- Details
Table of Contents
- Introduction
- Scope
- General Procedure for flow diagram preparation
- The Process Flow Diagram
- The Pressure (P) - Temperature (T) Profile
- The Engineering Flow Diagrams (P&ID)
- The Utility Flow Diagram (UFD)
- The Interconnectiong Flow Diagram
- The Process Safeguarding Flow Diagram
- The Revamping Flow Diagram
- Check List
- Preparation of Line Table
- List of Related Red-Bag Standards
- List of Other Standards
- Typical Arrangement of Equipment Installation
1. Introduction
1.1 Purpose
The purpose of this document is to outline the procedures for the preparation of process flow diagrams, pressure-temperature profile diagrams, engineering, utility and interconnecting flow diagrams and special diagrams as revamp flow diagrams and pressure safeguarding flow diagrams.
1.2 Concept
Flow diagrams are highly specialized “language for information transfer. They represent the engineer’s concept of how plant equipment should be interconnected. The diagram is almost physical in a sense, since every piece of equipment, every pipeline, valve and instrument is shown. Diagrams are used to convey information between groups working on the project and translate the plant design into ‘real’ piping and equipment.
1.3 Use
By preparing the diagrams properly, the engineer can convey a great deal of technical information, quickly and accurately, with a Limited amount of paper work.
1.4 Tee of Diagrams There are 7 types of flow diagrams:
1.4.1 The Process Flow Diagram (PFD)
The PFD is developed by the Process Engineering Department. Final drafting by the Flow Diagram Squad. On this document are given the main process equipment, fluid flows, main control loops and critical valves. It is a tool for the process engineer(s) to convey information to project and specialist engineers to design the installation in detail (see fig: 6).
1.4.2 The Pressure Temperature Profile Diagram(PTP)
The PTP diagram is a document prepared by the Process Engineering Department with the purpose of providing project, control systems and piping engineers with the correct pressure and temperature correlations between the various piping systems, vessels, exchangers, etc. The document ensures that proper values are being used for preparation of data sheets, line tables and other documents as, e. g. painting systems, insulation, etc.
For PTP preparation procedures refer to Standard Specification BN-EG-UE-1 (Design guide for Pressure and Temperature profile).
1.4.3 The Engineering Flow Diagram (EFD)
On this document are shown all equipment connecting piping, utility piping, complete with control, loops and all other instrumentation, all valves a safety measures. It is the main tool for the project engineer to convey information to the piping design office and control systems engineering group for the detailed piping and control systems design (see fig: 13).
1.4.4. The Utilities Flow Diagram
This document. shows how utilities are generated and distributed from the source or supply point to the various parts of an installation. The diagram shows coon control loops, additional equipment that is deemed necessary to supply the utility as required and the safety measures necessary (see fig: 18). The diagrams shall be drawn in accordance with the geographical layout of the plant.
The diagrams are generally divided per generation activity, e.g. steam generation, inst air, cooling water, fuel oil, etc. The utility equipment shall be shown. Packaged units to be shown within, heavy dotted line.
1.4.5 The Interconnecting Flow Diagram (IFD)
These diagrams are prepared to show the interconnecting lines between various plant units and, e.g. tank farms, etc,
1.4.6 The Process Safeguarding Flow Diagram (PSFD)
This document shows the correlation of safety devices installed but indicated on separate EFD's. It “highlights” the final level of protection provided by the safety systems installed.
This document will be produced on client's request only, e.g. SIPM
1.4.7 Revamp Flow Diagram
“Revamping Flow Diagrams” shall be prepared to indicate which equipment, lines, control loops, etc. must be demolished, modified, removed or relocated, etc. in a revamping project. The existing engineering flow diagrams of a plant or unit to be revamped shall be used.
In general two sets of diagrams are to be prepared:
a) An updated existing EFD's version for demolishing purposes, RFD's.
b) New “as built” EFD's
For more details refer to Chapter 10.
1.5 Notes:
1.5.1 It must be noted that particular instructions given by client or licensor with respect to his requirements or special requirements covered by any authority decrees shall be observed.
1.5.2 If any of such rules, decrees or instructions exist, these must be mentioned in the “Project Specification”.
1.5.3 When these instruction have not been incorporated, the documents produced will be unacceptable to the client or licensor and/or authorities.
1.5.4 Where in the following text of this Engineering Procedure has been referred to other Company procedures or standards, this is only true where the Company standards are not conflicting with those mentioned under para 1.5.1.
1.5.5 To obtain maximum uniformity with regard to line thickness, lettering, symbols, etc. the drafting on vellums shall be executed by the Flow Diagram Squad.
1.5.6 There is still another flow diagram, prepared by the control systems engineering group, exclusively for use by process and control systems engineers. This flow diagram is principally a PFD on which the control system engineer indicates specific instrument physical data. The document is called; “Instrument Data Flow Sheet”. It is not further mentioned in this ‘Engineering Procedure”.
1.5.7 The examples presented in this Engineering Procedure are taken from actual jobs and include general Clients requirements. Therefore, the symbols used will not always be identical to the symbols shown on the legend sheet fig: 22.
1.5.3 On an EFD, a package unit, e.g. compressor, can be indicated with a heavy drawn block with reference to one or more vendor flow diagrams (process, lube oil, seal oil, water cooling, etc.) which can be adopted.
2. Scope
2.1 This Engineering Procedure shall be used as a standard for the preparation of process and engineer flow diagrams as outlined in para 1.4 of the Introduction.
2.2 It shall also be used to edit systematically the text for the Project Specification on the subject of flow diagram preparation.
2.3 The purpose of this Engineering Procedure is to provide the engineers with all necessary information to generate the various diagrams needed with the greatest consistency and efficiency possible.
(...)
The full procedure is available for registered users. The procedure is part of the Introduction and Basic Piping Design course at InIPED.
