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1 PURPOSE......................................................................................................................... 5
2 SCOPE ............................................................................................................................. 5
The purpose of this document is to establish the general requirements for the design of
various process piping systems, equipments and services necessary to develop of "EPC
OF CRUDE OIL PROCESSING PLANT OPERATIONS CENTER PETROMONAGAS
(COPEM) – BASIC ENGINEERING", to increase temporarily the processing capacity
while the third production train, with processing capacity of 210 MBPD extra heavy crude,
is constructed. The calculation methodology will be according to the codes and standards
used for the development of technical specifications and documents for the purchase of
equipment skid-type according to the contract-type of facilities adopted by Schlumberger.
2 SCOPE
Establish design criteria and basis, herein includes reference documents listed in Section
3 of this document, to be applied in the development of documents and drawings of the
Mechanical (piping and equipments) Discipline, as part of the development of "EPC OF
CRUDE OIL PROCESSING PLANT OPERATIONS CENTER PETROMONAGAS
(COPEM) – BASIC ENGINEERING", which is located near of the PETROMONAGAS
CENTRAL PRODUCTION FACILITIES in Morichal area, Independencia Municipality in
southeast of Anzoategui State, corresponding to the Carabobo division of the Orinoco Oil
Belt.
The information presented below of is general nature. For particular cases, the design will
be based on data provided in the documents referred to herein and/or the information
provided by equipment material’s manufacturer.
For the development of these Mechanical Design Criteria, were taken as reference
documents detailed below.
All piping and equipments design are governed by codes, standards, procedures,
practices and documents listed in this section that form an integral part of this Document;
in case of any contradiction between the codes, standards, procedures and/or practices
for the project, it will override the more restrictive criteria, undergoing any deviation shall
be approval by COMPANY. Unless otherwise stipulated, the applicable version of these
documents, including relevant appendices and supplements, is the latest revision
published at the EFFECTIVE DATE of the CONTRACT; in all cases the latest available
revision of the applicable standard or code design specified the present document, will be
used.
Any divergence between any of the Contractual Reference Documents, or between this
specification and any other Contractual Reference Document, shall be reported to the
COMPANY for decision. In such a case, and unless otherwise agreed or decided by the
COMPANY, it’s understood that the more stringent requirement shall apply.
Exceptions to, or deviations from this Document are not permitted unless previously
accepted in writing by the COMPANY. For this purpose, requests for substitutions or
changes of any kind shall be complete with all pertinent information required for the
COMPANY assessment.
For the location of equipment and the provision of free on escape routes, maintenance
and operation areas, the following PDVSA’s Standards were considered.
EM-04-10/01 Polyethylene tape applied in cold and/or hot for Metallic Pipe
Coating
3.4.9 ANSI / AWWA (American National Standards Institute / American Water Works
Association)
NACE 0175 Petroleum and natural gas industries – Materials for use in
H2S-containing environments in oil and gas production
3.4.15 Others
4 DEFINITIONS
EQUIPMENTS: these are defined in the document “Equipment List – Process, Services
and Auxiliary Systems” No. H1M0011501-CO413-PD11007.
BATTERY LIMIT: Are the limits within which has responsibility for the design, for the
present project.
COORDINATES SYSTEM: then coordinate systems are indicated for use in the Project,
according to SIRGAS – REGVEN UTM, based on Geographical Information Systems
(GIS).
MAIN AREAS OF OPERATION: Are defined as those areas at ground level or higher,
where plant operations personnel will be continuously present at least once per shift.
AREAS OF AUXILLIARY SERVICE: Are defined as those other areas of the plant at
ground level or higher where plant operations personnel will be present only if required
his presence.
The system used for the identification and tagging of piping and equipments for the
installation of the Early Production Station (EPF), which is part of the "Basic and Detailed
Engineering Oil Processing Plant Petromonagas in Petromonagas Operating Centre
(COPEM)"
The tagging system adopted is based on the procedure described in PDVSA Norms,
Design Engineering Handbook Volume 15, L-TP1.3 "Identification of Equipment, Process
Piping and Instruments".
The units of measurement to be used for equipments and piping in documents, drawings,
calculations and other documents will be the English system unless specifies otherwise.
The calculation procedures established in another system will present their results in the
specified system.
6 UNIT OF MEASUREMENT
For purposes of this project, the point (".") as decimal separator and the comma (",") as
thousands separator unit will be used hereinafter.
7 PROJECT LANGUAGE
The Project language will be Spanish. For documents used for equipments purchase will
be in English.
8 FACILITY LOCATION
The Oil Treatment Plant Petromonagas Early Production will be located in an area of
approximately 12.85 Ha, around to 100 m. Petromonagas Operating Centre (COPEM) in
the area of Morichal, southeast of the Anzoategui State, Independence Municipality
corresponding to the Carabobo Division Orinoco Oil Belt, which it shares some services
and operational functions. The Table 1 shows the reference coordinates (PTO-01)
East North
483.000 959.800
The coordinates of New Early Production Station (EPF) agree to the interconnection point
with the Petromonagas Operations Centre (COPEM) adjacent thereto, referred to as
indicated in the Implementation Plan Civil Modular Plant - Proposal 02 No. COPEM -PM -
5- ENG - 002 Rev.B, June 2015.
The environmental conditions of the installation site to be used during the project
implementation are defined in the document “Bases y Criterios de Diseño de Procesos”
No. H1M0011503-CO4D3-GD11001 (Section 10). According to the Venezuelan Standard
COVENIN 1756-1-2001 and document reference “Requerimientos de Diseño” No. 2012-
TM-GIC-069 supplied by CLIENT.
9.1 General
The main consideration in the implementation of equipments and piping systems at the
plant is to provide an effective operation, safe, economical, easy to operate and maintain.
Arrangements must be compact and generally senses satisfy process flow, typical for a
modular plant. Spaces will be considered for safe and reliable access for operation and
maintenance of the plant.
All materials and equipment shall be new, they shall be clean and free of rusts,
subsidence or any other defect. The materials and chosen equipment shall satisfy the
limitations of pressure and permissible temperature that area specified in the present
document.
The Piping System is designed for the worst pressure / temperature condition and all load
shall be included. It might exists differences between the material of the Piping and the
established material specifications by norm due to the design conditions. These
differences shall be allowed only if they are equal or improve the requisites of approved
material by COMPANY.
The battery limits established in the Project are listed in the “PLOT PLANT
CONCEPTUAL IMPLANTACION PLANTA MODULAR” preliminary received of CLIENT
and defined in the document No. H1M0011401-CO4I3-GD11001 “BASES Y CRITERIOS
DE DISEÑO" Section 8.8.
All process equipment should be located in accordance with the Section 3.3.1.2 National
standards, part PDVSA’s Risk Engineering Handbook, Norms No. IR-M-01 and IR-M-02.
These must be optimized space but always considering safety.
In the event of any conflict between the requirements set forth in any document, code,
standard and / or the specification; CONSULTANT get clarification of the case, by the
COMPANY before proceeding.
10 DESIGN CRITERIA
10.1 General
All the materials and equipment shall be new, they shall be clean and free of rusts,
subsidence or any other defect.
The materials and chosen equipment shall satisfy the limitations of pressure and
permissible temperature that are specified in the present document.
The Piping system is designed for the worst pressure / temperature condition and all load
shall be included.
It might exist differences between the material of the Piping and the established material
specifications by norm due to the design conditions. These differences shall be allowed
only if they are equal or improve the requisites of approved material by THE COMPANY.
All piping shall be arranged in a simple and orderly manner, as much as possible, to
achieve economical use of space and minimize pressure drop without actually prevent or
hinder access to equipment for operation and maintenance.
Piping arrangements are sufficiently flexible to absorb the thermal effects and prevent
system failures.
In all the lines within the battery limit the process units are arranged on raised supports.
Except to the drainage lines.
The use of pipe trenches, inside the units will be avoided where possible.
Lines outside the battery limits generally be routed to ground level on sleepers, except in
areas adjacent to units requiring vehicular or pedestrian access.
