles
Damages trim
Special trim designs
available
Flashing not as dangerous
as cavitation
Needs to be specified to
vendor
CHOKING
Occurs for gaseous systems when downstream
pressure less than about 50% of inlet pressure

Can occur at much higher % for two-phase
systems
Fluid accelerated to sonic velocity in valve
Formation of shock waves
Avoided by use of multiple valves or use of ROs
FAIL
- SAFE POSITION
Action for valve when air supply fails
Three options
Fail open
Fail close
Fail last
Energy adding valves to be fail closed e.g. steam
Energy removing valves to be fail closed e.g.
cooling medium
Line sizing
An introduction
Flow rate basis for line sizing

PFD and mass balance
Utility summary and utility flow diagrams
Design margin: General
considerations
For all process lines 10%
Start up, intermittent flow 5%
Utility lines 15%
Utility main header 20%
Line sizing basis

For revamp, basis differs.
Circulating fuel oil system-design ring main for

125 to 150% of flow

Pipe wall roughness basis
Carbon steel, new- 0.047 mm
Brass, aluminum, Copper, Plastics, Glass
0.03 mm
Stainless steel 0.025 mm
Rusty steel 0.2 mm
Galvanized steel 0.13 mm
Normal pipe size

Avoid 30NB,65NB,125NB, 550NB
Nominal pipe size for process lines shall
be 25mm
Pipe rack lines shall be minimum 40NB
Schedule number as per pipe
specification index
Piping length estimate based on project
status-preliminary or plot plan/equipment
layout based or isometrics based
Equivalent length calculations:

Le/D values
Globe valve
Angle valve
Gate valve
Ball Valve
90Deg Elbow
Conventional check valve
Globe lift check valve
45 degree elbow
Flow through run
Flow through branch
450
200
13
18
30
135
450
16
20
60
Pressure drop calculations

Preliminary line size based on velocity criteria
Actual pressure drop to be verified with
allowable pressure drops as per process design

General criteria: Pump suction line delp is
0.085kg/cm2 per 100m of pipe
General criteia: Pump discharge line delp is
0.15 to 0.6 kg/cm2 per 100 mtr pipe
Reynolds number: Try to be in turbulant region
or laminar region. Avoid transition region(2300
to 4000 Nre)
Cooling water lines

DeltaP per 100 mtr is generally 0.3 kg/cm2
Flow possible through various pipes- in m3/h based on
above criteria
1.5
40
3.8
50
8.5
80
26
100
51
150
160
200
350
250
640
300
1000
25

Gravity lines
The maximum recommended velocity for
gravity lines is 1 m/s

The minimum line size for gravity lines
within process area to be 40mm
Sizing of self venting lines- velocity at
about 0.3 to o.7 m/s
Column draw off lines based on static
head available
Compressible fluid line sizing

If pressure drop is less than 10% of the
upstream pressure, use density and

average linear velocity based on either
inlet or outlet conditions
If pressure drop is between 10%-40% of
the upstream pressure, use density and
average linear velocity based as
averages of inlet and outlet conditions
First estimate- v= c/row; c is 13 to 24
Tower overhead lines

For pressure between, 0 to 0.7 kg/cm2g, use
velocity range as 40 to 60 m/s and max

allowable pressure drop of 0.011 kg/cm2 for
100 mtr pipe
For pressure between, 0 to 3.5 kg/cm2g, use
allowable pressure drop of 0.033 kg/cm2 for
100 mtr pipe
For pressure between, 3.5 to 15 kg/cm2g, use
allowable pressure drop of 0.15 kg/cm2 for 100
mtr pipe
Special services
Recommended velocity in m/s for special
services:
Concentrated H2So4
Salt water
Caustic solution
Plastic pipe
Liquids with suspended solids
Liquid lines to chillers
Refrigerant lines
Liquid from condenser
Reboiler trap out
1.2
1.8
1.2
4.5
0.9 min.
1.8
1.2
2.1
1.2
HAZARDOUS AREA CLASSIFICATION
OBJECTIVE OF AREA
CLASSIFICATION
Fire triangle: Oxygen / Fuel / Ignition source
Oxygen: Air abundantly available
Plant leak: Fuel supply started
A minor spark and EMERGENCY
Different fluids, different thresholds
Area classification makes sure that ignition
source is not available
ZONES: HOW TO DECIDE

Zone 0 normally means vapour space above continuous
vents, storage tanks, open tanks of volatile materials

Zone 1 normally have following locations

Frequent maintenance, leakage prone area

Areas where frequent upstream upsets mean downstream
released to atmosphere
Location adjacent to zone 0 area
Zone 2 normally means areas like

Accidental failure of gaskets/packings etc
Zone adjacent to zone 1 area
FUEL PROPERTIES
Classification based on minimum ignition energy
Fluids classified as either IIC or IIB or IIA
IIC fluids very sensitive. Explode at slightest spark
energy. E.g. acetylene, hydrogen

IIB / IIA rather less sensitive
No difference between electric equipments for IIB
and IIA
Basically fluid group either IIC or IIA/IIB
TEMPERATURE CLASS
Makes sure that
temperature of electrical
equipment surface does
not exceed fluid
autoignition temperature
Temperature
Code
oF
oC
T1
842
450
T2
572
300
T3
392
200
T4
275
135
T5
212
100
T6
185
85
EXTENT OF ZONES
Defined by codes
Depends on whether source of hazard is lighter or heavier
than air
Depends on location of source i.e. near ground / above
ground, open or closed space etc
ELECTRIC EQUIPMENT
SPECIFICATIONS
Method of containment: contain explosion within
confines of electric equipment e.g. Flameproof

apparatus (Ex d)
Method of segregation/separation: Separate spark
from fuel e.g. Oil immersion (Ex o)
Method of prevention: Provide just sufficient
energy and reduce faulty conditions e.g. Increase
Safety (Ex e)
Identified on electric equipment by notations
Pressure Relief
WHAT IS THE ROLE OF PSV?