- Details
Table of Contents
- Orifice Plate Calculation
- Restriction Orifice Calculations
- Appendixes:
Appendix A, Calculation of Compressibility Factors
Appendix B, Flow Formula
Appendix C, Additional Specifications for Maximum Metering Accuracy
Appendix D, Conversion Formulae for Orifice Meters
Appendix E, Calculation of Meter Maximum Flow, When Orifice Bore Is Given
1. Orifice Plate Calculations
SCOPE : This standard gives instructions for the use of Company orifice plate calculation sheets :
- form B.N. -K003-1 (English Units)
- form B.N. -K003-2 (Metric Units)
GENERAL : The method of the orifice plate calculations mentioned above is based on: “Principles and practice of flow meter engineering” by
LK Spink, 8th edition, and is in accordance with AGA-ASME standards, and the AGA gas measurement committee reports numbers 2 and 3.
Moreover the draft ISO recommendation No. 532 (revised text) dated September 1964 has been used as a basis as well.
For a simplified description of the theoretical background see appendix B.
REFERENCES :
- Principles and practice of flow meter engineering L.K. Spink, 8th edition.
- Flow measurement with orifice meters R.F. Stearns, R.R. Johnson, R.M. Jackson, C.A. Larson published by D. van Nostrand Co. Inc.
- Gas measurement committee report No. 2 AGA, May 1935.
- Gas measurement committee report No. 3 AGA, April 1955, Reprint 1956).
- AGA flow constants (Foxboro)
- Draft ISO recommendation No. 532 September 1964.
INSTRUMENTATIONS : The instructions are numbered 1 to 30.
The same numbers appear on the calculation sheets for reference.
No. 1: FLUID: Fill in process fluid flowing through the orifice.
No. 2: MEASUREMENT UNITS: (see also note below)
Fillin the units of measurement in which the client requires the meter to read. These units should be agreed upon with the client and are generally specified in the applicable general specification for instrumentation. These units may be different from the units in which normal flow is given.
No. 3: BASE PRESSURE: (see also note below)
Fillin the common base pressure to which all measurements in the plant are referred. This again is to be agreed upon with the client.
Common accepted base, pressures are 14.70 psia, 760 mm Hg and 1 Kg/cm²A.
No. 4: BASE TEMPERATURES: (see also note below)
Fillin the common base temperature to which all measurements in the plant are referred.
Agreement with client necessary. Some accepted European base temperatures are:
- Liquid : 15°C or 60°F
- Gas : 0°C or 60°F
Note: See BN-SP-K1 Specification for Instrumentation.
No. 5: BASE SPECIFIC GRAVITY:
Fillin the specific gravity at base conditions as specified under Nos. 3 and 4. For liquids, the specific gravity is related to water, for gases to air. When working in metric units, liquid specific gravity is related to water at 15°C (density of water at 20°C is 0.99823 grams/cm³).
The specific gravity of gases can be obtained by dividing the molecular weight of the gas by the molecular weight of air (28.996).
For English Units the specific gravity is referred to water at 60°F.
No. 6: STEAM QUALITY:
Fillin quality of the steam, and when it is superheated or saturated, state this.
No. 7: NORMAL FLOW AT BASE CONDITIONS:
Fillin the normal flow at base conditions as specified and the units in which it is given.
No. 8: NORMAL FLOW IN WEIGHT UNITS:
Fillin the normal flow rate and the units in which this is given.
No. 9 and 10: METER MAXIMUM FLOW:
Fillin meter maximum flow after calculations as outlined under 27.
No. 11: MINIMUM FLOW:
If the minimum flow falls below 20% of the meter maximum flow, consideration should be given to the use of a second lower differential range instrument or a second orifice run.
No. 12: COMPRESSIBILITY:
Fillin the compressibility ratio’s Zb, Zf for gas flow which are defined as:
Zf = deviation from true gas law at operating conditions.
Zb = deviation from true gas law at base conditions.
The compressibility ratio’s can be determined from reduced pressure and reduced temperature as outlined in Spink, pages 351 and 352. See also appendix A.
No. 13: MOLECULAR WEIGHT:
Fillin molecular weight for gas flow only.
No. 14:OPERATING PRESSURE:
Fillin upstream pressure in psia or Kg/cm² Abs.
(Kg/cm²A = Kg/cm² gauge + 1.0336).
(PSIA = 14.70 + psig).
No. 15:OPERATING TEMPERATURE:
Fillin the operating temperature at the orifice in degrees Rankine for the English calculation sheet and degrees Kelvin for the metric calculation sheet (°R = °F + 459.6, °K = °C + 273.2).
No. 16: OPERATING SPECIFIC GRAVITY:
Fillin specific gravity at operating conditions. For liquids this specific gravity is referred to water of 60°F, when working in English units and 15°C when working in metric units.
No. 17: OPERATING DENSITY:
The operating density is in some cases to be found in tables such as the steam table but in other cases must be calculated as out-lined under 27.
No. 18 ABSOLUTE VISCOSITY:
The operating viscosity shall be given in centipoises. Viscosities of several liquids are given on pages 325 thru 331 of “Flow measurement with orifice meters” published by D. van Nostrand Co. Inc. or page 184 of “Principles and practice of Flow Meter Engineering” by L.K. Spink.
To convert from centistokes to centipoises multiply by the specific gravity. For other conversions see page 311 thru 324 of the Van Nostrand book.
No. 19: METER DIFFERENTIAL: (h)
A meter differential of 100 ins W.G., or its metric equivalent is preferable. To avoid swaging up higher ranges 150” W.G., 200” W.G., etc., may be used.
For compressible fluids, the range in inches water should be lower than the absolute static pressure, (at upstream side), this to keep the Y factor (see 29 III) within reasonable limits.
For computer calculations these values are:
- gas : (in H2O) = 1.3 upstream pressure
- steam : (in H2O) = 2 upstream pressure
No. 20: NOMINAL PIPE SIZE AND SCHEDULE:
Fill in the nominal size of the pipe, and the schedule (see piping specification).