Pipes insulated for hot service in 3 " (NPS) and larger will not be supported directly on the
steel structures and will be provided with saddles long enough to handle any possible line
expansion.
Multiple lines or services will be grouped in the lower levels of the structures ("Pipe
Racks") wherever possible.
Pipes supported in common structures must have the same elevation at the bottom of
deck for isolated lines must have the same elevation of the lower portion of the lines not
isolated.
The difference in elevation between north-south lines and lines direction east-west
direction shall be at least 750 mm.
Direction changes will be made with butt welding long radius elbows ("Buttweld"), screw
or plug type according to the specification of piping materials. If space does not permit the
use of long radius elbows butt welded, short radius elbows can be used.
Structural supports on pipe bridges or concrete sleepers are usually spaced at 6000 mm
centers, and the minimum diameter of the pipes to be supported will be 2” (NPS) above
said supports.
Nominal pipe sizes (NPS) 1-¼ ", 2-½", 3-½ ", 5" and 7" shall not be used unless they are
required for connection to equipment and should be kept to a minimum. Equipment
connections made to these sizes, the pipes will be adjusted to a standard size
immediately adjacent to the connection via a special flange or reducer.
The sizes (NPS) lines permissible inch pipes are ½", ¾", 1", 1-½", 2", 3", 4", 6", 8", 10",
12", 14", 16", 18", 20", 24" (NPS) and larger in increments of 6" (NPS) that are
guaranteed by the ASME B36.10 standard.
Dead spots in the pipes to facilitate the use of media will not be allowed in process lines,
in these cases the type "dummy" media will be used.
Piping arrangements are planned for easy removal of the equipment and / or components
for inspection, servicing and / or maintenance.
Control valves, relief valves, etc. will be accessible from platforms or ground level and
grouped in the main operating level.
The piping, valves and fittings will be designed for a service life of 10 years.
Free space for equipment, structures, platforms, pipelines and their supports shall be in
accordance with Attachment No.1.
Thermal movements will be taken into consideration in determining the gap between
lines.
The lowest point of the flanges or insulated lines located in trenches is 75 mm (3 in)
above the floor of the trench minimum.
The minimum horizontal clearance for pedestrian walkway between piping and
mechanical equipment shall be 915 mm (36 in).
10.2.2 Materials
Pipe materials for different kinds of pressure, temperature and service will be subject to
the requirements in accordance to PDVSA Norm H-221, OCN-CPF-SP-G-00-2004-420
“Piping Material Specifications Cerro Negro DB | GFM Project” and HS011001-CO0D3-
MD16304 “Piping Material Specification Addendum”.
The pressures and temperatures to be used as a basis for the design of piping systems
and the selection of materials will be subject to the requirements of ASME B31.3, with
maximum operating conditions shown in the respective documents of processes, such as
those are: DTI's, Lines List processes and services, etc.
The pipeline will be designed for the more severe condition of coincident pressure and
temperature expected during normal operation of the line, taking into account the
following considerations:
• The design pressure of the equipment which will be connected. In the different
specifications will be established start-up, operation and shutdown conditions of all
equipment and associated systems. See more details on Document No.
H1M0011503-CO4D3-GD11001 “BASES Y CRITERIOS DE DISEÑO DE
PROCESOS” and each one of the Equipment’s Technical Specification.
• The noise level indicated in particular data sheet for each equipment.
• The burst pressure of the safety valve which protects the system.
Piping discharge line of a centrifugal pump is not protected by a safety valve will be
designed to the highest value of:
All operating below atmospheric pressure systems will be designed to vacuum condition
("Full Vacuum").
All pipes out of the battery limits will be designed for a closed valve condition in the
battery limit the entire plant (offsite) destination.
The minimum allowed corrosion thickness in accordance to PDVSA Norm H-221, OCN-
CPF-SP-G-00-2004-420 “Piping Material Specifications Cerro Negro DB | GFM Project”
and HS011001-CO0D3-MD16304 “Piping Material Specification Addendum”, for all piping
systems.
As allowed for the carbon steel pipe corrosion plan will be according to the following
conditions:
• Corrosion allowance shall be the necessary to archived the useful life, based in the
corrosion rated expected.- High alloy (> = 9% chromo).
• 1/16" - Carbon Steel with integral cladding. No one in metal base Skirt and saddle
external part.
When the containers have higher "ratings" that connected lines, valves connected to the
computer have the same "rating" of the equipment if they remain normally closed during
operation.
10.2.6 Flanges
Weld Neck Flanges (WN) for pipe diameter greater than or equal to 2" (NPS) flange (SW)
for diameters less than 2" (NPS) will be used.
The cast iron flanges, Class 125 and 250 comply with the specifications of the ASME
B16.1 standard.
Flanges Class 150 to 1500 size ≤ 24" (NPS) and Class 2500-12" (NPS) will be submitted
for Specification ASME B16.5.
Flanges Class 150 to Class 900, with larger sizes of 26"(NPS) perform in accordance with
ASME B.16.47. Use the Series A flanges in applications in plant and where there are
space limitations.
Flange not corresponding to the standards ASME B16.5, ASME B16.1 or ASME B16.47
shall be specified and approved by COMPANY.
All butt weld less than or equal to 48" (NPS) Accessories "must comply with the ASME
16.9 standard and MSS-SP-75.
When bends are substituted for butt-welding elbows, the pipe wall thickness at the
thinnest point after bending, less corrosion allowance, shall not be less than the
calculated thickness required for pressure and temperature. Fabricated fittings, branch
connections, and pipe bends shall meet the requirements of installation and quality
control.
Pipe bends shall only be made from the pipe specified for the service except that only
seamless pipe or EFW pipe (which has had 100% radiographic or ultrasonic inspection of
the longitudinal seam and an Ej = 1.0) may be used.
Neither creased nor corrugated pipe bends may be used (306.2.2 of ASME B31.3).
The use of screwed fittings shall be limited to galvanized malleable iron fittings except
couplings may be used in instrument air and water services.
The wall thickness of the small end of a swaged nipple shall not be less than that of the
larger end.
Threaded bushings, street ells, close nipples, and all-thread nipples shall not be used.
Threaded elbolets or full length couplings threaded one end only may be substituted for
threadolets for instrument, vent and drain connections on elbows.
Solid round pipe plugs shall be used for threaded end closures in flammable, toxic, or
corrosive service. Plug material shall have a corrosion resistance equal or greater than
the pipe.
The 90° elbows be long haul. They should not use elbows shop fabricated. If different
angle turns 45° or 90° are required, they shall be manufactured from elbows 90° and 45°.
a. It shall be used for unions in Piping of: 1/4", 1/2", 3/4", 1 ", 1 1/2" (NPS)
b. Dimensions: In accordance with the code ASME B16.11.
c. Class Type:
- Class 2.000 and 6.000 - Accessories weld.
Non-metallic gaskets, asbestos-free, for flanged pipe joints must comply with
ASME B16.21.
Metallic gaskets for flanged pipe joints correspond to ASME B16.20, and must have
internal reinforcing ring.
Sizes and limitations for flanged pipe fittings up to 24 "agree as specified in ASME B16.5.
Dimensions of gaskets for flanges larger than 24" should be subject to standard flanges
specified for the particular pipe class.
The dimensions of the studs shall correspond to the provisions of the ASME B18.2.1.
Nuts for studs shall be hexagonal heavy American series to ASME B18.2.2.
For steel piping operating above –20F, alloy steel studs ASTM A193 Grade B7, with
ASTM A194 Class 2H semi-finished heavy hex nuts shall be used except for sulphide
stress cracking service where stud bolts shall be ASTM A193 Grade B7M. For steel
piping operating below –20F, ie: blowdown service, ASTM A320, Gr L7 studs, with ASTM
A194, Gr 7 semi-finished hex nuts shall be used, except for sulfide stress cracking
services where stud bolts shall be ASTM A320, Gr L7M.