Makes sure that vessel pressure does not exceed vessel

design pressure
Pressure increase in a system occurs due to imbalance of
either energy or flow i.e. input is not equal to output
Relief events
Example of energy imbalance = Fire
Example of material imbalance = Blocked outlet
Imbalance corrected by releasing material out of the
system (to atmosphere or flare)
STEPS IN PSV SYSTEM

SIZING
Identify relief events
Calculate relieving capacity required
Select type of valve to be used
Calculate PSV orifice area
Select Standard orifice having area more than calculated
orifice area
Fix PSV inlet and outlet line size based on rated capacity
Design flare system (if any) considering worst case
scenario for entire plant
ACCUMULATION
Accumulation allowed by API:
3% for fired and unfired steam boilers
10% for vessels equipped with a single pressure
relief device in non-fire case
16% for vessels equipped with multiple pressure
relief devices
21% for fire contingency
PSV overpressure should be such that at no
instant relieving pressure is reached

Consider vessel operating at 1.5 bar (g)
What are Relief Events?

External fire
Control valve failure leading to uncontrolled
flow of fluid or energy

Blocked outlet
Cooling water failure
Power failure
Exchanger tube rupture
OTHER RELIEF EVENTS

Blocked outlet case: relief flow is flow into the system
(credit can be taken for pump curve shift)

Control valve failure case: Vendor certified full open
control valve flow (corrected for relieving pressure)
Cooling water / power failure: uncondensed vapour
minus vapor normally exiting the system
Tube rupture: Calculated based on orifice theory
All calculations at relieving pressure
RELIEF DEVICE TYPES

Pressure Safety Valves

Conventional spring operated valves

Balanced bellows valves
Pilot operated valves
Rupture Devices

Rupture discs
Rupture pin devices
CONCEPT OF BACKPRESSURE
Backpressure = pressure from valve outlet which tries to
close the valve i.e. forces disk down

Superimposed backpressure: backpressure on disc
before valve opens

Superimposed backpressure can be constant or variable
Built-up backpressure: backpressure developed due to
flow after valve opens
BALANCED BELLOWS
VALVE
Balanced bellows work on similar principle of
spring tension, but bellows takes care of problems

of backpressure
Conventional valves okay if backpressure limited
to 10% of set pressure
Balanced bellows can go easily upto 30%
backpressure and upto 50% at reduced capacity
Problem of bellow rupture due to fatigue etc
RUPTURE DISC
Nonreclosing device
Once ruptured, material
loss continues
Used in place of or
upstream of PSV in
corrosive, viscous services
etc
Reduce capacity of valve if
upstream of PSV
PSV INLET AND OUTLET

LINE
PSV inlet line size should atleast be equal to PSV inlet

flange
PSV inlet line size pressure drop limited to 3% of set
pressure avoids chattering
3% limit not applicable to pilot operated valves
PSV outlet line size should atleast be equal to PSV outlet
flange
PSV outlet line size selected to meet backpressure
requirements

10% of set pressure for conventional valves

30 50% of set pressure for balanced bellow valves
Max. 90% for pilot operated valves possible
THANK YOU

Process Design, CV, Line Size, Hazard, Safety Valve Guide

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Conceptual Process

Basic process steps

Process design basis, PFD, P &ID,

Agenda for this presentation

Conceptual process design

Conceptual process design

Conceptual process design

(DCS/PLC, SIL study)

development (Example.reflash column)

BATCH VS. CONTINUOUS

BLOCK FLOW DIAGRAM

approximate operating cost

Any Questions so far?

per its TEMA type

Control valve Selection and Sizing

CONTROL SYSTEM BLOCK

CONTROL VALVE SYSTEM

position and compares with

VALVE TYPES AND

CONTROL VALVE SIZING

pressure difference across valve

HOW TO ASSIGN PRESSURE

tanks in series experiment)

SELECTING CHARACTERISTICS: FLOW

CAVITATION AND FLASHING

pressure less than about 50% of inlet pressure

Flow rate basis for line sizing

Line sizing basis

125 to 150% of flow

Normal pipe size

Equivalent length calculations:

Pressure drop calculations

allowable pressure drops as per process design

Cooling water lines

gravity lines is 1 m/s

Compressible fluid line sizing

upstream pressure, use density and

Tower overhead lines

velocity range as 40 to 60 m/s and max

HAZARDOUS AREA CLASSIFICATION

source is not available

ZONES: HOW TO DECIDE

vents, storage tanks, open tanks of volatile materials

Frequent maintenance, leakage prone area

Zone 2 normally means areas like

energy. E.g. acetylene, hydrogen

confines of electric equipment e.g. Flameproof

WHAT IS THE ROLE OF PSV?

STEPS IN PSV SYSTEM

instant relieving pressure is reached

What are Relief Events?

flow of fluid or energy

OTHER RELIEF EVENTS

(credit can be taken for pump curve shift)

RELIEF DEVICE TYPES

Conventional spring operated valves

close the valve i.e. forces disk down

before valve opens

flow after valve opens

spring tension, but bellows takes care of problems

PSV INLET AND OUTLET

10% of set pressure for conventional valves

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