If the pipe size is given to DIN standards, fill in outside diameter and the wall thickness. (When the form English units is used, state also the inside diameters in mm).
No. 21: ACTUAL I.D.:
The internal diameter as given in line tables and the square of this figure shall be stated in units as indicated.
When the form for English units is used, and the pipe is to DIN standards, fill in I.D. in inches, converted from I.D. in mm. stated in 20.
No. 22: CHART GRADUATION AND CHART FACTOR:
A chart graduation shall be specified preferably 0-10 or 0-100 square root.
This should be agreed upon with client. In special cases, a direct reading graduation may be used.
The chart factor is the rounded off meter maximum flow divided by the maximum chart reading.
No. 23: PRESSURE TAKE-OFF LOCATION:
When the static pressure measuring point has been specified, state if pressure is taken-off from upstream or downstream tapping. This in connection with the use of diagrams for expansion coefficient. (See 29, correction III).
It is Company’s standard practice to take off the pressure from the upstream tapping, as specified in the ISO standard no. 532 (Draft recommendation). Pressure measured at downstream tapping may be considered, when the static pressure is very low, so that the rule of thumb as mentioned is no. 19 page 7 can not be followed.
( ... )
The full procedure is available for registered users.
- Details
Table of Contents
1. Scope
This standard gives instructions for the use of Company control vale calculation sheet form BN-K 006.
2. General
The formulas and valve slide-rule are in accordance with the "Recommended voluntary standard formulas for sizing control valves", issued by the Fluids Control Institute with bulletin
F.C.I. 62-1.
However, temperature corrections have been added to these recommended basic formulas.
The valve sizing formulas have been based on the "U.S. VALVE FLOW COEFFICIENT CV", which is the yardstick of the valve capacity.
A valve flow coefficient CV is the number of U.S. gallons per minute of water at 40 to 120°F which will pass through a given flow restriction with a pressure drop of 1 psi.
The determination of the valve CV by the manufacturer should be based on Fluids Controls Incorporation, bulletin F.C.I. 58-2.
Because the CV coefficient is measured by the valve manufacturer at rather low pressure drops across the valve and at rather low static pressures the CV coefficient will be lower at higher pressure drops, depending upon the type of valve and design of the valve body.
Reference is made to booklet "The valve flow coefficient and its contribution in control valve sizing" and to the section "Limitations of valve sizing formulas", sheets 19 and 20.
European and especially German manufacturers sometime use a "Valve Coefficient KV ".
A valve flow coefficient KV is the number of cubic meters per hour of water at 5 to 30°C which will pass through a given flow restriction at a pressure drop of 1 kg/cm2.
Kv = 0.86 Cv and Cv = 1.17 Kv
A few valve manufacturers in Great Britan specify the CV valve coefficient based on an "Imperial gallon", instead of the U.S. gallon.
Cv (Imp. gpm) = 0.83 Cv(US gpm)
and Cv (US gpm) = 1.2 Cv(Imp. gpm)
The full procedure is available for registered users.
- Details
- General
- Formulae
- Instructions for the Use of Safety Relief Valve Calculation Sheet (General) Form BN-K008 10
- Instructions for Use of Safety Relief Valve Calculation, Attachment “A”
(External Fire) Form BN-K009 - Instructions for Use of Safety Relief Valve Calculation, Attachment “B”
(Heat Exchangers) Form BN-K010 - Instructions for Use of Safety Relief Valve Calculation, Attachment “C”
(Miscellaneous) Form BN-K011
Appendix A - Calculation of Latent Heat of Evapourization
Appendix B - Calculation of the Maximum Duty of a Heat Exchanger
Appendix C - Derivation of API-ASME Code Formula
Appendix D - Formulae for Safety Valve Calculation in Accordance with German Rules (TÜV and AD-Merkblatt A2)
Appendix E - Comparation between API-Code Rumanian-Code for the Calculation of Pressure Relieving Valves
Appendix F - Comparation between API-Code and the Italian-Code for the Calculation of Pressure Relieving Valves
1. General
1.1 Scope
This standard has been developed to standardize the method of safety relief valve calculations in accordance with API, ASME codes and local codes.
1.2 Calculation Sheet
For the calculation of a safety relief valve, the following standard calculation forms can be used:
BN-K008 : Safety relief valve calculation
BN-K009 : Attachment “A” (External fire)
BN-K010 : Attachment “B” (Heat exchangers)
BN-K011 : Attachment “C” (Miscellaneous)
The main safety relief valve calculation sheet, form BN-K008 has been developed to evaluate the governing hazard and to calculate the area of the relief valve.
The attachments have been designed to evaluate the quantity which has to be relieved by the safety relief valve.
1.3 References
1. API Recommended Practice for the design and installation of pressure relieving system in refineries, API RP 520, second edition, Sept. 1960.
2. The design and construction of pressure relieving systems by Nels E. Sylvander and Donald L. Katz, April 1948.
3. Data Handbook on Hydrocarbons by J.B. Maxwell, 5th edition.
4. Engineering Data Book by the National Gasoline Supply Men’s Association (NGSMA), 7th edition 1957.
5. Chemical Engineers’ Handbook, John H. Perry, 3rd edition, 1950.
1.4 Definitions
Safety valve
An automatic pressure relieving device actuated by the static pressure upstream of the valve, and characterized by rapid full opening or pop action. It is used for stream, gas, or vapor service.
Note: This type of valve is normally not specified by Company.
Relief valve
An automatic pressure relieving device actuated by the static pressure upstream of the valve, which opens in proportion to the increase in pressure over the opening pressure. It is used primarily for liquid service.
Note: This type is normally only used in the size 3/4” x 1” or 1” x 1” for thermal expansion.
Safety relief valve
An automatic pressure actuated relieving device suitable for use as either a safety or relief valve, depending on application.
Note: This type is used for general applications.