For sizing studs flanges from 1/2" to 24" (NPS) ASME B16.5 will be used, for older
flanges 24 "Standard Class indicated in particular pipes were used.
10.2.9 Valves
10.2.9.1 General
The following give specific COMPANY requirements regarding the selection and use of
valves. Valves shall be in accordance with piping material class sheets in PDVSA Norm
H-221 and OCN-CPF-SP-G-00-2004-420 “Piping Material Specifications Cerro Negro DB
GFM Project” and the following:
a. Drain, bleed or by-pass connections may be tapped into a valve body where
necessary to simplify piping or to insure complete drainage.
Welded body ball valves are preferred, however three piece ball valves may be used if
the ends, end seals, and through bolting are adequately designed to resist the design
hydrostatic end forces, expected bending moments, and design temperatures.
Ball valves of the end-assembled type shall not rely on adjacent pipe work for safe
operation.
Ball valve shall be reduced port type except where specified as fullbore on the P&ID’s. In
addition, ball valves used for isolation of relief valves shall be full port.
b) Gate Valves
Rising stem gate valves shall be provided with a stem thread protector. This thread
protector shall be clear or be provided with another method of determining the stem
position. A rod attached to the end of the stem and fitted through a weather seal on top of
the thread protector is an acceptable alternate. Stems on 2" (NPS) and smaller gate
valves may be protected with a heavy application.
c) Globe Valves
Globe valves in accordance with ASME B16.34 and metal to metal seats shall be used for
limited throttling services.
d) Check Valves
Check valves shall not be installed in vertical lines in which the flow is downward.
For erosive service and for piping that is to be pigged, only swing check valves shall be
used.
The type of valve is according to the Technical Specification for Materials. Face-to-face
gate valves, globe, check, ball and plug dimensions are in accordance with ASME
B16.10.
Block valves are generally gate, ball, butterfly or plug. Globe valves in sizes of 3 "(NPS)
and higher will be used only when regulation service (restriction) required.
Plug valves will be used (when conditions operating temperature is within acceptable
limits) instead of gate valves for services with solids to prevent loss of seal in the valve.
Operators gear (manual) will be supplied to the gate valves and globe (which are
operated more than four times a year), ball and cap and butterfly (fire-safe) in the
following sizes and higher as shown in Table 3:
Butterfly –
Gate or Globe Ball or Plug
Security (3)
Butterfly –
Gate or Globe Ball or Plug
Security (3)
(3) Generally, this valve type not available above ASME class 600.
For Class 600 (ASME) and over, valves shall be provided with pressure equalizing
bypass globe valve, as indicated in Attachment N° 2, when the operating differentia
pressure across the closed valve approximately equal the pressure rating of the valve at
the operating temperature.
Integral valve bypass shall not be used unless absolutely required due to design
limitations. If used shall be globe valves, only.
The bypass valve and the related bypass piping shall be of the same piping class as the
principal valve.
10.2.10 Blinds
Blinds (Pancakes and spacers) shall normally be installed on all process lines at battery
limits and where required to facilitate testing, inspections or maintenance of equipment.
Blind and eight figures needed for operation plant, systems tests, etc. Blinds shall be in
accordance with the specified in the table 326.1 of ASME B31.3.
The "Bypasses" around equipment and control valves shall be supplied only to the extent
required for normal operation and as shown in the P&ID.
10.2.12 Bolts
The dimensions of the bolts must correspond with the provisions of the ASME B18.2.1.
The nuts for the bolts must be American heavy hexagonal series ASME B18.2.2.
The tolerances shall be Clase 2A and 2B for bolts and nuts respectively. Nuts for bolts
shall be of the American Hexagonal Heavy series.
When bolts A193 Gm. B7 are specified, they must fit to the conditions of temperature of
the liquid.
Bolts shall be of continuous thread and with hexagonal heavy nuts with the following
features:
- Material: Table A-2 "Design Stress Values for Bolting Materials" by ASME B31.3
- Thread:
- Material: Table A-2 "Design Stress Values for Bolting Materials" by ASME B31.3
- Thread:
Provisions (anchors, guides, etc.) and forecast (space, for example) to thermal expansion
and contraction will be considered on the lines according to ASME B31.3.
Provisions for thermal expansion will normally be made with expansion loops, anchors
and guides. Prestressed cold and expansion joints will be avoided where possible and
could be used only with the approval of the COMPANY.
Piping systems shall be designed so that the moments and forces exerted on the nozzles
of the mechanical equipment do not exceed the permissible reactions, according to
manufacturers and / or applicable standards.
Nozzle loads for the thermal case, the pressure and weight case, the pressure and weight
case plus seismic or wind (whichever is greater), and the combined thermal, pressure and
weight cases shall be compared with the equipment manufacturer's recommendations.
Piping reactions against equipment shall not exceed the manufacturer's
recommendations or limits in local codes, whichever is less. Where rotating equipment
manufacturers make no recommendations, the reactions shall not exceed the limits in the
appropriate API Standard (e.g., API 610).
In addition to stress analysis, piping systems shall be reviewed for the possibility of flow
induced vibration, pressure pulse induced vibration and hydraulic surge. This includes,
but is not limited to, compressor piping, high velocity gas lines (including relief valve
discharge lines), and loading lines. The method of analysis and computer program used
for this analysis is subject to COMPANY approval.
• For piping systems studied will be made only static analysis, due to operating
conditions, sustained and thermal expansion.
• Except for the lines connected to the equipment referred to above, will only be
considered for the analysis of flexible pipes greater than or equal to 24 diameter ", with
special attention to those who are in pipe bridges and sleepers ("Piperack/Pipeway ").
• In piping systems where there are branches that have the same geometric
configuration and operational conditions, the most critical is modeled as a typical
arrangement.
• Verification of the occasional efforts piping arrangements will be made under the
following considerations:
- To wind: This analysis applies to heights above 9 meters lines whose diameters
are greater than or equal to 12".
- For earthquake: This analysis applies to pipes diameter greater than or equal to
24 "straight lengths” greater than 30 meters.
• For verification efforts pipelines will be considered pipe sections both buried and
surface, as well as road and river passes.
b. Supports for piping at equipment shall be designed so that excessive forces and
bending moments caused by temperature changes shall not be transmitted to the
equipment. Where deck level pipe supports are required at pumps, compressors or
turbines, they shall be supported on integral extensions of the equipment support
structure, and not be anchored to the equipment baseplate.
c. Supports shall be placed as near as practicable to both lateral and vertical hanges in
direction, yet be designed to not interfere with operation or maintenance.
d. The design of all piping supports and pipe supporting elements shall assume that the
piping shall be subjected to hydrostatic testing (321.1 of ASME B31.3). Spring supports
shall be protected against overload during hydrostatic test. All restraints or stops installed
for this purpose shall be removed immediately after the hydro-testing has been
satisfactorily completed.
e. The layout and design of piping and its supporting elements shall meet the objectives
of Par. 321.1.1 of ASME B31.3 with the further provision that sag between supports
during operation shall be limited to 1 in. or 1/4 of the NPS whichever is less.
f. Spacing for overhead pipeway supports shall be based on the piping size mix to secure
maximum economy. Where support spacing exceeds allowable spans for small lines
(2" (NPS) and smaller), they shall be grouped (wherever practicable) to simplify
supporting methods. To eliminate an intermediate support for small line, it may be
economical to increase line size.
h. Only where resting type supports are not practicable may hanging type supports be
used. Shop-welded trunnions and lugs are preferred to bolted clamps.
l. Support lines such that control valves and equipment can be removed for maintenance
and flanges parted to install blanks.
j. MSS SP-58 support types 1, 2, 5, 6, 7, 9, 10, 11, 12, 15, 16, 19, 20, 23, 28, 29, 30, 41,
43, and 49 shall not be used. Guidance for the selection and application of pipe hangers
and supports is contained in MSS SP-69.
k. Each support for a line should carry approximately the same portion of the line weight.
