Engineering Encyclopedia

Saudi Aramco DeskTop Standards

General Design Considerations

Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s
employees. Any material contained in this document which is not already
in the public domain may not be copied, reproduced, sold, given, or
disclosed to third parties, or otherwise used in whole, or in part, without
the written permission of the Vice President, Engineering Services, Saudi
Aramco.

Chapter : Instrumentation For additional information on this subject, contact

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Engineering Encyclopedia Instrumentation
General Design Considerations

CONTENTS PAGES

SAUDI ARAMCO AND INDUSTRY STANDARDS........................................... 1

MATERIALS SELECTION ................................................................................... 2

Hydrogen..................................................................................................... 3
Hydrogen Sulfide ........................................................................................ 6
Cyanide........................................................................................................ 7
Caustic......................................................................................................... 7
Chlorides ..................................................................................................... 9
Hydrochloric Acid..................................................................................... 10
Sulfuric Acid ............................................................................................. 11
Example Problem 1........................................................................ 11

DESIGN TEMPERATURE AND PRESSURE .................................................... 13

Design Temperature .................................................................................. 13

Design Pressure ......................................................................................... 14
Short and Intermediate Time Basis............................................................ 14
Example Problem 2........................................................................ 14

PIPING SYSTEM DESIGN ................................................................................. 18

Pipe............................................................................................................ 18
Flanges ...................................................................................................... 24
Example Problem 3........................................................................ 26
Piping and Tubing ..................................................................................... 27
Valves, Fittings, and Gaskets .................................................................... 28
Expansion/Contraction .............................................................................. 37
Example Problem 4........................................................................ 37

USING PFD AND P&ID DRAWINGS................................................................ 40

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PLOT AREA CONSIDERATIONS...................................................................... 44

Example Problem 5........................................................................ 46

RELIEF AND FLARE SYSTEMS ....................................................................... 49

Safety Valves and Relief Valves ............................................................... 49

Process Design Basis ..................................................................... 49
Required Relief Rate...................................................................... 50
Fire Vapor Rate.............................................................................. 52
Safety Valves/Safety Relief Valves ............................................... 53
Example Problem 6........................................................................ 65
Single Pressure Relief Device for Several Components in a
Process System .............................................................................. 67
Block Valves ............................................................................................. 69
Flare Systems ............................................................................................ 69
Flare Lines/Manifolds.................................................................... 69
Blowdown Drum............................................................................ 69
Vapor Recovery ............................................................................. 70
Flare ............................................................................................... 71

KEY FORMULAS................................................................................................ 72

NOMENCLATURE.............................................................................................. 74

REFERENCES...................................................................................................... 75

WORK AID 1: ADEQUACY OF ALLOY IN HYDROGEN SERVICE ............ 77

WORK AID 2: CALCULATION OF EQUIPMENT DESIGN

TEMPERATURE AND PRESSURE.......................................... 78

WORK AID 3: ADEQUACY OF CARBON STEEL IN HYDROGEN

SERVICE AND CALCULATION OF PIPEWALL
THICKNESS............................................................................... 79

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WORK AID 4: PLOT AREA CONSIDERATIONS............................................ 80

WORK AID 5: CALCULATE SAFETY RELIEF VALVE CONDITION

AND SIZE .................................................................................. 81

GLOSSARY ......................................................................................................... 82

DESCRIPTIONS OF APPLICABLE SAES AND SAMSS

REQUIREMENTS................................................................................................ 85

SAES-L-006, "Metallic Pipe Selection".................................................... 86

SAES-L-007, "Selection of Metallic Pipe Fittings" .................................. 86
SAES-L-008, "Selection of Valves".......................................................... 86
SAES-L-009, "Metallic Flanges, Gaskets, and Bolts"............................... 86
SAES-L-030, "Material for Low-Temperature Service" ........................... 86
SAES-L-031, "Fracture Control of Line Pipe".......................................... 87
SAES-L-032, "Materials Selection for Piping Systems"........................... 87
SAES-L-060, "Nonmetallic Piping".......................................................... 87
SAES-L-061, "Technically Acceptable RTR Piping" ............................... 87
01-SAMSS-001, "Asbestos-Cement Pipe, Fittings, and Gaskets" ............ 87
01-SAMSS-005, "Pipe, Cement-Lined, Shop Applied"............................ 87
01-SAMSS-010, "Fabricated Carbon Steel Piping" .................................. 87
01-SAMSS-016, "Sour, Wet Service Line Pipe" ...................................... 87
01-SAMSS-017, "Auxiliary Piping for Mechanical Equipment".............. 88
01-SAMSS-022, "Fracture Control Testing Procedures for Line
Pipe" .......................................................................................................... 88
01-SAMSS-029, "Unrestrained Gasketed Joint RTR Sewer Pipe
Fittings" ..................................................................................................... 88
01-SAMSS-033, "API 5L Electric Resistance Welded Line Pipe" ........... 88
01-SAMSS-034, "RTR Pressure Pipe and Fittings".................................. 88

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01-SAMSS-035, "API Line Pipe" ............................................................. 88

01-SAMSS-036, "Low-Temperature Pipe" ............................................... 88
02-SAMSS-001, "Piping Components for Low-Temperature
Service" ..................................................................................................... 88
02-SAMSS-005, "Butt-Welded Pipe Fittings" .......................................... 89
02-SAMSS-010, "Flanged Insulating Joints/Spools for Cathodic
Protection"................................................................................................. 89
04-SAMSS-003, "Additional Requirements for Low-Temperature
Valves" ...................................................................................................... 89

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SAUDI ARAMCO AND INDUSTRY STANDARDS

Saudi Aramco has adopted the ANSI Code (B31) as the basic requirement for pressure piping.
Saudi Aramco Engineering Standards (SAES) contain additional mandatory requirements that
supplement the ANSI Code. Standard SAES-L-000 (index for all piping standards) has been
included in the Addendum. This index will provide an awareness of the complex nature of
piping design and the subjects in the ANSI code supported by Saudi Aramco Standards.
Every piping standard (SAES) has a corresponding Saudi Aramco Design Practice (SADP) of
the same number. The design practice provides background and other related information on
the subject in question.