Set pressure
- Liquid service:
for a relief or safety relief valve on liquid service, the set pressure, in pounds per square inch gauge, is to be considered the inlet pressure at which the valve starts to discharge when discharging against atmospheric conditions. - Gas, vapor or steam service:
for a safety relief valve on gas, vapor or steam service, the set pressure, in pounds per square inch gauge, is to be considered the inlet pressure at which the valve pops when discharging against atmospheric conditions.
Popping pressure
Same definition as set pressure for gas, vapor or steam service, when discharging against back pressure. (Pressure at which the valve pops when in use.)
Differential test pressure
The pressure differential in pounds per square inch between the set pressure and the constant superimposed back pressure.
It is applicable only when a conventional type safety relief valve is being used in service against constant superimposed back pressure.
Net spring setting
Same definition as for differential test pressure.
Cold differential test pressure
The set pressure or the differential test pressure at which a safety relief valve must be set on cold fluid on a test drum plus a predetermined increase in the cold fluid setting, in pounds per square inch, that will result in the valve opening at the correct set pressure in service when the actual service temperature is higher than that of the cold fluid which is used in the test drum. This is the pressure at which the valve should be set on repair shop testing facilities.
Note: The difference in cold and hot setting is the result of change in characteristic of the spring.
Cold net spring setting
Same definition as for cold differential test pressure.
Operating pressure
The opening pressure of a vessel is the pressure in pounds per square inch gauge, to which the vessel is usually subject in service. A vessel is usually designed for a maximum allowable working pressure, in pounds per square inch gauge, which will provide a suitable margin above the operating pressure in order to prevent any undesirable operation of the relief device. (It is suggested that on processing vessels this margin be approximately 10 percent, or 25 psi - whichever is greater.)
Note:
- Take care for reciprocating engines, where peak pressure might reach the set pressure of the valve.
- When setting closer to the operating pressure is required, pilot operated safety valves or “0” ring seal might be considered.
Design pressure
The gauge pressure at which the vessel has been designed.
Note: Safety relief valves are usually set at this pressure.
Maximum allowable working pressure
The maximum gauge pressure, at the coincidental design temperature, permissible at the top of a vessel in its operating position, and which could be the basis for the upper limit in pressure setting of the safety relieving devices for any specific operation.
Note:
- When designing a vessel, the calculations will result in a material thickness. This thickness is rounded off to the first higher thickness which is commercially available. Recalculation of the vessel using actual plate thickness will result in a maximum allowable working pressure which is usually higher than the design pressure.
- Usually recalculation is not done (difference in plate thickness is low for European standards), in that case maximum allowable working pressure is equal to the design pressure.
Overpressure
Pressure increase over the set pressure of the primary relieving device is overpressure. It is the same as accumulation only when the relieving device is set at the maximum allowable working pressure of the vessel.
Accumulation
Pressure increase over the maximum allowable working pressure of the vessel during discharge through the pressure relief valve, expressed as a percentage of that pressure, or pounds per square inch, is called accumulation.
Notes:
- For European plants, it is usual to take an accumulation of 10% . For American plants a value of 20% may be taken for external fire. 25% for liquid relief and in all other cases 10%.
Blowdown
Blowdown is the difference between the set pressure and the resealing pressure of a pressure relief valve, expressed as percentage of the set pressure, or pounds per square inch.
Note: A blowdown between 4% and 5% is usually specified. Care is to be taken that the inlet piping does not have a total pressure loss in excess of 3%. The total pressure loss shall include the velocity head loss ( 1/2 rV2). Note however, that the friction loss should not exceed 1% and the velocity head loss should not exceed 2% of the allowable pressure for capacity relief.
Lift
The rise of the valve disc in pressure relief valve when the valve disc moves from the closed position is called lift.
Back pressure
Pressure on the discharge side of a pressure relief valve.
- Constant back pressure:
back pressure which does not change appreciably under any condition of operation whether or not the pressure relief valve is closed or open. - Variable back pressure:
back pressure which develops as a result of the conditions outlined below.
a) Built-up back pressure: variable back pressure as a result of flow through discharge piping after a single pressure relief valve starts to open.
b) Superimposed back pressure: variable back pressure that is present before the pressure relief valve starts to open.
Note: Variable back pressure on conventional safety relief valves shall never exceed 10% of the gauge set pressure.
Variable back pressure on bellow seal safety relief valves shall never exceed 50% of the absolute set pressure as that is the limit for critical flow, on which the formulae are based.
Coefficient of discharge
Correction factor for the nozzle area, due to contraction etc., include all deviations from ideal flow through the nozzle.
Note:
For full lift safety relief valves, this factor is usually 0.97.
For relief valves at 25% accumulation: 0.64.
For relief valves at 25% accumulation: 0.64.
These low coefficients correct also for the reduction in area which occurs at lower lifts of the disc above the seat.
General rules for the use of safety relief valves
Following, a few general rules will be given for the application of safety relief valves. These rules are only to be used as a guidance.
Safety relief valves are required:
- On all vessels containing fluids which may vaporize when the vessel is subject to fire.
- On all vessels where a closed outlet valve may cause an over pressure.
- On all reciprocating pumps and compressors, if not protected internally.
- On the outlet of turbines, where the design pressure of the low stage casing is lower than the inlet pressure.
- On all distillation and fractionating towers where reflux or cooling water failure may cause excessive vaporization.
- On heaters and furnaces where low flow may cause cooking.
- On heat exchangers or heaters where the cold medium may be blocked.
- On all storage tanks, not vented to atmosphere, where vapor pressure or pumping may cause over or under pressure. In this case special combined pressure vacuum relief valves are to be specified. (Breather valves).
- 3. In cases of long lines, containing liquid, which may be blocked when exposed to the sun (for example butane, propane).
- 4. In all cases where a volatile liquid may get into a vessel under conditions that it vaporizes where the vessel is not designed for the vapor pressure.
- In cases where non-condensable accumulate in a condenser, decreasing the efficiency, so that a pressure rise may occur.
- Tube failure in heat exchangers, which may cause vaporization, or excessive pressure on the shell.