When it is anticipated that a line will deflect vertically due to thermal expansion or
contraction, and thereby unload some supports and overload others (including equipment
nozzles), spring hangers should be provided. If the deflection is of the order of 2" or less,
variable spring hangers should be used. For deflections greater than 2", constant support
spring hangers should be considered. Maximum allowable variation in supporting effect
shall be 25% for the total vertical travel between the hot and cold positions.
l. All springs shall be provided with stops to prevent excessive spring deflection. The
stops shall also be able to carry the piping load in the case of spring failure. All spring
hangers shall be provided with means to indicate at all times the proper position of the
spring with respect to the hot and cold positions of the piping. Spring supports shall be
hot-dip galvanized except that springs shall be neoprene (or equal) coated.
m. Where corrugated or bellows type expansion joints are approved for use, anchors and
guides shall be provided to force the expansion movement into the joint. These anchors
shall be designed to withstand a force equal to the force recommended by the
Manufacturer for the operating pressure at which the joint is to be used. If the
Manufacturer makes no recommendation, the anchors shall be designed to withstand a
force equal to the sum of the pressure end load (maximum working pres-sure times
maximum cross-sectional area of expansion joint) and the force necessary to compress
the joint (friction factor). Where friction factor is not known, the anchor shall be designed
to withstand a force equal to twice the pressure end load.
n. All supports shall be steel. Where the environment makes a galvanic cell possible,
insulating material is required between dissimilar clamp type supports and the pipe (e.g.
steel supports and cupro-nickel pipe).
o. The use of integral attachments of a material that differs from that of the piping is
prohibited.
Connected pipe valves and mechanical equipment such as pumps, which require regular
maintenance, will be supported so that these elements and equipment can be removed
without installing additional temporary supports.
The number of non-welded joints (e.g., flanged and threaded) shall be kept to a minimum
with only those necessary for cleaning, maintenance, operation, and inspection. Welding
end valves shall be used in services where valve maintenance shall be minimal or where
valve maintenance can be done in place.
Expanded joints and flanges having expanded joint inserts shall not be used (308.2.2 and
313 of ASME B31.3).
For joint requirement services, threaded construction shall be limited to vent and drain
piping downstream of primary vent and drain valves and to instrument piping downstream
of the primary instrument block valve, e.g., pressure gauge connections and orifice flange
taps. Threaded construction is also permitted in 2" (NPS) and smaller utility piping.
Pipe unions (and other piping joints involving straight threads - see Fig. 335.3.3 of ASME
B31.3) shall not be used in severe cyclic conditions. 2" (NPS) and smaller joints of this
type may be used in Category D (air, water, open drain) fluid service. For non- Category
D fluid service, they shall not be used in 1-1/2" (NPS) and larger (314.2.2 of ASME
B31.3).
Joints using flared, flareless, or compression type fittings shall not be used under severe
cyclic conditions. Use of fittings other than bite-type compression fittings requires prior
COMPANY approval (315.2 of ASME B31.3).
Together in all piping systems equal to or greater than 2" (NPS) will be executed with butt
weld ("Butt Welding").
Joints in pipes of 1-½" (NPS) and smaller will be executed with welding plug type ("Socket
Welding"), preferably. Threaded joints as indicated in PDVSA Norm H-221, OCN-CPF-
Connections that may require bracing include sample points, instruments, purges, thermal
relief valves, corrosion probes, and vent and drain connections (particularly where double
blocks and bleeds are required). The bracing method shall be subject to COMPANY
approval. Care must be taken in the location of small connections in piping subject to
thermal movement.
Full-sized or reducing branches at angles other than 90 degree shall not be employed
except when required for flow and pressure drop considerations (e.g., flare lines):
1) The angle between the branch and the run of the header shall not be less than 45
degree. The centerline of the branch shall preferably intersect the centerline of the
header. Exception - where flow conditions control and COMPANY has given prior
approval, the branch may intersect the header in a tangential or semi-tangential directions
provided the angle between the branch and the run of the header is not less than 60
degree and the intersecting surfaces form a welding angle of not less than 45 degree.
2) Integral forged 45 degree fittings (e.g. WFI Vesselets) shall be used for 45 degree
branch connections.
Contoured insert branch fittings (e.g. Sweepolet, Vesselet, and Laterolet) which have
been qualified in accordance with 304.7 of ASME B31.3 may be used in place of tees. If
used, the weld attaching the fitting to run shall be examined as a circumferential buttweld
in accordance with 304.3.2 (a) of ASME B31.3.
Spacing between adjacent branch connections shall not be less than 1-1/2 times their
average diameter (304.3.3 (e) of ASME B31.3).
Reinforced integrally welded attachments which abut the outer surface of the head, in
sizes 4" (NPS) and higher, are not permitted under any of the following conditions:
• The ratio d/D (diameter of the branch / head diameter) exceeds 0.8.
• The wall thickness of the head is less than Schedule 40 (Schedule 40).
Valves frequently operated and not so frequently required for emergency operations,
where the centerline of the wheel is more than 2.3 m above the floor or platform level,
they will be operated with chains of impact type and height of these will be defined in the
next phase of the engineering review and/or approval by COMPANY.
Other infrequently used valves that are above 2.3 m above the floor or platform level will
be installed so that they can be accessed from a ladder or mobile platform.
Valves frequently operated, located in trenches will be provided for extension of the
wheel, leaving this in a range of 100 mm (4 in.) Below the plate (covered), if the steering
wheel is more than 305 mm (12 in.) below the plate (cover).
Gate or globe valves which operate normally open, if possible, will be installed so that the
shaft is horizontal.
All sample connections shall consist of a 3/4" (NPS) line class ball valve, a swaged
reducer and a 1/2" (NPS) needle valve. Sample connections shall be installed in the side
of pipe rather than top or bottom. Sample connections shall be located at deck drains.
Valved vent connections shall be installed at trapped high points of 3" (NPS) and larger
piping. Those high point vents which are provided for hydrostatic testing purposes only
are an exception and should be provided with a seal welded solid plug but no valve.
Piping systems shall be provided with vents and drains to hydrostatic testing and
maintenance. These will be placed in the highest and lowest points of the pipe,
respectively. Test vents may be sealed once it has finished. The lines are pneumatically
tested vents not need proof.
Operating drains must be provided with permanent systems drainage closest connection.
These sewer lines, water must be blind below the valve disc lock.
Discharges to drain pressurized closed drainage heads. These are completely sovereign
of the system of open drains.
Vents and drains should be as short as possible. If longer connections such as are
required, because of insulation thickness mains, connection brackets or higher they may
be employed.
Drains should be located so that facilitates the installation of temporary connections for
draining liquids or other products.
Relief valves with atmospheric discharge through a pipe, have the same extended three
meters (10 ft) or more above any platform or work area within a radius of 7.6 m (21.5 ft)
from the discharge point.
Relief valves will be connected to flare and/or other disposal system only when so
indicated in the Process Diagrams (P&ID's). Also particular requirements for the design of
these pipes, for example avoid "pockets" in the path, it will be according to the DTIs.
The bottom or low point of the pipeline in the discharge of pressure relief valves, when
they discharged into the atmosphere, will be provided with a drain hole ("weep hole") of
6 mm diameter (minimum).
Relief heads have continuous slope towards the receiving containers (KO Drums). The
slope will be indicated in the Process Diagrams (P&ID's).
In general, all lines with a requirement sloping, this condition must be reflected in the
respective P&ID's, in the same way should be reflected slope requirements for closed
drains.
Instrument connections and block valves shall be not less than 3/4" (NPS) except that
connections to orifice flanges may be 1/2" (NPS). Instrument connections that require
periodic rodding out to overcome plugging shall be considered on an individual basis by
Contractor. The details of proposed installations shall be subject to COMPANY approval.
The instrument connections up to, and including, the first instrument block valve shall
conform to the same design and material specifications as the line or vessel to which it
connects. The first instrument block valve shall be a ball valve.
Instrument piping downstream of the first instrument block valve shall consist of austenitic
stainless steel tubing, fittings, and valves.