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MATERIALS SELECTION

The factors affecting piping material selection are listed below:

• Initial cost
• Service life
• Maintenance costs
• Ease of replacement
• Cost of inhibitors or corrosion control

Sub-factors to consider within the above group are:

• Material strength
• Corrosion resistance
• Toughness
• Fabricability
• Suitability for wet sour service
• Availability

In selecting materials, the engineer must have a knowledge of:

• The type of piping system and applicable codes

• The fluid characteristics (temperature, corrosivity, H2S, etc.)
• The basic principles of material science

Saudi Aramco SADP-L-032 (a design practice for piping systems materials selection)
provides background and other related information on the selection of materials for piping
construction. For specific services, materials are specified in Saudi Aramco SAES-L-032 (an
engineering standard for piping systems materials selection). The materials that are specified
in SAES-L-032 are basically the most economical choice. With adequate corrosion
allowance, the SAES-L-032 selection will withstand the environment; however, the material
selections from SAES-L-032 are subject to further requirements, as stated in the ANSI B31
Code and amendments. If there is any doubt about the applicability of an SAES-L-032
selection to the service in question, the Saudi Aramco materials specialist in the Consulting
Services Department should be contacted. Refer to Saudi Aramco Engineering Standards
SAES-L-006 and SAES-L-030, and Design Practices SADP-L-006 and SADP-L-030 for the
associated impact testing requirements for materials for piping in low-temperature services.

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The Addendum lists applicable Saudi Aramco standards. A short description of each standard
is also included. A more complete coverage of piping materials selection is covered in Saudi
Aramco's PEDP course, MEX 101.03.

The remainder of this write-up on materials selection provides background and other related
information on the selection of piping materials of construction for the specific compounds:
H2S, cyanides, caustics, chlorides, HCl, and sulfuric acid. Comments relative to the process
pressure and temperature effects on these corrosive substances will be given.

Hydrogen

Before specifying materials for liquid and/or vapor systems that contain hydrogen, the
engineer should read SADP-L-032, Paragraph 2.7.12 which contains material selection design
practices for services with hydrogen.

The presence of hydrogen at high temperature and pressure causes embrittlement of carbon
steel and some alloy steels. Damage by hydrogen at high partial pressure is attributed to the
ability of atomic hydrogen to permeate into steel and react with iron carbides to form
methane. The methane collects at grain boundaries or discontinuities and cannot diffuse out
of the metal, thus causing high internal stresses that ultimately lead to fissuring of the metal at
the grain boundary.

Hydrogen attack differs from "corrosion" in that damage will occur through the thickness of
the component without metal loss. It is not practical to provide a corrosion allowance to
allow for a small amount of attack. In addition, once attack has occurred, the metal cannot be
repaired and must be replaced. For these reasons, it is very important to review all potential
operating conditions before selecting materials for hydrogen service.

Hydrogen attack is prevented by adding carbide-stabilizing elements to the steel or alloy. In

order of importance, the carbide-stabilizing elements are molybdenum, chromium, tungsten,
vanadium, titanium, and columbium. All of the austenitic (18 Cr-8 Ni) stainless steels are
resistant because of their high chromium content. The noncarbide-forming elements, such as
nickel and silicon, have no effect in preventing hydrogen attack in refinery processes that
employ high-pressure hydrogen (e.g., reforming, hydrotreating, hydrocracking, etc.). An
important reference that includes complete information on steels in hydrogen service is API
Publication 941, Fourth Edition, April 1990.

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Another type of corrosion phenomenon that is experienced in refinery equipment is

"hydrogen blistering." In this case, atomic hydrogen diffuses into the surface of the carbon
steel equipment. Then, the atomic hydrogen collects in discontinuities within the metal and
forms molecular hydrogen. Because molecular hydrogen will not diffuse through the steel,
the pressure builds up inside the voided area and cause the metal to rupture. The ruptured
area is confined to a local area and appears on the surface of the metal in the form of blisters
or fissures. Hydrogen blistering occurs most commonly in an aqueous medium that contains
cyanides and a mild corrosive. Hydrogen blistering has been found primarily in catalytic
cracking light ends units, one of the few types of units that have this problem.

The temperature/pressure conditions under which hydrogen attack can be a problem are
shown by Figures 1 and 2. The curves in Figures 1 and 2 should not be used for materials
selection without first referring to all notes and references for these figures in API 941, April
1990. The simplified representations of the API 941 presentation in Figures 1 and 2 illustrate
the potential extent of the hydrogen attack problem for that material. A process condition that
has temperature/hydrogen partial pressure points that are above or to the right of a particular
material curve indicates a hydrogen attack problem. In such a case, a higher grade material
must be selected (see SAES-L-032, Table 1, and SADP-L-032, Paragraph 2.7.12).

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Source: API Publication 941, Steels for Hydrogen Service at Elevated Temperatures and Pressure in Petroleum
Refineries and Petrochemical Plants, Fourth Edition, April 1990. Reprinted courtesy of the American
Petroleum Institute. (Nelson Curves).

Operating Limits for Steels in Hydrogen Service

Figure 1

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Source: API Publication 941, Steels for Hydrogen Service at Elevated Temperatures and Pressure in Petroleum
Refineries and Petrochemical Plants, Fourth Edition, April 1990. Reprinted courtesy of the American
Petroleum Institute.
Time for Incipient Attack of Carbon Steel in Hydrogen Service
Figure 2

Hydrogen Sulfide

Hydrogen sulfide, in the vapor phase (dry pipewall), is not particularly corrosive. Wet H2S
(wet pipewall) can be quite corrosive, however, particularly when in the presence of other
compounds such as cyanides, ammonia, phenols, and carbonates. Different combinations and
concentration levels of these compounds in the presence of wet hydrogen sulfide are
commonly found in gas scrubbing facilities (Diethanol Amine (DEA), Methyl Ethanol Amine
(MEA) systems, etc.), sour water stripping systems, and conversion plant light ends facilities
(crackers, cokers).

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A wet hydrogen sulfide service is a process stream that contains liquid water and H2S. The
water should be present as a separate liquid phase, not as dissolved water in a hydrocarbon. It
is not necessary to have a continuous water phase such as a water boot. Water that condenses
on the surface of a drum or tower above a liquid level will cause damage; as a result, any
process stream that contains water in excess of the solubility in the hydrocarbon present or to
those streams that are water based, such as MEA solutions, must be considered potential
corrosion problems.

Carbon and other ferritic steels experience mild corrosion in water that contains hydrogen
sulfide. One product of this corrosion is atomic hydrogen, which is produced on the steel
surface. Another product is iron sulfide scale, which inhibits the combination of the hydrogen
atoms to form molecular hydrogen. The atomic hydrogen, because of its small size and high
concentration on the steel surface, diffuses into the steel and causes several forms of
deterioration. In most cases, carbon steel with post-weld heat treatment is used for equipment
that is exposed to wet hydrogen sulfide corrosion. For services where one or more of the
previously mentioned compounds (cyanides, etc.) are also present and/or there is a high-
velocity condition the plant engineer should contact the Saudi Aramco assigned materials
specialists in the Consulting Services Department.