- Control valve failure or instrument failure which either results in one of the hazards 1 through 12, or in any other hazard as for example a reducing station, failing in the open position.
Notes:
- Where more vessels are connected, so that they cannot be separated by block valves, they are to be considered as one system. (Except when local codes imply separate valves.)
- In cases where equipment has to be protected against two or more of the above mentioned hazards, the safety valves shall be calculated for the condition causing the highest flow rate to be relieved, thus assuming that only one hazard will occur at the same time. (Single risk concept.)
- It is evident that when a hazard is the result of another hazard, both hazards are to be taken into account.
2. Formulae
Below a summary of formulae has been given. Most of these formulae already appear on the calculation sheet, but this summary also gives some other formulae which are to be used in special cases.
The formulae given on the calculation sheet for evaluation of nozzle area for vapors is a safe approximation: when accurate calculations are to be made, formula number 2 has to be used in which the “C” factor can be evaluated from formula 2A, or from Binder IV with curves and tables.
Formula 4 gives the nozzle are for steam when the safety valve has to be calculated as per ASME boiler code. Formula 10 gives a quantity of thermal expansion when no normal size is taken. See 68, liquid expansion.
In each formula for vapors the super compressibility factor (Z) can be included as a multiplier of the absolute temperature (also under the square root sign).
This will result in a smaller valve size.
Leaving it out always gives a safe approximation.
SUMMARY OF FORMULAE
UNITS OF MEASUREMENT
DESCRIPTION | ENGLISH UNITS | METRIC UNITS | NO. |
RELIEF QUANTITY VAPOURS (GENERAL PURPOSE) | ![]() |
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1 |
RELIEF QUANTITY VAPOURS (ACCURATE) | ![]() |
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2 |
CONSTANT BASED ON k (C OR C') | ![]() |
C'=4.81 x C | 2A |
RELIEF QUANTITY STEAM (GENERAL PURPOSE) | ![]() |
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3 |
RELIEF QUANTITY STEAM (ASME BOILER CODE) | ![]() |
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4 |
RELIEF QUANTITY LIQUID (INCLUDING VISCOSITY CORRECTION) (NOT FOR BALANSEAL VALVES) | ![]() |
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5 |
VAPOURATION WITH CONDENSATION | ![]() |
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6 |
VAPOURATION WITHOUT CONDENSATION | ![]() |
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7 |
CONSTANT Y | ![]() |
![]() |
7A |
SPLIT TUBE (NO VAPOURIZATION) | ![]() |
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8 |
SPLIT TUBE (VAPOURIZATION) | ![]() |
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9 |
THERMAL EXPANSION | ![]() |
![]() |
10 |
RELIEF QUANTITY LIQUID (INCLUDING VISCOSITY CORRECTION) (FOR BALANSEAL VALVES ONLY) | ![]() |
![]() |
11 |
FORMULAE IN METRIC UNITS, GIVING AREA IN CM2
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||
RELIEF QUANTITY VAPORS (GENERAL PURPOSE) ![]() |
1A | |
RELIEF QUANTITY STEAM (GENERAL PURPOSE) ![]() |
3A | |
RELIEF QUANTITY LIQUID ![]() |
5A |
The full procedure is available for registered users.
- Details
Preparation of Equipment Classification Lists for the PED Authority
Table of content
- Purpose
- General
2.1 Classification Lists
2.2 Pressure Vessel Authority for the Netherlands - Responsibilities
- Guide Lines
4.1 Data Supply and Handling
4.2 Status of the Equipment Classification List in the Netherlands
4.3 Forms, Units, Language and Document Numbering
4.4 Details per Classification List Column
4.5 Other Notes
4.6 Further Handling of the Classification List - Flowchart
- References
- Attachments
1. Purpose
The purpose of this guide line is to describe how the equipment classification list, required for submission to Stoomwezen B.V in the Netherlands, shall be completed with relevant data.
2. General
2.1 Classification Lists
A general guide line on equipment classification lists for pressure vessel authorities is contained in ref. 6.4. It describes the process that should lead to conclusions regarding the required nature and level of pressure vessel inspection by authorities or designated third parties.
2.2 Pressure Vessel Authority for the Netherlands
The pressure vessel authority for the Netherlands is Stoomwezen B.V. This is the sole organization, that can approve and stamp equipment classification lists for Dutch projects. For piping, the classification is normally shown in the line designation tables; these are then subject to Stoomwezen B.V. approval in the same way.
3. Responsibilities
The Project Manager has the overall responsibility for the control of the prepararation and the approval of the classification list for projects in the Netherlands.
The Project Engineering group has the responsibility for the preparation of the classification list for projects in the Netherlands.
The Authority Engineering group has the responsibility for checking the contents of the classification list, for determining the classifications and further handling of the list for projects in the Netherlands.
These responsibilities are worked out in more detail in ref. 6.4.
4. Guide Lines
4.1 Data Supply and Handling
Ref. 6.4 gives guidance for the supply and the checking of equipment classification list data and describes a number of handling aspects of this list.
4.2 Status of the Equipment Classification List in The Netherlands
The equipment classification list in the Netherlands is a document which requires formal approval by Stoomwezen B.V. for every issue. After approval, it is normally stamped for concurrence only, which does not imply responsibility for Stoomwezen B.V. for its contents.
Certain activities such as the submission of Stoomwezen application forms for equipment and piping can not start if there is no formally approved classification list.
4.3 Forms, Units, Language and Document Numbering
4.3.1 Basic Form
The handwritten basic form used by Company for a Dutch equipment classification list is shown in Attachment 3 of this guide line. The column numbers 1 through 21 have been added for easy reference. It shall be noted that the form deviates slightly from the requirements set forth in ref. 6.7.
Some clients (e.g., Exxon Chemicals) still prefer to use have their own basic form, even if not in accordance with ref. 6.7; such forms may have less or even more columns.