1/4 0.035
3/8 0.042
1/2 0.049
Type 316 bite-type compression fittings shall be used except that they shall not be used
under severe cyclic service, or above 2000 psig without COMPANY approval. Acceptable
fittings is Swagelok.
Tubing valve bodies, stems and trim shall be Type 316 stainless steel. Valve stems shall
be blow-out proof design. Valve manufacturer shall perform a leakage test to verify that all
joints and seat are bubble tight at 100 psi air pressure. Stem packing and seat material
shall be capable of withstanding the maximum temperature and pressure encountered in
service and during steamout.
All instrument pressure piping shall be suitably supported and protected from accidental
damage. This is especially true for those pressure gauges subject to vibration which
require support separate from the connection. Siphons or pigtail condenser seals shall be
provided in connections to close mounted pressure gauges in steam or other
condensable vapor service.
All safety devices, pressure safety valves, emergency shutdown valves, and flow safety
(check) valves shall be provided in accordance with Section VIII of the ASME Pressure
Vessel Code, the Project P&I Diagrams, this Specification, and API RP 520 and 521.
Pressure relief valve inlet lines shall be kept as short as possible. Pressure drop in inlet
piping shall not exceed 3% of the relief valve set pressure.
All block valves around relief-valves shall be full bore and provided with a seal or a
locking device with a master key for all locks.
Where parallel pressure relief devices are used, each sized for full flow, separate block
valves shall be used for each relief device and a 3/4" (NPS) valved bleeder connection
shall be provided between the upstream block valve and the relief valve. The connection
may be on the block valve body.
The locking device shall be designed to ensure that simultaneous blocking of relief valves
cannot occur.
Relief valves shall be installed in a vertical position. Pressure relief devices shall be
accessible and installed for easy removal from a deck, permanent platform, or from a
mobile platform where the space under the valve is accessible and clear of obstructions
and the pressure relieving device is not more than 12' above the deck.
Pressure relief devices discharging to a closed pressure relief system shall be located
higher than the header and discharge down into the header unless otherwise approved by
COMPANY.
Pressure relief device vents discharging to the atmosphere shall not be smaller than the
relief device outlet. The discharge piping shall be designed and restrained to
accommodate axial, lateral and upward reaction forces due to discharge. The discharges
shall be directed away from walkways, personnel areas, and equipment. Any discharge
piping containing hot fluids shall vent and drain safely away from equipment and
personnel.
Relief headers shall slope towards the knock-out drum, avoiding pocketing as much as
possible. Where pocketing is unavoidable, a client-approved means of continuous
draining of the header is required.
The fire system design will be based on the principle that only a major fire occurs at the
same time see the PDVSA Norm IR-M-03.
Major fire is one that involves a block or section of a separate installation, a particular
block will be required maximum water consumption and will determine the maximum total
required capacity on the ground, see PDVSA Norm IR-M 03.
Requirements or fire water flow to the different sections of a facility is typically determined
based on minimum rates of application. These rates have been established taking into
account, among other factors: the separation between equipment, the type of hazard
present and the nature of the products involved. The total water requirement for a facility
Each plant area has a suppression system and / or cooling according to PDVSA Norm
IR-M-03.
• Flood gas systems "Inergen" - (trade mark) electrical equipment in enclosed areas.
Paint systems for different piping arrangements will be selected according to PDVSA
Norm O-201 "Selection and application specifications of anticorrosive coating systems"
according to environmental conditions in the document Process Basis and Design
Criteria. Additionally, the procedure abrasive surface preparation before applying the first
coat of paint will be according to NACE No. 1 / SSPC-SP 5.
Outside the system of underground pipes used for coating project, will be the corrosion
protection system which will consist of three elements: the liquid adhesive, tape corrosion
and mechanical protection tape. The minimum requirements to be met by siding are set
out in the technical specification PDVSA EM-04-10 / 01.
The thickness and material for thermal insulation of pipes will be selected according to the
design conditions and operation of each line and in accordance with documents in its
latest review available established in PDVSA Norm L-212 "Hot Insulation and Service".
In case of any contradiction in the design between the specifications, standards, codes
and standards cited, the more restrictive criterion is used. Any deviation will be discussed
and submitted for consideration by the COMPANY for approval.
The criteria for the performance of hydrostatic tests specified for piping systems shall be
as indicated in PDVSA Norms PI-08/02/01.
In all cases, the tests must be approved by the inspection of the COMPANY before its
execution.
Piping systems shall be hydrostatically pressure tested with potable water to the greatest
extent practicable at the MANUFACTURER's yard before shipment. This test shall be
performed regardless of any shop hydrostatic pressure testing of piping spools.
Hydrostatic testing shall not be performed when there is an air temperature of 40 °F or
less, nor during periods of rain or fog. Piping with less than l/2" wall thickness shall not be
field pressure tested at metal temperatures below 5 o C. Piping 1/2" and thicker shall not
be tested at metal temperatures below 60 °F unless impact tested materials were used, in
which case the minimum metal temperature may be 5 °C.
Shop and field pressure tests shall be performed in accordance with the provisions of
ASME B31.3, except that pneumatic testing shall be subject to COMPANY approval. Any
pneumatic test must meet the requirements of Paragraph 345.5 of ASME B31.3.
Contractor shall submit all testing procedures and schedules for approval. Pressure
gauges and recorders used in the tests shall have been calibrated within the previous 30
days. Care shall be taken to remove all water from piping to be operated below 2 °F.
This includes relief valves, control valves and other piping components which have been
tested in the shop.
Relief or blow down systems shall be tested in accordance with ASME B31.3; however, in
no case shall the test pressure be less than 15 psig. Relief valves and rupture discs shall
not be included in the test.
Each reinforcing pad (or segment thereof) for pressure openings shall be tested with air at
a pressure of 60 to 100 psig. A bubble test solution such as Sherlock, Snoop, or the
equivalent shall be applied to inspect all welds.
When the inside surface of branch weld reinforcing pads cannot be visually inspected,
pressure tightness (as evidenced by no loss of pressure) shall be determined by means
of a pressure gauge. Test openings in reinforcing pads shall not be plugged following the
test.
Instrument air supply lines and air lines to air-motor operated valves shall not be tested
with water. They shall be tested with dry compressed air (or nitrogen) at a pressure
substantially equal to (80 to 100 percent), but not exceeding, the maximum allowable
operating pressure for the weakest equipment in the group under test. The test pressure,
in any case, shall not be required to exceed the air pressure available at the job site. All
joints, welds, and connections shall be swabbed with soap or similar solution to facilitate
the detection of leaks during air tests.
Should a leak develop in a weld during test, the defect shall be removed by chipping,
grinding, flame gouging, or arc-air gouging, and the area shall be rewelded. Either the
magnetic particle or the dye penetrant method shall be employed to determine the extent
of the defect. All repair welds shall be preheated and postheated as originally required,
and the basic principles of the same welding procedure as initially used shall be
employed as far as applicable. After repair, the weld shall be retested. The progressive
inspection requirements of Paragraph 341.3.4 of ASME B31.3 apply as they do for
defects discovered during inspection.
The mechanical design of the different equipments is carried out taking into account the
information generated by the disciplines of Process and Mechanical Engineering for Early
Production Station (EPF) presented in the documents "Design Criteria and Basis -
Process" and "Mechanical Design Criteria", in addition to the information in the Data
Sheet of each of the equipments and/or Packaged Units.
• The equipments will be specified following the latest edition of codes and standards
specified in Section 3.3 of this document.
• The unit system to be used and are in Data Sheets, calculations and other documents
will be the English system, and will be different to these, in some cases which are
specified. The calculation procedures established in another system present their
results in the specified system.
• The equipment will be designed for a service life of 20 years. Different equipments are
known and proven design.
A modular process skid is a process system contained within a frame that allows the
process system to be easily transported. Individual skids can contain complete process
systems and multiple process skids can be combined to create larger process systems or
entire portable plants. They are sometimes called “a system in a box.” An example of a
Equipment is selected due to its combined safety features, compatibility with the module
construction, maintenance features, and known operating reliability.