Cyanide

Cyanide is not commonly found at concentration levels that will attack steel in refineries
unless conversion facilities are present. Corrosive cyanide compounds are usually created by
severe conversion units, such as catalytic cracking facilities. Depending on the type and
concentration level of the harmful cyanide compound, a neutralizing agent such as ammonia
polysulfide or a film-forming corrosion inhibitor is injected into the process stream. The
neutralizing agent converts the harmful cyanide compound into a neutral cyanide compound.
When a plant engineer suspects that a corrosion problem could be the result of cyanides
and/or that cyanides may be present for a new equipment service, analytical work on the
process stream should be analyzed to define the quantity and type of cyanides. Also, the
problem of how to neutralize the cyanides should be referred to a Saudi Aramco materials
specialist in the consulting services department.

Caustic

Caustic embrittlement is a form of stress corrosion cracking that occurs in ferrous alloy
equipment that is exposed to strongly alkaline solutions such as NaOH and MEA.
Simultaneous exposure to stress and a strong alkaline solution are both required for caustic
embrittlement to occur. Figure 3 relates temperature and caustic solution concentration with
susceptibility to caustic embrittlement. Caustic embrittlement initiates and proceeds along the
boundaries of metal grains. In Figure 3, any process condition of caustic concentration versus
temperature that falls above the curve could cause a caustic embrittlement problem.

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Notes:
1. 30% nickel Ni-resist or Monel material line.
2. Each curve represents the lower boundary of caustic stress corrosion cracking for the material
designated next to curve.
3. Type 304 is stainless steel Type 304.

Stress Corrosion Cracking Due to Caustic

(Sodium Hydroxide)
Figure 3

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Caustic embrittlement is prevented in two ways. One means of prevention is by using stress
relief to remove residual stresses. The other method is by substituting nonferrous alloys
(Monel, nickel, etc.), or other alloys that are not subject to caustic embrittlement for ferrous
alloys. Nickel and nickel alloys are widely used for combating corrosion by caustic.

Figure 3 provides a general visual representation of the extent of the caustic embrittlement
problem. Figure 3 should not be used for material specification work without going back to
the data source (Swandby, Chemical Engineering, Nov. 12, 1962) and reviewing all
associated notes and qualifications. Saudi Aramco SAES-L-032, Table 1, contains material
recommendations for systems that are exposed to caustic solutions.

Chlorides

Austenitic stainless steels that contain less than 45% nickel are susceptible to stress corrosion
cracking (SCC) in the presence of oxygen, moisture, and chlorides. This type of cracking
affects both stabilized and nonstabilized steels and it may occur in fully solution-annealed and
sensitized steels.

Factors that influence the rate and severity of attack are oxygen concentration, temperature,
stress level, and solution pH. Tests that are conducted with identical solutions, with and
without oxygen, have demonstrated that oxygen is required to have chloride cracking of
austenitic stainless steels. Plant experience demonstrated that a stainless steel bundle did not
crack until it was removed from the unit and exposed to the air. Also, at lower oxygen
concentrations, the quantity of chlorides that are required for cracking increases. A threshold
temperature of 140°F has been established, below which chloride cracking is seldom found in
water with salt concentrations up to the concentration of sea water. Cracking has been known
to occur at ambient temperatures where there is a high level of cold working in the stainless
steel. The severity of cracking increases as the temperature increases. The more acid a
solution, the faster cracking occurs; however, cracking can occur in highly alkaline solution
that have higher chloride contents over longer periods of time.

These factors prevent the establishment of minimum chloride ion content, below which stress
corrosion cracking will not occur. Considering only chloride ion concentrations, the time to
produce cracking can vary significantly and can be as little as several hours at high chloride
ion concentrations. Practical limits have been established to limit chloride ion concentrations.
If no further concentration is possible, chloride concentrations of up to 50 ppm are normally
considered acceptable. Even nominal concentrations as low as 1 ppm can be hazardous if a
mechanism for concentration exists (e.g., crevices and vapor traps around baffles in heat
exchangers). In these areas, high concentrations (several thousand ppm) have been found
even though the nominal concentration is only a few ppm.

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For hydrotest and flushing water, a limit of 50 ppm of chlorides is used (see SADP-L-032,
Paragraph 2.6, and SAES-A-004). This limit will allow the use of potable water without the
need for testing. Because hydrotesting and flushing are carried out at temperatures below
140°F, the risk of SCC only exists due to residual chlorides in the equipment when it is
returned to service at higher temperature. The use of sea water or brackish harbor water for
fire-fighting on units with stainless steel equipment is permissible with one precaution: water-
soaked insulation must be replaced and the equipment must be washed with fresh water prior
to startup after a fire.

The preceding discussion of chloride ion attack on austenitic stainless steel is a very limited
presentation of a complex subject. The plant engineer should obtain the Saudi Aramco
operating procedures for the care and treatment of austenitic component parts of the plant
from the assigned materials specialists in the Consulting Services Department.

Hydrochloric Acid

Hydrochloric acid (HCL) is a very corrosive compound. HCL is commonly found in refinery
atmospheric crude unit overhead systems. The salts in crude cause corrosion by hydrolysis of
MgCl2 and CaCl to HCl during heating in the crude preheat circuit where temperatures exceed
250°F. HCl does not cause any problems in pipestills at temperatures above the water dew
point, but at lower temperatures HCl readily dissolves in water to form corrosive hydrochloric
acid. As a result, acid corrosion is usually confined to the pipestill overhead equipment where
water is condensed. Desalting of the crude significantly reduces the amount of chlorides
available to be converted to HCl.

Corrosion from HCl formed by the hydrolysis of the salts in the crude can be controlled by
chemical additives, alloys, or both. Caustic and ammonia are added to the cold crude in order
to limit the quantity of HCl that is evolved and to control the pH of the overhead condensed
water. A second technique uses a neutralizer and a filming amine corrosion inhibitor in the
overhead stream. Alloys that are commonly used for pipestill overhead condenser tubes
include Monel, 70 Cu-30 Ni and titanium. The plant engineer should refer to SAES-L-032,
Table 1, and contact the assigned materials specialist in the consulting services department
prior to specifying materials for corrosive compounds such as hydrochloric acid.

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Sulfuric Acid

Sulfuric acid (H2SO4) is unusual in regards to its corrosiveness. Within certain ranges of
H2SO4 concentration, temperature, and velocity, carbon steel can be used satisfactorily.
Mixtures of sulfuric acid and hydrocarbon are generally less corrosive than fresh sulfuric acid.
Also, sulfuric acid corrosivity is not linear with concentration. Dilute acids are much more
aggressive than concentrated acids. For example, carbon steel is satisfactory for 85% and
stronger concentrations of H2SO4, but not satisfactory for H2SO4 weaker than a 85%
concentration level. In contrast, temperature and fluid velocity have a direct relationship to
the corrosion rate and they can increase the corrosion rate substantially if the selected
temperature and/or fluid velocity is excessive. The plant engineer should refer to SADP-L-
032, Paragraph 2.7.4, and SAES-L-032, Table 1, for recommended processing conditions as a
function of process velocities, temperature, and acid concentration level.

