Polaris Engineering Standard

100.2 Rev.: 0 Page: 1 of 9 Date: 07/05/09

DESIGN PHILOSOPHY TABLE OF CONTENTS I. II. III. SCOPE GENERAL OBJECTIVES GENERAL DESIGN PHILOSOPHY 3 A. B. C. D. E. IV. Process Design Design Life Abnormal Operation Operation During Power Failure Off-Test Operation 3 3 3 3 3 4 4 4 5 5 5 5 7 9 9 PAGE 2 2

SPARE EQUIPMENT A. B. Pumps Compressors

V. VI. VI.

SELECTION OF PUMP AND COMPRESSOR DRIVERS SELECTION OF COOLING METHOD PROCESS DESIGN GUIDELINES A. B. C. D. Vessels Exchangers Pumps Line Sizing Criteria

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DESIGN PHILOSOPHY I. SCOPE This Standard outlines the design philosophy to be followed for refinery, chemical, and production facilities. Where conflicts exist between this Engineering Standard and other POLARIS Engineering Standards and/or applicable codes or regulations, the more stringent requirement shall govern. All conflicts shall be brought to Clients attention for resolution. Client shall be the sole arbiter of any conflicts. II. GENERAL OBJECTIVES It is the Client's objective that all facilities be provided at minimum cost while satisfying requirements for operability and safety as stated herein. No design, regardless of cost, is permitted which reduces safety of operation below the Clients or industry standards, whichever is more stringent. Quality of materials, equipment and workmanship are not to be sacrificed to obtain lower investment. Rather, savings shall be obtained by elimination of unnecessary equipment, compact layout to reduce materials, sound engineering design, and avoidance of unjustified surplus capacity. Incremental investments above this minimum will be approved only when they satisfy the economic criteria for the project. It is the Clients intent to operate all process facilities continuously for a minimum of three years without shutdown for inspection and maintenance; therefore, the design, materials, and equipment shall be of proven reliability to provide this objective. To assist in attaining these general objectives, the following design guidelines shall be followed by the Contractor unless he can demonstrate to the Client a less costly and more efficient way to accomplish these same objectives. Contractor must have the Client's prior approval in writing before proceeding in these cases. III. GENERAL DESIGN PHILOSOPHY A. Process Design In general, the process design shall provide the capacity, product quality and yields specified by Client. No reserve for future potential capacity or flexibility is desired unless otherwise specified. B. Design Life Except where more stringent requirements are specified by POLARIS or industry standards, equipment and piping shall be designed for twenty years operating life.

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Where corrosion rates are specified by Client, they shall be used to determine corrosion allowances that are to be built into the equipment. Where corrosion rates are not specified, corrosion rates generally accepted in the petroleum industry shall be used, and the Contractor shall specify the corrosion rate or corrosion allowance he has used for each limiting material on each piece of equipment. Corrosion allowances specified in these standards shall be considered the minimum acceptable values. C. Abnormal Operation Plant design, including equipment capacities and necessary piping shall provide for start-up, shutdown, fail safe operation on power or cooling water outage, offtest operation, and other unusual but inevitable operating conditions or upsets. D. Operation During Power Failure It is not intended that the processing facilities will operate during a complete power failure. However, the facilities shall be designed and supplied with enough steam drivers, alarms, warning devices, automatic steam cut-ins, and the like so that in the event of a complete power failure, all processing facilities can be shut down by a minimum operating staff in an orderly manner without damage to any facilities or equipment. E. Off-Test Operation Process units shall be designed to internally recycle any off-test or slop stocks whenever practical. If necessary, off-test pumping and control facilities shall be provided to permit disposal of off-test and other "slop" stocks to tankage. Off-test connections shall be centralized (preferably at the Battery limit) to form a slop manifold where possible. IV. SPARE EQUIPMENT A. Pumps In general, all pumps except those considered non-critical to process operations by Client are to be spared. 1. Where pumping duty is handled by a single pump, the spare pumps shall be of equivalent (100%) capacity. Where multiple pumps are required for the design duty, the spare pump shall be equivalent in capacity to one such pump (50%, 33%, etc.). Common spares will be considered with Clients approval when the pumping services spared by the common pump are streams of similar characteristics.

2.

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3.