After equipment selection, the overall layout of the equipment is developed. This is the
most critical phase of the design, as it defines the number of modules, length of piping
runs, accessibility, and ultimately the overall plot plan. Often, modular construction is
especially beneficial for locations where plot space is at a premium. In these situations,
the access is engineered into the unit; therefore, the initial layout is key in meeting these
special design requirements. Special attention is required so that the layout will fulfill the
following requirements. a. Safety in Operation b. Ease of Operation c. Operating, Routine
Maintenance, and Turn-around access.
In order to meet the COMPANY’s requirement, required module assembly and fabrication
schedule, very close cooperation is required between engineering, design, drafting, and
the fabrication shop. Timely issuance of the drawings, accuracy of drawings, coordination
of equipment deliveries, rapid solution of day-to-day problems, and coordination of
subcontracts are all key factors to meeting the project schedule requirements. With
proper planning and execution, modular projects consume less time from kick-off to
commissioning than do field-erected projects. Site preparation, excavation and foundation
installation occurs in parallel with equipment manufacturing, and shop fabrication
activities. Weather related delays are non-existent in a fabrication shop. Earlier plant
start-up translates into an early market entry and early cash flow.
Modules are usually shipped via trucks if they are no larger than approximately 14 ft wide,
12 ft high, and 55 ft long. Weight limits vary but are typically limited to 50,000 to 100,000
pounds. A more costly alternate is rail transportation, where up to 16 feet wide and up to
100 feet long modules can be shipped. Weight is not usually a limitation in rail
• Outdoor installation.
• The facility must comply with all applicable laws, national and local, including safety
aspects and environmental protection.
• Will be selected the different construction materials for each equipment according to
the type of service and as set out in the corresponding standards.
• High reliability.
10.5.1 Pumps
Pumps that exceed any of the conditions listed above for hazardous or flammable
services are designed according to the API Standard 610 standard, latest edition.
Available NPSH (NPSHA) must exceed the Required NPSH (NPSHr), at least 3 feet (1
meter) in all operating range, from a low flow to the design flow.
If the selected pump fails to comply with the margin between NPSHr and NPSHd,
VENDOR AND/OR MANUFACTURER is required to perform the NPSH Witnessed Test.
Also will be developing the Running-Test witnessing.
Pumps should have normal operating point or left of the point of maximum efficiency, in
the curve of the pump impeller diameter proposed.
Pumps in service of oil and hazardous materials are equipped with mechanical seal and
seal plan according to API 682 (if applicable). Seals are cartridge type.
The lubrication system of pumps is provided with oilers constant level and protected with
steel mesh.
Pumps with constant speed drivers must have the impeller diameter such that at least the
head can increase by 5% to the design flow, with the installation of a larger diameter
impeller in the corresponding pump.
The sizing of electric motors is made considering the final curve of the pump or increasing
the pump power at the point of design in a percentage that which can vary according to
the pump power.
• Design capacity: All the pumps shall be designed for 20% additional to the required
normal capacity.
• Shut-off: The pump head at shut–off shall be approximately 110%, but not exceed
120% of head at the specified capacity point. Low capacity, high head pumps may be
exempt from these requirements with the approval of COMPANY.
Motor ratings, including motor service factor, shall be at least equal to the following
percentage of rated pump power in Table 5.
30 hp to 75 115
For the design, selection and specification of centrifugal pumps in the project taking into
consideration the recommendations based on COMPANY’s Requirements.
The pumps and auxiliaries shall be designed for a continuous operation to the pressure
set up in the relief valve of and at the point of overspeed trip set up in the variable speed
system.
Steel casings are required for any pump located within process unit areas handling a
stream containing any flammable or toxic materials.
If special nonferrous materials are required, the COMPANY shall specify the casing
material.
The casings subject to pressure and in contact with the fluid shall have a minimal
corrosion allowance of the 3 mm (1/8”).
The values of available NPSH specified in the data sheets shall be referred to the top of
the foundation for all the pumps.
The liquid speed through the discharge valves must not exceed the double of the speed
through the suction valves. RF flanges in the connections that use spiral metallic gasket
shall be 125 to 200 AARH, unless otherwise is specified in the categories of individual
lines.
Skid, paint and noise shall be in accordance with the specifications given for THE
COMPANY.
Available NPSH (NPSHA) must exceed the Required NPSH (NPSHr), at least 3 feet (1
meter) in all operating range, from a low flow to the design flow.
• Pumps are provided with relief valves, in the discharge line and the power of the
pump driver is determined by the pressure relief of the system.
For the design, selection and specification of rotative (or positive displacement) pumps in
the project taking into consideration the recommendations described in the Process
Documents based on COMPANY’s Requirements.
Pressure vessels are designed, fabricated and tested in accordance with "Boiler and
Pressure Vessel Code", ASME Section VIII, Division 1 and the document H1M0011503-
CO4D3-MD16001 "PRESSURE VESSELS TECHNICAL SPECIFICATION". Alternative
design methods for ASME Section VIII Division 2 can be used if it results in a more
economical design but is subject to approval by the client, supported with reliable
technical- economic argument.
All Pressure Vessels shall be stamped under ASME “U” and National Board Registration,
unless otherwise specified in the Material Requisition and/or Data Sheet.
The corrosion allowance is indicated in the Data Sheets of the equipment and if section
5.6 Corrosion Allowance (AC) of document H1M0011503-CO4D3-MD16001 "PRESSURE
VESSELS TECHNICAL SPECIFICATION", is added to the calculated thickness of the
body, heads and nozzle connections. No additional corrosion thickness is added to the
flange faces. Flanges shall be according to the Standard ASME B16.5 and B16.47 or
according to the Code ASME, Section VIII, Div 1, The allowed stress shall be determined
according to the Code ASME, Section II. ASME B16.47.
Relief valves and drainage for vessels shall be per Table 6 shown below.
<=1.42 3/4” 2”
1.45 a 17 1” 2”
> 70.8 2” 3”
The pressure vessels are designed for earthquake and wind loads according to applicable
Codes and Standards and indicated in the data sheet.
The manholes and containers are designed for earthquake and wind loads according to
what is indicated in the corresponding Data Sheet.
Inspection openings (manholes, railings, etc) according to the ASME Section VIII Code
are provided. The manholes are 20” (NPS) for Vessels 60 in. inside diameter and less; for
Vessels over 60 in. inside diameter, one-third the vessel diameter, but not to exceed 40”
(NPS) and the hand-rails, 8" (NPS) diameter, as minimum.
All internal moving parts are designed for installation and removal through the manhole.
The design pressure of the pressure vessels shall be as indicated in each one of the data
sheets.
Any internal device required by process conditions will be provided by VENDOR AND/OR
MANUFACTURER as part of a modular system and installed field as mentioned in the
corresponding data sheets.
The Calculation’s scope determines the thickness of the heads, body and estimated
weight, empty, filled with water and in operation. These calculations take into account the
operational conditions generated by process and established in the Mechanical Data
Sheets generated.
Design Pressure
When vessels, exchangers or other equipments are interconnected without block valves
all those equipments shall have the same Design Pressure (MAWP), which shall not be
minor than the following table:
Table 10. Minimum Design Pressure for Connected Vessel without Block Valves
MAXIMUM OPERATING DESIGN PRESSURE
PRESSURE (psig) (PSIG)
The minimal metal design temperature for the pressure vessels shall be determined using
the rules of the Code ASME Section VIII Div. 1 UG-20 (b).
Location of Equipment
• The location of the equipment shall be based on the safety, economy and facility to
realize maintenance works and examinations. The required secure distances shall
agree with the norms PDVSA IR-M-01 “Separation Between Equipment and Facilities”
and PDVSA IR-M-02 “Separation of Equipment and Facilities with Relation to Third”.
• For location of equipment shall be considered the following aspects: predominant wind
direction, relative location of the station, location of piping, location power lines,
existence of natural drainages and geographical features.