When a computerized form is used (for example, in dBase III software, see Attachment 4) a certain flexibility will be possible in the presentation and any deviations from ref. 6.7 can be agreed with Stoomwezen B.V. per project. Due to computerizing, the form can also be made suitable for other (internal) Badger purposes by adding further columns.
A completed version of a handwritten classification list is shown in Attachment 5.
4.3.2 Units
Pressures are indicated in "Bar" and understood as "Bar(g)", which equals Bar(abs) minus one. Full vacuum is indicated as '-1' (bar), although the use of the abbreviation 'FV' is not prohibited.
Older equipment classification lists often show pressures in kg/cm2. They can be converted to bar on a 1:1 basis while ignoring the difference between the units.
Temperatures are always given in degrees Celsius. Volumes are indicated in cubic meters (m3) or cubic decimeters (dm3). Densities, if filled out, are indicated in kg/m3; they are used for the hazard category calculations (ref. 6.5 and 6.8).
4.3.3 Language
The language on the equipment classification list is normally Dutch, but the use of English is accepted by Stoomwezen B.V.
4.3.4 Document Numbering
For document numbering see ref. 6.4.
4.4 Details per Classification List Column
The column numbers refer to the manual form shown in Attachment 3. The computerized form misses columns 4, 12, 15 and 21 for space reasons or because they are less useful.
4.4.1 Columns 1, 2, 4, 6 and 21 (Equipment number, P&I diagram number, number of pieces, manufacturer, remarks)
The columns 1, 2, 4, 6 and 21 are self-explanatory. Column 4 is rarely used any more and, consequently, left out on the computerized form; instead, all individual items are listed.
4.4.2 Columns 3 and 5 (Registration Number, Serial Number)
The columns 3 and 5 must be advised by Stoomwezen B.V. after approval of the filled out data; both numbers serve administrative purposes.
Notes:
- The Client may state his own serial number, but this number has to be approved by Stoomwezen B.V.
- The registration numbers have to be obtained from the manufacturer's documents; these numbers are normally shown in the approval letter from Stoomwezen B.V. or the Nieuw Bouw Rapport (NBR) for the equipment.
- A piece of equipment receives only one registration number, irrespective of the number of spaces the equipment has.
4.4.3 Column 7 (Substance and Phase)
In column 7 the names of the substances and their phases shall be stated. Mixtures should be described in sufficient detail for assessing the effects of each component (see also 4.5.3).
Notes:
For definitions of the phases: see Attachment 1 ("phase" is not identical with the concept "phase" in physics).
- For vessels without tubes only the shell side data shall be filled out.
- For heat exchangers both shell and tube side data shall be given. Reactors etc. consisting of one shell with internal separation walls are considered as one vessel, the data shall be specified for all individual spaces because the classification will be determined by the space with the highest requirements. In all these cases, an additional line per equipment item is required, because the majority of data will be different for the two (or more) spaces. For discussion of spaces, see Attachment 1.
4.4.4 Column 8 (Hazard Category)
In column 8 the hazard category shall be indicated. The hazard categories of shell and tube sides of heat exchangers as well as other individual spaces within the same shell may be different.
Notes:
For the hazard category calculation procedure, see ref. 6.8; for practical hints, see ref. 6.5.
4.4.5 Column 9 (Boiling Point at 1 Bar(abs))
In column 9 the boiling point at 1 bar(abs) shall be stated. For mixtures, the lowest temperature of the boiling range should be taken.
Notes:
- For a sublimating solid, the temperature at which the sublimation starts should be stated.
- The remark on mixtures refers to the most common type of mixtures, i.e. mixtures of liquids only.
For other cases such as a solid/liquid mixture, the lowest temperature at which the liquid starts boiling should be regarded as the boiling temperature. - For special or complex cases, e.g. involving a decomposition reaction, the Authority Engineering group should be contacted.
4.4.6 Column 10 (Vapor Pressure)
Column 10 shall indicate the vapor pressure at the permitted temperature (see 4.4.10). For mixtures the vapor pressure is the sum of the partial vapor pressures of the components. The vapor pressure can never be higher than the set pressure of the pressure safety device protecting the equipment or equipment part.
4.4.7 Columns 11 and 14 (Normal Operating Pressure and Temperature)
Columns 11 and 14 shall state the normal operating pressure respectively temperature.
Notes:
- These values should preferably in accordance with the process flow scheme(s), if these are submitted (see ref. 6.3).
- Client's forms sometimes do not state this information.
- For exchangers and other equipment with varying temperature either the range of temperatures should be shown, or the highest temperature only. Pressure variations can usually be ignored unless they are extreme.
Column 12 (Permitted Working Pressure)
Column 12 shall state the permitted (working) pressure. This is the pressure at which a piece of equipment may be used jointly with the installation in which it is placed.
The permitted pressure usually equals the pressure for which the equipment is protected, or, in case of a pump discharge without protection, the pump shut off pressure. The permitted pressure is the pressure which will be stated on the license.
Notes:
- The permitted pressure shall be understood as "maximum possible operating" pressure. The word "permitted" is used from the view point of the license and in this sense, permitted equals allowable.
- Newer types of the basic form, in particular the computerized ones, do not contain this column any more. The function of this figure (preventing that too high pressures will be licensed) is for most cases fulfilled by the design pressure. See 4.4.9.
Column 13 (Design Pressure)
Column 13 shall indicate the design pressure, which should be equal to or higher than the permitted pressure. The design pressure will be stated on the "Bewijs van Onderzoek en Beproeving"(BOB, certificate of examination and pressure testing), and is the pressure for which the equipment or the equipment part will be assessed by Stoomwezen B.V.
Notes:
- If no permitted pressure is specified, the license will use the design pressure as such. By doing so, the often difficult discussion regarding the 'maximum possible operating pressure' is avoided.
- The concept 'maximum possible operating pressure' is mainly useful for cases where the design pressure specification has other reasons than the process conditions only. An example are the design pressures for a Claus-type sulfur recovery unit.
- For each single space only one design pressure should be specified (so, for a column no difference between top and bottom design pressure). Any static effects should be taken into account in the manufacturer's design calculations.