Pumps in non-critical service, such as basement sump pumps and certain chemical injection pumps are generally not spared. The Client shall verify which services are considered non-critical. In critical services the main pump shall be steam turbine driven and the spare pumps shall have motor drivers. The motor driver shall be provided with an auto-start system. Critical services, such as lube oil, shall be as defined by the Client.

4.

B.

Compressors All process compressors shall be spared unless approved by Client. In general, all utility compressors except those considered non-critical to process operations by Client are to be spared. Consideration shall be given to providing the required capacity in two or more machines for a particular service when: 1. 2. Loss of total compressor capacity would endanger operations, poison catalyst, and the like. Processing can continue at a reduced rate without appreciable affect on other processing facilities or without reducing the throughput of the entire refining facility. The incremental cost for the multiple units over the single machine can reasonably be justified on an insurance basis or by continuation of operation at a reduced rate.

3.

V.

SELECTION OF PUMP AND COMPRESSOR DRIVERS Pumps and compressors shall generally be motor driven except where specifically stated otherwise. However, Contractor may utilize steam turbine drivers, with Clients approval, where required to achieve economic steam balance, and where reduced operating costs warrant the additional investment within the criteria established by Client for the project.

VI.

PROCESS DESIGN GUIDELINES The following are selected process design guidelines that are to be used by the Contractor as indicated. These criteria represent Clients minimum requirements, except where stated in Project Design Specifications or Basic Engineering Design Data and are not intended to supercede Contractors customary design practices. Other process design criteria will be per the Contractors standard practices. Contractor will identify any significant conflicts and bring them to Clients attention for review and approval. Contractor shall provide Client with access to his standard practices for spot checks to ensure conformance of the Contractor to these standards. A. Vessels

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1.

Towers/Drums Design Pressure a. Non-liquid Full Vessels 1) 2) b. Operating pressure x 1.10 or + 25 psi (whichever is greater) Unless otherwise specified, all vessels to be designed for full vacuum at 300F

Liquid Full Vessels Same as above but calculate as shut-in pressure 0.9. Use this for design if higher than a.1) above. This will avoid lifting of relief valve on major liquid full vessels when exposed to pump shut-in conditions.

2.

Towers/Drums Design Temperatures a. b. c. d. Maximum Operating Temperature + 50 F Min. Unless otherwise specified, 300 F @ full vacuum Minimum design temperature = 300F at design pressure. Unless otherwise specifed, use 650 F minimum design temperature for Carbon Steel unless this requires a higher flange rating.

3.

Trays a. b. c. Maximum percent flood shall be 80% based on using conventional trays. Design for turndown to 40% of design rates. Trays in foaming and high pressure services are to be sized by using appropriate system factors. Examples of typical system factors are: Amine Absorber Amine Regenerator Hydrocarbon Absorber Gas Plant Stripper Sour Water Stripper 0.80 0.85 0.75 0.85 0.75

For high pressure fractionation, with vapor densities of 1.8 lb/ft3 or higher, use the following:

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d. 4.

System factor = 1.21 / dv0.32, where dv is vapor density, lb/ft3

Minimum spacing between trays shall be 24 unless approved by Client.

Vessel Sizing Horizontal Drum Hydrocarbon residence time (HLL-LLL) Low Liquid Level (LLL) High Liquid Level (HLL) 5 minutes minimum Minimum 1-0 above bottom or as required for water settling Maximum 1-0 below top or as required per vapor / liquid separation criteria

Water Boot Water residence time (HLL-LLL) Low Liquid Level (LLL) High Liquid Level (HLL) Vapor Flow Area Droplet / particle size for separation

4 minutes Minimum 1-0 above bottom tangent line Maximum 1-0 below top tangent line

150 500 microns with demister pad 300 microns maximum without demister pad 150 microns maximum for Compressor Suction and Interstage Drums Greater of: a) 3 minutes on net product plus reflux. b) 1 minute on total liquids(including pumparound) Remove 100% of all entrained droplets 8 microns and larger. Maximum 20 ppb Na in product steam. Chevron type separators external to steam drum are required.

Chimney Tray residence time

Steam Generation Quality

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B.