• The minimal breadth of the pedestrian paths at area level shall be 3 ´0 “(915 mm).
• Platforms and ladders must be installed for maintenance and examinations of the
vessels, valves stations and instrumentation, when they are in a high level from the
ground.
The assembly formed by the pressure vessel, electrodes, indirect heater, transformers,
accessories, air blowers, heat exchangers and pumps shall be submitted as a package, in
accordance and the followings P&ID:
The design life for all equipment and pipes forming part of Electrostatic Desalter shall be
20 years.
The requirement of the ASME Section VIII for Pressured Vessels shall be mandatory at
the time to choose the material and the manufacturing processes.
The Desalters shall be design to withstand as a minimum, the loading exerted by internal
pressure, weight of the vessel, weight and pressure of the test water, wind, earthquake,
reaction of supports and temperature, accordance with the Section 10.5.2 of this
document and the Section 5 of Pressure Vessels Technical Specification (H1M0011503-
CO4D3-MD16001).
The minimum pressured vessel thickness permitted for shell and head shall be 1/16” (1.5
mm) without any corrosion allowance in accordance with the Section 5.1 of Pressure
Vessels Technical Specification (H1M0011503-CO4D3-MD16001).
The Maximum Allowable Working Pressure Calculated under UG-27 ASME Section VIII
Division 1, for shell and head must be higher than the Hydrostatic Pressure.
All the Desalters shall be designed for either wind or earthquake loading. It is assumed
that wind and earthquake loads do not occur simultaneously.
For welded head, all the seam in the head shall be 100 RT, regardless the Code
requirement.
Storage tanks are designed and fabricated according to the Code "Welded Steel Tanks
for Oil Storage" API 650, considering that they are filled with water at 60 °F. Comply with
the maximum volume of 20 m3 of storage for non-cylindrical or round tank. API 620 / API
2000 / NFPA 20 standards are used where applicable.
The tank diameter or greater height of four (04) meters are manufactured on-site .
All internal moving parts are designed for installation and removal through the manhole.
They have dual pump system for disposal in cases that so warrant process.
The tanks are checked against overturning by wind speed and seismic load. Anchor bolts
are adequate to withstand both rising due to internal pressure as earthquake or
overturning by wind independently.
The mechanical evaluation of existing tanks to be used for new services is made by the
API 653.
In cone roof tanks, internal design pressure is near atmospheric pressure. Is adopted as
design pressure twelve (12) inch water column (0.43 psig), this is only to consider an
internal pressure of about twelve (12) inch water column (0.43 psig) when the tank is filled
with liquid.
For the design of the storage tank fire water should meet the requirements in NFPA 22
and API 650 each one in its latest edition, with a tolerance to corrosion on their plates,
minimum 1.6 mm (1/16 inch).
The foundation or base of the storage tank installation of fire fighting water should be
designed according to soil studies and structural calculations to withstand the weight of
the water tank itself and containing a maximum filling capacity and minimize differential
settlement, the inner surface of the ring covered with sand or compacted soil, should be
covered with a layer of asphalt 10 centimeter or 3.93 inch (10 cm, [3.93 in]) minimum and
with a slope of 0.5 percent (0.5%), measured from the center core to the periphery; the
concrete base or circle must have the same slope. You must apply a waterproof seal with
the base material between the tank and the bottom plates around the circle in order to
prevent entry of moisture that causes corrosion.
The calculation of the wall thickness of the atmospheric tanks will be performed as set
forth in the standards and codes listed in Section 3.2 of this document and based on the
Heat exchangers are designed in accordance with "Boiler and Pressure Vessels Code"
ASME Section VIII, Division 1 and the document H1M0011503-CO4D3-MD16002 "HEAT
EXCHANGER TECHNICAL SPECIFICATION". Shall be stamped under ASME “U” and
National Board Registration, unless otherwise specified in the Material Requisition and/or
Data Sheet.
Shell and tube Heat exchangers also must comply with TEMA Standard.
Typical fouling factor specified in the Norm TEMA and norm PDVSA shall be used, unless
specific information is given by THE COMPANY.
If a Duty Capacty superior to the maximum normal capacity established by the thermal
balance is needed, their rasons shall be indicated in the data sheet.
Corrosion allowance for the exchanger shall be taken normally from the Norms TEMA,
section R-1.51 unless other values are specified for the corrosive service.
Insulation is needed for personal protection when temperatures of 150°F or major are
reached.
The space between the baffles must be between 0,3 to 0,5 of the heat exchanger internal
diameter.
Distance between the tubes (Pitch) must be as a minimum 1,25 times the tube outer
diameter .
A shock baffle shall be insalled in the inlet nozzle, to prevent the fluids eroding the tubes.
The minimum corrosion allowance must be consistent with that specified in the data
sheets and applicable diagram materials.
Materials shall conform to the specifications tabulated in the TEMA Standards, and all
materials subject to internal or external pressure shall also conform to the specifications
given in ASME Code Section II or other governing codes.
Alloy protective linings may be used in the design of exchangers in services for which
severe corrosion can be predicted.
The flanges of the body must be made of wrought material. Pressure holding components
shall be of the same or comparable material as that used for the shell or heads. And, the
material of internals such as baffles, tie rods, etc. may be similar to the shell material; if
the shell is cladded, those internals shall be similar to the cladding.
The minimum design pressure for the exchanger shall be 3,5 kg/cm2 (51,45 psi) both for
the tube side and/or the shell side.
The preferred tube diameter is 1 inch outside diameter (1” OD) for hydrocarbons and ¾
inch outside diameter (¾" OD) for water.
The body or shell diameter must not exceed 100" (NPS) diameter and preferred lengths
of the tubes 20 feet (20’) and/or nominal length, as indicated in the data sheets, in order
to have a team of modularized type heat transfer. The total weight of each tube bundle
must not exceed 20 tons for easy transportation and installation.
10.5.6.1 GENERAL
Except as shown and/or specified otherwise, a “Packaged Equipment System” is a self-
contained, skid mounted, operational piece of equipment including all interconnecting
piping, ancillary devices and control systems required for its operation. All piping within
Until other dimensions are specified and be approved by the COMPANY, the dimensions
of the exterior skid will not exceed 60 foot of length, 12 foot of width and 14 foot of high
place (for the transport).
Overall dimensions of the skid shall not be less than the overall dimensions of the
equipment mounted upon it. No item shall extend outside the perimeter of the skid base.
Skid flooring shall consist of either removable section of galvanized grating or non-skid,
raised-pattern steel plate, ¼ in minimum thickness. If the flooring type is not stated in the
equipment specification, the default type shall be grating. Floor grating shall not be used
as a mounting surface for equipment or supports. Minimum design live load for walkways
and platforms shall be 100 psf (pounds per square foot).
a) The equipment mounted in skid, pipelines, pressure vessel, rotary equipments and the
components will be inside the exterior edge of the skid.
c) The skid shall be rectangular and designed in such a way that the equipment can be
removed to realize maintenance.
d) The systems of instrumentation and pipelines shall be designed to allow isolation and
removal of minor equipments, including:
- Isolation of valves of blockade (if it applies) and parts or unions and nipples
- Points of connection.
e) The skid shall have access adapted to realize easily tasks of daily operation and
maintenance of routine from the axis of the skid or across areas opened with paths,
platforms or both considering:
- The manual valves, switches, starters and other mechanisms needed for the daily
operation shall be located inside a suitable scope of the axis of the skid or an area of
access.
f) The access areas with paths or platforms shall be free from dangers of stumble,
obstructions at level of the head, dead ends and restricted passages.
b) The minimal design charges shall be determined in accordance with ASCE 7 and/or
PDVSA A-261 Criterion and Minimal Action for the Design of Industrial Structures.
c) Las cargas de diseño mínimas serán determinadas de acuerdo con ASCE 7 y/o
PDVSA A-261 Criterio y Acciones Mínimas para el Diseño de Estructuras Industriales.
d) The seismic charges shall be in conformity with ASCE 7 or Uniform Building Code and
COVENIN 3621-2000 Designed resistant Earthquake of Industrial facilities
e) The wind charges shall be based in: COVENIN wind Actions on the Construction 2003-
1989.
g) Type of exposition C.