Example Problem 1
This example problem consists of three sets of plant operating conditions. Each set of
operating conditions will be reviewed and a material will be selected to withstand the system
environment.

System A - A significant change in plant operating conditions is anticipated. Heat and

material balance information for the new operation shows the process conditions in a section
of pipe will be 800°F with a hydrogen partial pressure of 1400 psia. The present pipe is made
of carbon steel. Is the existing pipe adequate for the new service?

Refer to Figure 1 and plot the point that represents 800°F and 1400 psia hydrogen partial
pressure. The plotted point falls above the 1.25 Cr, 0.5. Mo steel and carbon steel lines, but
below the 2.0 Cr, 0.5 Mo steel base. As a result, the existing carbon steel line must be
replaced by a 2.0 Cr, 0.5 Mo steel line.

System B - Management has asked the engineer in charge of the treating facilities to conduct
a materials review of the system. The review should, among other things, determine if there
are any potential caustic embrittlement problems in the unit. The existing pipe at the point in
the system of highest temperature combined with the strongest caustic solution is made of
stress relieved carbon steel. Existing process conditions are 20 wt% caustic and 120°F.

Refer to Figure 3 and plot the point that represents 20 wt% caustic and 120°F. The plotted
point falls below the carbon steel line; therefore, the existing carbon steel pipe is adequate.

System C - A tower overhead line contains a mixture of hydrocarbon, hydrogen sulfide, and
water vapor. The line is made of carbon steel and is insulated. Process calculations show that
the gas will always stay superheated until reaching the condenser. Is the carbon steel line
adequate?

Yes, hydrogen sulfide in the vapor phase, dry wall, is not particularly corrosive.

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DESIGN TEMPERATURE AND PRESSURE

The official definition for process design conditions is stated in Saudi Aramco Standard
SAES-L-002, Paragraph 2.1. The technical material in standards SAES-L-002, SAES-L-003,
and design practices SADP-L-002 and SADP-L-003 should be read and understood before
any attempt is made to select process design conditions or piping material, or to calculate the
required wall thickness for a pipe. Determination of the appropriate pipe material and wall
thickness will be discussed on an introductory basis in the following write-up. In particular,
the selection of design conditions based on the anticipated normal, abnormal, emergency, and
startup conditions will be discussed. Other considerations such as those applied to
transportation piping, piping loads resulting from wind, pipe thermal expansion, solar
radiation, liquid thermal expansion, earthquake, weight effects, slug forces, are addressed in
the previously mentioned standards and design practices and will not be covered in this
module.

Process design conditions (temperature and pressure) are developed from the fluid normal
operating temperature and pressure plus deviations from the normal. The deviations to be
considered include those deviations that result from startup, shutdown, depressurizing,
alternate operations, control requirements, upsets, and general operating flexibility for the
process unit. Calculations for wall thickness, and the wall material selection process use the
most severe condition of coincident maximum pressure and maximum temperature. For the
process design temperature, the minimum design temperature must also be considered to
ensure that the selected pipewall material has sufficient toughness (Charpy impact test) to
avoid brittle fracture of the pipe. Brittle fracture becomes a potential problem for piping
systems where the minimum process design temperature is less than -20°F. For the process
design pressure, the minimum design pressure must also be considered to ensure that the
calculated wall thickness can withstand a partial or full vacuum.

Selection of the maximum design pressure and design temperature can be made following a
set of guidelines such as those listed. Local standard practices should be referred to for all
design pressure (D.P.) and design temperature (D.T.) determinations.

Design Temperature

• For operating temperatures up to 750°F, use the maximum operating temperature

plus 50°F.

• For operating temperatures above 750°F, each case must be evaluated for the most
economical solution, since the decrease in allowable stress for carbon steel is
significant for small temperature increases above 750°F.

• Considerations such as steamout of equipment or cooling water failure.

• A design temperature for uninsulated piping flanges can be 10% lower than the
piping design temperature.

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• A design temperature is developed for the piping that is consistent with upstream
and downstream circuit process design conditions.

Design Pressure

• For pressures of up to 250 psig, use maximum operating pressure plus 10% or 15
psig (the greater of the two).

• For pressures at, or above, 250 psig, use maximum operating pressure plus 10% .

• If the exchanger is fed by a pump, the design pressure is normal pump differential
pressure (∆P), plus maximum suction pressure, or pump shutoff ∆P plus normal
suction pressure (the greater of the two). Use 120% of pump normal ∆P if the
pump shutoff pressure not defined.

• For pumps only, design pressure is equal to maximum suction pressure plus pump
shutoff ∆P. For two pumps in parallel, the suction end of the pump and block
valve must have a design pressure of at least 75% of the pump discharge pressure.

• Consider fluid vapor pressure, static head, system pressure drop, pump or
compressor shutoff pressure, and ambient temperature changes in the determination.

• A design pressure is developed for the piping that is consistent with upstream and
downstream circuit process design conditions.

Short and Intermediate Time Basis

The duration of the most severe condition of coincident maximum pressure and maximum
temperature should be defined. For a short-term or intermediate term maximum condition, a
significantly higher maximum allowable stress level is allowed when defining the pipewall
thickness. Short-term conditions are defined as 10 hours or fewer/occurrence and 100 hours
total/year. Intermediate term conditions are defined as 50 hours or fewer/occurrence and 500
hours total/year (refer to ANSI B31.3 Piping Code). Short time basis will increase the
allowable stress which will be covered later.

Example Problem 2
This example problem consists of two sets of plant operating conditions. Each set of
operating conditions will be reviewed and a design temperature/design pressure will be
selected for each major part of the system.

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System A - The system under review is a tower bottoms circuit (Figure 4) where design
conditions must be set for the tower, bottoms circuit piping, bottoms pump, and bottoms
product water cooler. Use the following process conditions:

Tower - Safety valve setting, 290 psig

- Tower liquid static head, 15 psig.
- Operating temperature/pressure, 370°F/260 psig.

Pump - Suction static head = 20 psig

(tower bottom elevated)
- Shutoff ∆P = 110 psig
- Normal ∆P = 85 psig
- Operating temperature, 370°F.

Product cooler - Temperature in/out, 370/120°F

(process side condition only)
- Pressure in/out, 380/360 psig.

(Refer to Design Pressure (D.P.) and Design Temperature (D.T.) guidelines.)