- Ref. 6.1 and 6.2 should be applied when determining design pressures.
Column 15 (Permitted Temperature)
In column 15 the permitted temperature shall be indicated. The permitted temperature, which usually equals the maximum operating temperature, is the temperature which will be stated on the licence.
Notes:
- The permitted temperature shall be understood as "maximum possible operating" temperature. The word "permitted" is used from the view point of the licence and in this sense, permitted equals allowable.
- Newer types of the basic form, in particular the computerized ones, do not contain this column any more. The function of this figure (preventing that too high temperatures will be licensed) is for most cases fulfilled by the design temperature. See 4.4.11.
Column 16 (Design Temperature)
In column 16 the design temperature shall be indicated, which should be equal to or higher than permitted temperature. The design temperature will be stated on the "Bewijs van Onderzoek en Beproeving" and is the temperature, for which the equipment part will be assessed by Stoomwezen B.V.
Notes:
- If no permitted temperature is specified, the license will use the design temperature as such. By doing so, the often difficult discussion regarding the 'maximum possible operating temperature' is avoided.
- The concept 'maximum possible operating temperature' is mainly useful for cases where the design temperature specification has other reasons than the process conditions only.
- For each single space only one design temperature should be specified (so, for a column no difference between top and bottom design temperatures). The effect on the wall thickness calculation is normally not large enough to enter into a long discussion with Stoomwezen B.V. which may, at its conclusion, not lead to the planned result.
- Ref. 6.1 and 6.2 should be applied when determining design temperatures.
Column 17 (Volumetric Capacity)
Column 17 should state the volumetric capacity for each space (e.g. shell and tube side). If not stated on the process data sheet this figure should be estimated based on - sometimes assumed - sizes, or, preferably, be obtained from the Vessel Engineering group.
All volumetric capacities should be verified with the manufacturer's documents as part of the regular updating of the classification list; this is particularly applicable to shell and tube heat exchangers and air coolers, with which the largest deviations from the estimated values are experienced.
Column 18 (Classification)
The Authority Engineering group shall determine the classification by means of Attachment 2 of this guide. The most common categories found are (1) steam or vapor equipment (either boiler or vessel - categories SK, DK, SV and DV) and (2) non steam-act pressure vessel (category DR). The classification is assessed for each space of the equipment.
The final classification is derived from the most severe set of design conditions for the different spaces; as a consequence, a water cooled heat exchanger can become classified as a 'vapour vessel' due to the conditions of the non-water side. See also 4.5.
The requirement for a license is usually determined by the Authority Engineering group; Stoomwezen B.V., however, may have a different opinion and will advise see by means of commenting on the classification list. The requirement for a BOB per condition of the Environmental permit should be determined by the Authority Engineering group.
For cases where a BOB is not possible (e.g. storage tanks) a BvK ("Bewijs van Keuring", certificate of inspection) or a VGB ("Verklaring van Geen Bezwaar", statement of no objection) can be requested.
Column 19 (Pressure Protection)
In column 19 the safety valves or rupture discs protecting a piece of equipment should be stated with set pressure and seat diameter. For rupture discs the nominal diameter and the nominal bursting pressure should be indicated.
Notes:
- In the first issue of the classification list it is usually only possible to indicate the valve item numbers and the set pressures.
- The set pressures and the back pressure of the safety valves need to be reviewed in an early stage of the project to avoid equipment design pressure changes in a later stage. For example, problems may occur when a safety valve in liquid service is located at some height above the protected equipment. See also ref. 6.1/6.2.
- In practice, only the safety valves on or very near to the equipment protected are listed; more remotely located safety valves should be reviewed with the Authority Engineering group before listing (example : sometimes a safety valve for a vessel is located downstream a directly connected heat exchanger rather than upstream of it; a survey of the complete circuit is then necessary to see what is protected by the subject safety valve).
Column 20 (Part)
In Column 20 the equipment part for which the data apply, should be indicated (e.g. for towers: top respectively bottom - see Attachment 4 gives an example). As noted above (see 4.4.9 and 4.4.11) this information is nowadays considered less useful. The computerized form does not contain a column to indicate the part, but if necessary a remark can be added.
Other Notes:
Equipment with More than one set of Operating Conditions
Equipment that may be subject to different operating conditions within the normal processing sequence (for example, regenerable reactors or vessels in multi-purpose plants) should be described with an additional line in the classification list. This will satisfy Stoomwezen B.V., that all possible operating conditions have been reviewed and that the final classification is in accordance with the most severe set of conditions found.
Equipment with Temporary Operating Conditions
Equipment with temporary operating conditions (for example, towers with steam out conditions) should only be marked as such, if these conditions may effect the classification. So, if the steam out pressure is limited to 0.5 barg or less, no separate mark should follow, because it does not change the classification nor does it cause Stoomwezen B.V. assessment or inspection work. Ref. 6.7 specifies the lower limits of this assessment or inspection work.
Temporary operating conditions should, in general, not be indicated on flow diagrams and similar documents, unless they are the result of a specific operational requirement and permanent provisions for their use (connections, controls etc.) will be installed. So, activities like regeneration, coke burning or run different processes in the same (or partially the same, such as for multi-purpose plants) installation are to be indicated on flow diagrams. Steaming out, on the other hand, is normally a maintenance activity, for which no permanent connection to the steam system is provided and should not be indicated on flow diagrams.
Special Requirements of Stoomwezen B.V.
In a number of cases Stoomwezen B.V. may comment on the design conditions chosen. This is e.g. the case with equipment, that is installed in the open air (thus, subject to the weather conditions inclusive of low temperatures) and can be put out of operation, but kept under pressure. The possible occurrence of such cases should be carefully reviewed during the early stages of engineering to avoid late comments and possibly material selection consequences. Other more or less frequent discussion points are the effects of substances such as hydrogen and hydrogen sulfide on the material.