- Location (ground).
j) The facilities of the skid shall be sufficiently rigid to prevent damage during fabrication,
assembly, transportation or installation.
l) Other skids are designed with a maximum deflection of L/300, where L is the length of
the skid.
m) The structures of the skid shall be designed for the severest effect during the following
charges:
c) Flanges of welding, stakes or temporary welded guides, it shall be removed before the
application of the recovering or painting
d) When it is needed to disarm the skid for the movement or erection in field, the fixers
shall be installed, and the parts or materials of connection, such as spikes, screws, nuts,
socket-pans shall be provided by the additional one of 10 % needed.
e) The skid shall be constructed in accordance with AISC S326 for welded components
and in accordance with AISC S329 for screwed components.
f) The equipments and pressure vessels with weight superior to 300 Pounds (Vacuum)
shall be connected or welded directly the structural members of the skid.
g) If it are included a floor of plate, this shall be cut and sealed for penetration in his
periphery.
h) The skid shall have a crane of vertical screw along the main structure.
i) The holes of the bolts of anchoring shall be located in the same reinforced area of the
crane of screw.
b) It shall have obtain approval on the part of THE COMPANY of the procedures of weld.
c) The personnel to realize the works welding, shall be qualified in according to AWS
D1.1, section 5.
d) The connections welded by both sides of the periphery of the beam and crossing the
beam, shall be of welding of complete penetration.
f) The not accessible area in the skid, shall be sealed with weld.
k) The VENDOR shall perform non-destructive testing of the skid structural welding
according to the following:
- Visual inspection of 100 percent of all welds according to AWS D1.1 “Structural Welding
Code-Steel” – last edition.
- Ultrasonic testing (UT) of 10 percent of the skid’s full penetration welds, exclusive of full-
penetration welds associated with lifting lug connection details, of which 100 percent shall
be tested.
- Magnetic particle testing (MT) of 10 percent of the skid’s fillet welds, exclusive of fillet
welds associated with lifting lug connection details, of which 100 percent shall be tested.
All MT shall be performed using an AC yoke.
- THE COMPANY reserves the right to dictate which welds are examined.
- It is Nonskid.
- It shall have a space of ½ in. for 3/16 in. between bars, minimum.
b) The space between supports of the grating of floor shall be of 48 in, maximum.
d) The support bars of the grating of floor shall be of 1 ½ in. for ¼, minimum.
e) The plate of floor shall be of ¼ in. of thickness, minimum, shall be constructed Nonskid.
f) The skid must possess drainage tray, which shall be constructed in structural steel
ASTM A36 by a minimal thickness of ¼ in.
j) The design of the Platform and stairs shall be in conformity with PDVSA JB-251
(Structures of Steel - Design).
On units type package design criteria are established based on process requirements,
standards and equipment’s supplies included in these packages.
In packaged unit’s process conditions inside and outside of these units and service
conditions available to feed these drives are included.
Packaged units data sheets will be developed estimated only and will be complemented
by engineering notes where the specifications that applies for each one to be reflected;
the definitive data sheets will be by VENDOR AND/OR MANUFACTURER.
Flare / Vent Stack system shall be designed for continuous and unattended burning of
produced gas, or the intermittent burning of hydrocarbons emergency relief and will be
available to operate under the environmental conditions in the documents listed below:
Flare will operate smokeless during low pressure gas continuous burning without injection
of steam or water. The design of this unit will be such as to allow easy transport and
maintenance.
Flare design and support must take into account the thermal expansion of the main body
as a result of the temperature conditions; the design must also take into account the stop
condition when flare’s housing is at room temperature. Support for tension wires, specific
design criteria applicable for tension wires.
To Vent Stacks not equipped with seals labyrinth greater than NPS 12 inch (12”) in
diameter, will be provided a grid (grating) in the flare, to no more than 12" below the
flange connection of the Tip of flare, for the purpose of prevent large objects falling from
the Mechurrio when the tip is removed. The grid (grating) should be made of pipe or flat
bars with the flat side aligned parallel to the flow direction to minimize the pressure drop.
The openings of the grid (grating) should be square with a maximum distance from the
center- to-center distance between the bars 9 inches (9”). The grid will be designed to
withstand an impact load of 500 kg over a distance of 3 m.
Flare stack will be designed with tension wires to withstand specified loads wind.
The electrical connection points will be located at the base of the Flare stack.
The elevation of the process gas connection to the flares will be as indicated in the data
sheet listed below. The stack base will have a connection for drainage directed towards a
drum for removal of liquids.
To calculate the radiation level solar radiation according to the following considerations in
the Table 8:
Stacks should be designed for a minimum of 1000 hours of useful life due to fatigue by
induced resonance due to the wind resonance speed for 100 hours and a safety factor of
10%.
Flare’s stack should have lifting ears to safety lift and install it on the foundation.
The design of the platforms and stairs shall be in accordance with OSHA Safety
Standards and PDVSA Norms mentioned in Section 3.2 of this document.
All surfaces specified to be painted shall be in accordance with PDVSA Norms O-201
SELECTION AND SPECIFICATIONS APPLICATION OF PROTECTIVE SYSTEMS
PAINTINGS. REV 7 DIC.13. This standard establishes criteria for color code and paint
systems to use. The painting system will be used for industrial environments.
Surfaces treated with abrasive blasting must be protected with the first coat paint system
selected in accordance to Codes and Standards applicable listed in the Section 5 of this
document, in phases pre - treatment or pre - manufacture.
At the completion of the work specified, all painted work shall be touched up and restored
where damaged, defaced or defective, and the entire work left free from blemishes.
12.1 General
Safety should be considered as an integral part of the work, starting with the basic
concept of the process and continuing throughout the design process, review piping and
instrumentation diagram (P&ID), equipment’s specification, design detail, procurement,
construction and finally the start-up.
The safety of a plant more efficiently obtain security building as part of the process, and
every piece of equipment instead of relying on complex controls and operating
instructions. Excessive complexity leads to confusion. Intelligence and hard work is
needed to make things simple; but the effort involved can be highly rewarded.
To assess the risk factors in the design to protect worker health, also, the integrity of
equipment, plants and environment, applying the principles of safety, health and
environment.
Health, safety and environment is based on a set of principles, policies, laws, standards,
norms and fundamental procedures to eliminate and control risk factors capable of
causing damage to persons, property and the environment.
Based on a set of principles, laws, standards and rules formulated, which aims to prevent
accidents and control risks that may cause harm to people, environment, equipment and
materials. To this end, will be considered when designing the COVENIN 22-70-1995.
For the design and installation of equipment and piping associated with the project items
5.3, 5.4 and 5.12 of PDVSA Norm 90622.1.001 "Design Safety Guidelines" will be
considered.
The noise level must not exceed the limit values laid down in the PDVSA Norm SO-S-08
"Guideline for implementation of hearing conservation programs" and the design of noise
allowable limit in plant and equipment will be made according to criteria established in
item 5.1.3 of that standard.
13 ATTACHMENTS
Source: PDVSA’s Design Engineering Handbook, PDVSA H -251, Process and Utility Piping Design
Requirements, Rev. 1 Dec 98
Notes:
1. Elevations are referred to the point of maximum elevation (PMEA)
surrounding floor finishing equipment. The elevation of the point of
support equipment (PSE) is shown in the pipe layout drawings is the sum
of the PMEA elevation and elevation indicated in this table pedestal and
referred to medium level the sea.
2. All levels of support in concrete should include a clearance of at least 25
mm for mortar’s leveling.
3. Developing detailed engineering, should verify all elevations of the
foundations of the equipment according to the latest equipment sizes
information certified by SUPPLIER AND/OR MANUFACTURER.
4. Unless specific process requirements.