Safety
Valve Overhead
Condenser

Cooling
Tower Water

Tower Liquid Distillation Drum

Static Head

Suction Product Cooler

Static Product
Head to
Tankage

Cooling
Water
Product
Pump

Tower Circuit Sketch

Figure 4

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Answer:

Tower Design Pressure:

Safety valve setting = 290 psig = [260 + .10 (260)] rounded up

Tower Design Temperature:

Operating temperature + 50°F = 370 + 50 = 420°F

Pump Design Pressure:

Maximum suction + Shutoff ∆P = (15 + 290 + 20) + 110 = 435 psig
(Maximum suction = Tower liquid static head + Tower D.P. + Suction static head)

Pump Design Temperature:

Inlet operating temperature + 50°F = 370 + 50 = 420°F

Exchange Design Pressure:

Maximum suction + Normal ∆P = (15 + 290 + 20) + 85 = 410 psig
(Maximum suction = Tower liquid holdup static head + Tower D.P. + Suction static
head)

Normal suction + Shutoff ∆P = (260 + 15 + 20) + 110 = 405 psig

(Normal suction = Tower operating pressure + Tower liquid static head + Suction static head)

Maximum design = 410 psig

Exchanger Design Temperature:

Inlet operating temperature + 50°F = 370 + 50 = 420°F

Piping Design Pressure:

From tower to pump - maximum suction pressure = 15 + 290 + 20 = 325 psig
From pump to exchanger - same as exchanger D.P. = 410 psig
From exchanger to tankage - same as exchanger D.P. = 410 psig
From pump to just downstream of discharge block valve - same as pump D.P. = 435
psig

Pump design pressure (D.P.) is calculated on a basis that is more severe than for any
other process of equipment, since pumps are usually started with a closed discharge
block valve.

Piping Design Temperature:

From tower to pump - same as tower = 420°F
From pump to exchanger - same as tower = 420°F
From exchanger to tankage - 120 + 50 = 170°F

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Engineering Encyclopedia Instrumentation
General Design Considerations

System B - The system under study is a tower overhead system (in Figure 4). A design
pressure and design temperature must be determined for the overhead condenser, distillate
drum, and connecting piping. Use the following process conditions:

Tower - Safety valve setting, 290 psig.

- Operating temperature/pressure (top), 190°F/257 psig.

Condenser - Temperature in/out, 190/130°F.

(process side only)
- Pressure in/out, 255/250 psig.

Drum - No safety valve.

- Operating temperature/pressure 130°F/250 psig.

Answer:

Condenser Design Pressure (D.P.):

Same as safety valve setting on tower = 290 psig because there is no valve between
tower and condenser.

Condenser Design Temperature (D.T.):

Inlet operating temperature + 50°F = 190 + 50 = 240°F

Drum Design Pressure:

Same as safety valve setting on tower = 290 psig because there is no valve between
tower and drum.

Drum Design Temperature:

Operating temperature + 50°F = 130 + 50 = 180°F

Piping Design Pressure:

From tower to condenser, from condenser to drum = Safety valve setting on tower = 290
psig.

Piping Design Temperature:

From tower to condenser = Condenser D.T. = 240°F
From condenser to drum = Drum D.T. = 180°F

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Engineering Encyclopedia Instrumentation
General Design Considerations

PIPING SYSTEM DESIGN

Pipe

Pipe is manufactured in standard diameters with each diameter available from the
manufacturer in several different standard wall thicknesses. The standard wall thicknesses are
referred to as the pipe schedule (Schedule 10, 20, 30, 40, etc., see Figure 5). The required
pipewall thickness is determined, and then the thinnest standard pipewall (schedule) that
meets the required thickness may be selected as the pipe for the circuit being designed. The
required wall thickness for straight pipe is a sum of the pressure design wall thickness (t) and
the mechanical allowances (c) (thread depth, corrosion and erosion allowances, wind loads,
expansion stress, etc.). As previously stated under the course heading, Process Design
Conditions, the following is limited to the calculation of the design pressure wall thickness (t,
in.).

Determination of the pressure design wall thickness (t) for piping is done using Barlow’s
formula:

(DP)D
t= +c
2SEc

where:
t = Pipewall thickness, in. (for pipe see Figure 5)
DP = Design pressure, psig (internal pressure, psia - atmospheric pressure, psia)
D = The pipe outside diameter, in.
S = Design stress, psi (see Figure 6).
Ec = Casting quality factor, no units (see Figure 7). (Usually 0.8).
c = Corrosion allowance, in. (usually 1/16” non corrosive and 1/8” corrosive
service)

Figure 8 has been provided for the purpose of converting the material specification numbers
in Figures 6 and 7 to a nominal group number designation made for each type of steel.
Barlow's formula is occasionally used for a screening quality check of an existing pipewall
thickness. The process design wall thickness plus the allowance for corrosion and erosion are
the dominant factors in setting the wall thickness. Therefore, if an existing pipe being
considered for use in a new service has a wall thickness that is greater than "t" plus the
corrosion/erosion allowance, there is a high probability that the pipe is adequate for the new
service. However, before the pipe is put into service in the new circuit, a complete analysis of
the piping system should be done.

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Engineering Encyclopedia Instrumentation
General Design Considerations

For piping only, there is a short-time and intermediate-time category where higher allowable
stresses can be used safely because of the short duration of a high-pressure condition. As
previously stated under the heading Process Design Conditions, short-term conditions are 10
hours or fewer/occurrence and 100 hours total/year. Intermediate term conditions are 50
hours or fewer/occurrence and 500 hours total/year. For the short-term case, the allowable
stress (S) used to calculate "t" can be 33% higher than the values given in Figure 8, and for
the intermediate term case 20% higher. Prior to using these higher stress levels, the assigned
mechanical specialist in the Consulting Services Department should be contacted.