Exchangers 1. Exchanger Design Pressure a. Pumped systems: 1) 2) b. Design pressure = shut-in 0.95 When protected by a common relief valve with a vessel calculate as shut-in pressure 0.9.

Reboilers, overhead condensers, feed exchangers, etc. Design pressure = System PSV setting pressure drop static head effects. In general, tower overhead condenser and receiver design pressure = column design pressure. Reboiler design pressure = column design pressure + the greater of tray pressure drop or 5 psi. In all cases, the design pressure of the lower pressure side should be set so that the low pressure side test pressure is equal to or greater than the high pressure side design pressure.

c.

2.

Exchanger Design Temperatures a. b. c. d. Maximum Operating Temperature + 50 F Min. Unless otherwise specified, 300 F @ full vacuum Minimum design temperature = 300F at design pressure. Unless otherwise specifed, use 650 F minimum design temperature for Carbon Steel unless this requires a higher flange rating.

3.

Fouling Factors a. In the absence of specific licensor or Client supplied data, the typical fouling resistances in TEMA shall be used as a guideline. It is preferable to use job specific fouling resistances approved by Client. Unless approved by Client the following minimum fouling factors shall be used: 1) For process streams: a) 0.002 ft2 - hr-F/BTU for Naphtha and lighter.

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b) 2) 3) 4) 4.

0.003 ft2 - hr-F/BTU for distillate and heavier.

For steam: 0.0005 ft2 - hr-F/BTU. For temperate water: 0.001 ft2 - hr-F/BTU For the air side of air coolers: 0.002 ft2 - hr-F/BTU.

Design Margins In general a minimum design margin (flows and duties) of 1.1 shall be used for all heat exchange services. For tower overhead condensers and pump-arounds the margin shall be 1.2. Good engineering judgement must be used to determine if other services warrant higher design margins, due to such factors as feedstock variability, future catalyst improvement, etc.

C.

Pumps 1. 2. 3. 4. Datum for NPSHA calculations shall be bottom tangent (vertical vessels) or bottom invert (horizontal vessels). Unless otherwise specified, NPSHA reported on data sheet shall be NPSH (calculated) 1 foot. Allow for permanent suction strainer 50% plugged or 0.3 psi delta P, whichever is greater. Shut-in Pressure: Pump shut in pressure is defined as shut in head plus maximum suction pressure (assume shut in head is equal to 1.25 times design head if a pump curve is not available). Maximum suction pressure is source PSV set pressure static head pressure drop effects. Reflux and pump-around pumps should be designed with 20% excess flow capability. All other pumps should be designed with 10% excess flow capability.

5.

D.

Line Sizing Criteria Apply 20% margin to friction factor. Use the following guidelines for pressure drop and velocity. Pressure Velocity Drop Ft / Sec PSI / 100 ft Boiling liquids (at equilibrium) to pump 0.05 0.25 14 Sub-cooled liquids (40 F below bubble point) 0.2 1.0 18

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Pressure Drop PSI / 100 ft to pump suction Cooling water to pump suction Pump discharge & liquids under pressure (Note 1) Cooling water at pump discharge Differential pressure liquids Process Gases Vacuum (Note 2) Atmospheric +/- (Note 2) Pressure (>50 psig) Steam 50 psig headers & laterals 300 / 600 psig - headers - laterals - Vacuum (Note 2) Two Phase Flow (Notes 3 & 4) Lean Amine Rich Amine Sour Water 0.2 1.0 1.0 2.0 0.5 2.0 0.02 0.3 0.1 0.5 0.5 1.0 0.1 0.25 0.5 1.5 0.5 2.5 Based on available delta P 4 Max. -

Velocity Ft / Sec 18 5 10 5 12 15 Max. 300 Max. 150 Max. 100 Max. 150 Max. 250 Max. 250 Max. 300 Max. 100/SQRT (mix density) Max. 5 Max. < 5 Max. 5 Max.

Notes: (1) For offsite rundown lines, keep pressure drop around 0.5 1.0 psi/100ft. (2) For critical services such as turbine exhaust and compressor suction size line such that available delta P/calculated delta P 1.20. (3) For thermosyphon reboilers available/calculated pressure drop should be 2/1 when using average mixed phase density. (4) For two phase systems with straight vertical runs in excess of 5 diameters, check for slug flow.