Further Handling of the Classification List
The further handling of the classification list includes, amongst others, the following activities (see also ref. 6.4):
Checking for completeness.
Preparing for issue.
Submittal of issued classification list to Stoomwezen B.V.
Evaluation and incorporation of comments received from Stoomwezen B.V.
Updating the classificiation list with new and revised data.
Advising the interested parties such as the Vessel Engineering group and the Project Engineering group on comments affecting the equipment c.q. the requirements imposed on the manufacturers.
5. Flowchart
6. References
Document
Number | Title | Level |
BN-EG-UE | Pressure Temperature Profile | 5 |
BE-EG-UE2 | General Rules to Establish Mechanical Design Pressures and Temperatures |
5 |
BN-EG-UE203 | Defining Information to be Submitted to Pressure Vessel Authorities | 5 |
BN-EG-UE204 | Classification Lists for Pressure Vessel Authorities | 5 |
BN-EG-UE216 | Practical hints for Hazard Category Calculations | 5 |
G-0201 | Stoomwezen Rule "Definitions; Quantities, Units and Symbols" | - |
G-0402 | Stoomwezen Rule "Classification of Pressure Vessels" (Classification List) | - |
G-0701 | Stoomwezen Rule "Hazard Categories" | - |
7. Attachments
- Definitions of Terms and Concepts for use in the Netherlands.
- Classification of Pressure Vessels in the Netherlands.
- Basic form for manually filled out Classification Lists for the Netherlands.
- Example of Computerized and filled out Classification List for the Netherlands (without columns for revision number and remarks).
- Example of manually filled out Classification List
1. Definitions of Terms and Concepts for Use in the Netherlands
The following definitions are given to clarify the terminology of the classification lists for Stoomwezen B.V. and the underlying concepts. A detailed overview is given in ref. 6.6; the text below emphasizes the most important definitions in general wording.
1.1 Phases
Liquid: Any substance in the liquid phase.
Vapor: The gas phase resulting from the heating of a liquid; if the liquid is water, the vapor is commonly called 'steam'.
Note:
The liquid phase of a substance with a critical temperature equal to or lower than 45°C is never considered as heated; the gas phase of such substance can therefore never be a vapor, but is a gas. For heating see 2, below.
- Gas: Any substance in the gas phase other than vapor.
1.2 Heating
Steam apparatuses and vapor apparatuses are considered to be heated when the working temperature exceeds 45 degrees.
Note:
Heat transfer in such apparatuses at a working temperature above 45 °C always involves heating.
1.3 Pressure Vessels/General
- A pressure vessel is a technical device intended to keep up a pressure differential. This definition includes boilers.
Note:
This is a very wide definition; for further details and definitions used outside the Netherlands see ref. 6.5. - The pressure section is that part of a pressure vessel that directly maintains the pressure differential.
The pressure section encloses one or more spaces. It also includes the walls etc., that maintain a pressure differential between two spaces, as well as connected nozzles, flanges and fasteners. Supports etc., are part of the pressure vessel, but not of the pressure section. - Appurtenances: technical devices serving to make possible the use of a pressure vessel or system or to promote its safe use.
Appurtenances accordingly comprise valves, level indicators, pressure protection, pumps, pressure gauges, blow-off cocks, feed apparatus, controllers etc.
1.4 Pressure Vessels/Details
Steam boiler: An apparatus in which water is heated by heat supply which is not derived from another apparatus to which the Steam Act is applicable.
Note:
This definition would imply, that e.g. a waste heat boiler located downstream a reactor would generally be classified as a steam or vapor boiler, despite the fact that a waste heat boiler has rarely a boiler management system. This situation should, wherever possible, have an impact on the safety valve installation only and be limited for e.g. inspection terms by Stoomwezen.
Steam apparatus: A steam boiler or apparatus which is connected to the former in such a way that heat transfer takes place between the apparatus and the steam boiler by means of vapor or liquid.
Vapor boiler: An apparatus in which a liquid other than water is heated by heat supply which is not derived from another apparatus to which the Steam Act is applicable.
Vapor apparatus: A vapor boiler or apparatus which are connected to the former in such a way that heat transfer takes place between the apparatus and the vapor boiler by means of vapor or liquid.
Vessel: A steam apparatus other than a steam boiler or a vapor apparatus other than a vapor boiler.
Pipeline: A pressure vessel which serves mainly for the conveyance of substances; they may be split into (1) installation lines and (2) transmission lines, i.e. pipe lines connecting installations or facilities without being part of it.
Storage Tank: A pressure vessel intended for the storage of liquids below their atmospheric boiling point and not being part of a processing installation.
Note:
As a consequence, pressurized storage vessels (spheres, bullets) are not storage tanks.
Non-Steam Act Pressure Vessel: A pressure vessel which does not belong to one of the following categories:
- Steam or Vapor Apparatus
- Gas Cylinder or Transport Tank
- Storage Tank
- Pipelines
- Machine Parts
- Pressure Vessels containing solely a liquid below its atmospheric boiling point.
Notes
- Vessels and non-steam act pressure vessels together correspond approximately to the English concept "unfired Pressure Vessels".
- The above as well as other definitions are described in ref. 6.5.
1.5 Pressure Vessels/Separate Sections
The following shall be regarded as a separate section (space) of a steam apparatus or a vapor apparatus:
- A space which is neither directly nor indirectly connected to another space of the steam apparatus or vapor apparatus.
- A space which is connected to another space of the steam apparatus or vapor apparatus by means of openings in the common wall of the two spaces having a total crosssectional area of passage not exceeding 20 cm2.
- A space which is connected to another space of the steam apparatus or vapor apparatus by means of pipes with an average length of at least ten times the diameter of the circle with an area equal to the total cross sectional area of passage of the pipes.
If the wall between two spaces is such that it must be expected to collapse when the working pressure is exerted on only one side, these spaces shall be considered together as a single space of the steam apparatus or vapor apparatus, irrespective of the preceding statements.
Classification of Pressure Vessels (Netherlands only)