Saudi Aramco DeskTop Standards 19

Engineering Encyclopedia Instrumentation
General Design Considerations

Nom- Outside Identification W all Inside Area T ransverse Moment External Section
W eight W eight
inal Diam. Steel Stain- Thick- Diam- of Internal Area of Pipe W ater Surface Modulus
Pipe less ness eter Metal Inertia
(a) (A)
Size Iron Steel (t) (d) Pounds Pounds Sq. Ft.
Pipe Sched.
No.
Sched. Square Square Square
(l)
4 per per foot per foot ( 2O.1D.)
Inches Inches Size No. Inches Inches Inches Inches Feet Inches foot of pipe of pipe
... ... 5S .083 3.834 1.021 11.545 .08017 1.960 3.48 5.00 1.047 .9799
3 1/2 4.000 ... ... 10S .120 3.760 1.463 11.104 .07711 2.755 4.97 4.81 1.047 1.378
STD 40 40S .226 3.548 2.680 9.886 .06870 4.788 9.11 4.29 1.047 2.394
XS 80 80S .318 3.364 3.678 8.888 .06170 6.280 12.50 3.84 1.047 3.140
... ... 5S .083 4.334 1.152 14.75 .10245 2.810 3.92 6.39 1.178 1.249
... ... 10S .120 4.260 1.651 14.25 .09898 3.963 5.61 6.18 1.178 1.761
STD 40 40S .237 4.026 3.174 12.73 .08840 7.233 10.79 5.50 1.178 3.214
4 4.500 XS 80 80S .337 3.826 4.407 11.50 .07986 9.610 14.98 4.98 1.178 4.271
... 120 ... .438 3.624 5.595 10.31 .0716 11.65 19.00 4.47 1.178 5.178
... 160 ... .531 3.438 6.621 9.28 .0645 13.27 22.51 4.02 1.178 5.898
XXS ... ... .674 3.152 8.101 7.80 .0542 15.28 27.54 3.38 1.178 6.791
... ... 5S .109 5.345 1.868 22.44 .1558 6.947 6.36 9.72 1.456 2.498
... ... 10S .134 5.295 2.285 22.02 .1529 8.425 7.77 9.54 1.456 3.029
STD 40 40S .258 5.047 4.300 20.01 .1390 15.16 14.62 8.67 1.456 5.451
5 5.563 XS 80 80S .375 4.813 6.112 18.19 .1263 20.67 20.78 7.88 1.456 7.431
... 120 ... .500 4.563 7.953 16.35 .1136 25.73 27.04 7.09 1.456 9.250
... 160 ... .625 4.313 9.696 14.61 .1015 30.03 32.96 6.33 1.456 10.796
XXS ... ... .750 4.063 11.340 12.97 .0901 33.63 38.55 5.61 1.456 12.090
... ... 5S .109 6.407 2.231 32.24 .2239 11.85 7.60 13.97 1.734 3.576
... ... 10S .134 6.357 2.733 31.74 .2204 14.40 9.29 13.75 1.734 4.346
STD 40 40S .280 6.065 5.581 28.89 .2006 28.14 18.97 12.51 1.734 8.496
6 6.625 XS 80 80S .432 5.761 8.405 26.07 .1810 40.49 28.57 11.29 1.734 12.22
... 120 ... .562 5.501 10.70 23.77 .1650 49.61 36.39 10.30 1.734 14.98
... 160 ... .719 5.187 13.32 21.15 .1469 58.97 45.35 9.16 1.734 17.81
XXS ... ... .864 4.897 15.64 18.84 .1308 66.33 53.16 8.16 1.734 20.02
... ... 5S .109 8.407 2.916 55.51 .3855 26.44 9.93 24.06 2.258 6.131
... ... 10S .148 8.329 3.941 54.48 .3784 35.41 13.40 23.61 2.258 8.212
... 20 ... .250 8.125 6.57 51.85 .3601 57.72 22.36 22.47 2.258 13.39
... 30 ... .277 8.071 7.26 51.16 .3553 63.35 24.70 22.17 2.258 14.69
STD 40 40S .322 7.981 8.40 50.03 .3474 72.49 28.55 21.70 2.258 16.81
... 60 ... .406 7.813 10.48 47.94 .3329 88.73 35.64 20.77 2.258 20.58
8 8.625 XS 80 80S .500 7.625 12.76 45.66 .3171 105.7 43.39 19.78 2.258 24.51
... 100 ... .594 7.437 14.96 43.46 .3018 121.3 50.95 18.83 2.258 28.14
... 120 ... .719 7.187 17.84 40.59 .2819 140.5 60.71 17.59 2.258 32.58
... 140 ... .812 7.001 19.93 38.50 .2673 153.7 67.76 16.68 2.258 35.65
XXS ... ... .875 6.875 21.30 37.12 .2578 162.0 72.42 16.10 2.258 37.56
... 160 ... .906 6.813 21.97 36.46 .2532 165.9 74.69 15.80 2.258 38.48
... ... 5S .134 10.482 4.36 86.29 .5992 63.0 15.19 37.39 2.814 11.71
... ... 10S .165 10.420 5.49 85.28 .5922 76.9 18.65 36.95 2.814 14.30
... 20 ... .250 10.250 8.24 82.52 .5731 113.7 28.04 35.76 2.814 21.15
... 30 ... .307 10.136 10.07 80.69 .5603 137.4 34.24 34.96 2.814 25.57
STD 40 40S .365 10.020 11.90 78.86 .5475 160.7 40.48 34.20 2.814 29.90
10 10.750 XS 60 80S .500 9.750 16.10 74.66 .5185 212.0 54.74 32.35 2.814 39.43
... 80 ... .594 9.562 18.92 71.84 .4989 244.8 64.43 31.13 2.814 45.54
... 100 ... .719 9.312 22.63 68.13 .4732 286.1 77.03 29.53 2.814 53.22
... 120 ... .844 9.062 26.24 64.53 .4481 324.2 89.29 27.96 2.814 60.32
XXS 140 ... 1.000 8.750 30.63 60.13 .4176 367.8 104.13 26.06 2.814 68.43
... 160 ... 1.125 8.500 34.02 56.75 .3941 399.3 115.64 24.59 2.814 74.29
... ... 5S .156 12.438 6.17 121.50 .8438 122.4 20.98 52.65 3.338 19.2
... ... 10S .180 12.390 7.11 120.57 .8373 140.4 24.17 52.25 3.338 22.0
... 20 ... .250 12.250 9.82 117.86 .8185 191.8 33.38 51.07 3.338 30.2
... 30 ... .330 12.090 12.87 114.80 .7972 248.4 43.77 49.74 3.338 39.0
12 12.75 STD ... 40S .375 12.000 14.58 113.10 .7854 279.3 49.56 49.00 3.338 43.8
... 40 ... .406 11.938 15.77 111.93 .7773 300.3 53.52 48.50 3.338 47.1
XS ... 80S .500 11.750 19.24 108.43 .7528 361.5 65.42 46.92 3.338 56.7
... 60 ... .562 11.626 21.52 106.16 .7372 400.4 73.15 46.00 3.338 62.8
... 80 ... .688 11.374 26.03 101.64 .7058 475.1 88.63 44.04 3.338 74.6
... 100 ... .844 11.062 31.53 96.14 .6677 561.6 107.32 41.66 3.338 88.1
XXS 120 ... 1.000 10.750 36.91 90.76 .6303 641.6 125.49 39.33 3.338 100.7
... 140 ... 1.125 10.500 41.08 86.59 .6013 700.5 139.67 37.52 3.338 109.9
... 160 ... 1.312 10.126 47.14 80.53 .5592 781.1 160.27 34.89 3.338 122.6
Identification, wall thickness and weight are extracted from ANSI B36.10 and B36.19. Transverse Internal area values listed in "sqaure feet" also
The notations STD, XS, and XXS indicate Standard, Extra Strong, and Double Extra represent volume in cubic feet per foot of pipe length.
Strong pipe, respectively .

Source: Crane Technical Paper No. 410 - Flow of Fluids Through Valves, Fittings and Pipe, © 1988.
With permission from Crane Company - see source for other standard sizes.

Pipe Data
Carbon and Alloy Steel - Stainless Steel
Figure 5

Saudi Aramco DeskTop Standards 20

 Basic Allowable Stress S, ksi, at Metal Temperature, °F
Specified Min.
Min. Min.
Strength, ksi
Spec. P- Temp., Temp.

Engineers.
Material No. No. Grade °F Tensile Yield to 100 200 300 400 500 600 650 700 750 800 850 900 950 1000 1050 1100
Carbon Steel
Pipes and Tubes

A 285 Gr. A A 134 1 ... -20 15.0 11.8 11.6 11.5 10.3 7.8 6.5 . . . ... ... ...
45 24 14.6 14.2 13.7 13.0 9.0
A 672 1 A45 2.5 1.6 1.0
A 285 Gr. A -20 45 24 15.0 14.6 14.2 13.7 13.0 11.8 11.6 11.5 10.3 9.0 7.8 6.5 4.5
... A 53 1 Type F -20 45 25 15.0 15.0 14.5 13.8 . . . ... ... ... ... ... ... ... ... ... ... ...
Engineering Encyclopedia

Butt Weld API 5L 1 A25 -20 45 25 15.0 15.0 14.5 13.8 . . . ... ... ... ... ... ... ... ... ... ... ...
Smls & ERW API 5L 1 A25 -20 25 15.0 15.0 14.5 13.8 . . . ... ... ... ... ... ... ... ... ... ... ...
45
... A 179 1 ... -20 47 26 15.7 15.0 14.2 13.5 12.8 12.1 11.8 11.5 10.6 9.2 7.9 6.5 4.5 2.5 1.6 1.0

Saudi Aramco DeskTop Standards

... A 139 1 A -20 48 30 16.0 16.0 16.0 . . . . . . ... ... ... ... ... ... ... ... ... ... ...
... A 587 1 ... -20 48 30 16.0 16.0 16.0 16.0 16.0 14.8 14.5 14.4 10.7 9.3 7.9 ... ... ... ... ...
... A 53 1 A -20 48 30 16.0 16.0 16.0 16.0 16.0 14.8 14.5 14.4 10.7 9.3 7.9 6.5 4.5 2.5 1.6 1.0
... A 106 1 A -20 48 30 16.0 16.0 16.0 16.0 16.0 14.8 14.5 14.4 10.7 9.3 7.9 6.5 4.5 2.5 1.6 1.0
... A 135 1 A -20 48 30 16.0 16.0 16.0 16.0 16.0 14.8 14.5 14.4 10.7 9.3 7.9 6.5 4.5 2.5 1.6 1.0
... A 369 1 FPA -20 48 30 16.0 16.0 16.0 16.0 16.0 14.8 14.5 14.4 10.7 9.3 7.9 6.5 4.5 2.5 1.6 1.0
... API 5L 1 A -20 48 30 16.0 16.0 16.0 16.0 16.0 14.8 14.5 14.4 10.7 9.3 7.9 6.5 4.5 2.5 1.6 1.0
A 134 ... 50 13.3 13.1 13.0 11.2 9.6 8.1 6.5 . . . ... ... ...
A 285 Gr. B 1 -20 27 16.7 16.4 16.0 15.4 14.6
A 672 A50 50 13.3 13.1 13.0 11.2 9.6 8.1 6.5 4.5 2.5 1.6 1.0
A 285 Gr. B 1 -20 27 16.7 16.4 16.0 15.4 14.6
A 442 Gr. 55 A 671 1 CE55 -20 55 30 18.3 18.3 17.7 17.2 16.2 14.8 14.5 14.4 12.1 10.2 8.4 ... ... ... ... ...
A 672 55 30 16.2 14.8 14.5 14.4 12.1 10.2 8.4 ... ... ... ... ...

Figure 6
A 442 Gr. 55 1 E55 -20 18.3 18.3 17.7 17.2
A 285 Gr. C A 134 1 ... -20 55 30 18.3 18.3 17.7 17.2 16.2 14.8 14.5 14.4 12.0 10.2 8.3 6.5 ... ... ... ...
... A 524 1 Gr. II -20 55 30 18.3 18.3 17.7 17.2 16.2 14.8 14.5 14.4 12.0 10.2 8.3 6.5 4.5 2.5 ... ...
... A 333 1 1 -50 55 30 18.3 18.3 17.7 17.2 16.2 14.8 14.5 14.4 12.0 10.2 8.3 6.5 4.5 2.5 1.6 1.0
... A 334 1 1 -50 55 30 18.3 18.3 17.7 17.2 16.2 14.8 14.5 14.4 12.0 10.2 8.3 6.5 4.5 2.5 1.6 1.0
A 285 Gr. C A 671 1 CA55 -20 55 30 18.3 18.3 17.7 17.2 16.2 14.8 14.5 14.4 12.1 10.2 8.4 6.5 4.5 2.5 1.6 1.0
A 285 Gr. C A 672 1 A55 -20 55 30 18.3 18.3 17.7 17.2 16.2 14.8 14.5 14.4 12.1 10.2 8.4 6.5 4.5 2.5 1.6 1.0
A 515 Gr. 55 A 672 1 B55 -20 55 30 18.3 18.3 17.7 17.2 16.2 14.8 14.5 14.4 12.1 10.2 8.4 6.5 4.5 2.5 1.6 1.0
A 516 Gr. 55 A 672 1 C55 -20 55 30 18.3 18.3 17.7 17.2 16.2 14.8 14.5 14.4 12.1 10.2 8.4 6.5 4.5 2.5 1.6 1.0
A 442 Gr. 60 A 671 1 CE60 -20 60 32 20.0 19.5 18.9
18.3 17.3 15.8 15.5 15.4 13.0 10.8 8.7 ... ... ... ... ...

Basic Allowable Stresses in Tension for Metals

A 516 Gr. 60 A 671 1 CC60 -20 60 20.0 19.5 18.9
18.3 17.3 15.8 15.5 15.4 13.0 10.8 8.7 6.5 4.5 2.5 ... ...
32

Specifications are ASTM Unless Otherwise Indicated

A 442 Gr. 60 A 672 1 E60 -20 60 20.0 19.5 18.9
18.3 17.3 15.8 15.5 15.4 13.0 10.8 8.7 6.5 4.5 2.5 1.6 1.0
32
A 515 Gr. 60 A 671 1 CB60 -20 60 20.0 19.5 18.9
18.3 17.3 15.8 15.5 15.4 13.0 10.8 8.7 6.5 4.5 2.5 1.6 1.0
32
A 515 Gr. 60 A 672 1 B60 -20 60 20.0 19.5 18.9
18.3 17.3 15.8 15.5 15.4 13.0 10.8 8.7 6.5 4.5 2.5 1.6 1.0
32
A 516 Gr. 60 A 672 1 C60 -20 60 20.0 19.5 18.9
18.3 17.3 15.8 15.5 15.4 13.0 10.8 8.7 6.5 4.5 2.5 1.6 1.0
32
... A 139 1 B -20 60 35 20.0 20.0 20.0 . . . ... ... ... ... ... ... ... ... ... ... ... ...

... 8.7 6.5 4.5 ... ...

A 135 1 B -20 60 35 20.0 20.0 20.0 20.0 18.9 17.3 17.0 16.5 13.0 10.8 2.5
... 8.7 6.5 4.5 ... ...
A 524 1 Gr. I -20 60 35 20.0 20.0 20.0 20.0 18.9 17.3 17.0 16.5 13.0 10.8 2.5

Source: ASME B31.3-1990, pages 152 and 153. With permission from the American Society of Mechanical
General Design Considerations
Instrumentation

21
Engineering Encyclopedia Instrumentation
General Design Considerations

Spec. No. Description Ec

Iron
A 47 Malleable iron castings 1.00
A 48 Gray iron castings 1.00
A 126 Gray iron castings 1.00
A 197 Cupola malleable iron castings 1.00
A 278 Gray iron castings 1.00
A 395 Ductile and ferritic ductile iron castings 0.80
A 571 Austenitic ductile iron castings 0.80

Carbon Steel
A 216 Carbon steel castings 0.80
A 352 Ferritic steel castings 0.80

Low and Intermediate Alloy

Steel
A 426 Centrifugally cast pipe 1.00
A 217 Martensitic stainless and alloy castings 0.80
A 352 Ferritic steel castings 0.80

Stainless Steel
A 451 Centrifugally cast pipe 0.90
A 452 Centrifugally cast pipe 0.85
A 351 Austenitic steel castings 0.80

Copper and Copper Alloy

B 61 Steam bronze castings 0.80
B 62 Composition bronze castings 0.80
B 148 Al-Bronze and Si-Al-Bronze castings 0.80
B 584 Copper alloy castings 0.80

Nickel and Nickel Alloy

A 494 Nickel and nickel alloy castings 0.80

Aluminum Alloy
B 26, Temper F Aluminum alloy castings 1.00
B 26, Temper T6, T71 Aluminum alloy castings 0.80
Source: ASME B31.3-1990, page 203. With permission from the American Society of Mechanical Engineers.

Basic Casting Quality Factors EC

Figure 7

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Engineering Encyclopedia Instrumentation
General Design Considerations

Material Groups Product Forms

Material Nominal Forgings Castings Plates
Group Designation Spec. Spec. Spec.
No. Steel No. Grade No. Grade No. Grade
1.1 Carbon A 105 . . . A 216 WCB A 515 70
A 350 LF2 ... ... A 516 70
C-Mn-Si ... ... ... ... A 537 Cl.1
1.2 Carbon ... ... A 216 WCC ... ...
... ... A 352 LCC ... ...
2 1/2Ni ... ... A 352 LC2 A 203 B
3 1/2Ni A 350 LF3 A 352 LC3 A 203 E
1.3 Carbon ... ... A 352 LCB A 515 65
... ... ... ... A 516 65
2 1/2Ni ... ... ... ... A 203 A
3 1/2Ni ... ... ... ... A 203 D
1.4 Carbon A350 LF1 ... ... A 515 60
... ... ... ... A 516 60
1.5 C-1/2Mo A 182 F1 A 217 WC1 A 204 A
... ... A 352 LC1 A 204 B
1.7 C-1/2Mo ... ... ... ... A 204 C
1/2Cr-1/2Mo A182 F2 ... ... ... ...
Ni-Cr-1/2Mo ... ... A 217 WC4 ... ...
Ni-Cr-lMo ... ... A217 WC5 ... ...
1.9 1Cr-1/2Mo A 182 F12 ... ... ... .. .
1 1/4Cr-1/2Mo A 182 F11 A 217 WC6 A 387 11 Cl.2
1.10 2 1/4Cr-1Mo A 182 F22 A 217 WC9 A 387 22 Cl.2
1.13 5Cr-1/2Mo A 182 F5 A 217 C5 ... ...
A 182 F5a ... ... ... ...
1.14 9Cr-1Mo A 182 F9 A 217 C12 ... ...
2.1 18Cr-8Ni A 182 F304 A 351 CF3 A 240 304
A 182 F304H A 351 CF8 A 240 304H
2.2 16Cr-12Ni- A 182 F316 ... ... A 240 316
2Mo A 182 F316H ... ... A 240 316H
... ... ... ... A 240 317
18Cr-13Ni- ... ... A 351 CF3M ... ...
3Mo ... ... A 351 CF8M ... ...
18Cr-9Ni-2Mo
Source: ASME/ANSI B16.5-1988, page 10. With permission from the American Society of Mechanical
Engineers.

List of Material Specifications

Applicable ASTM Specifications
Figure 8

Saudi Aramco DeskTop Standards 23

Engineering Encyclopedia Instrumentation
General Design Considerations

Flanges

The majority of piping flanges (24 in. and smaller) that are used in refineries are
manufactured to a standard set of dimensions, which conform to ANSI B16.5.
Pressure/temperature ratings are then assigned to each of the standard flanges, which allows
the plant engineer to select the appropriate standard flange for the piping system under design.
ANSI B16.5 contains pressure/temperature rating tables for flanges of different materials.
Tables are provided for pressure classifications 150, 300, 400, 600, 900, 1500, and 2500 psi.
A copy of the tables for 150 and 300 psi pressure classifications (carbon steel flanges) have
been included, as Figures 9 and 10, for use in connection with calculations that are performed
as part of this module.

Class 150

Source: ASME/ANSI B16.5-1988, page 16. With permission from the American Society of Mechanical
Engineers.

Pressure/Temperature Ratings
Pressures are in Psig, Class 150
Figure 9

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Engineering Encyclopedia Instrumentation
General Design Considerations

Class 300

Material
Group
No. 1.1 1.2 1.3 1.4 1.5 1.7 1.9 1.10 1.13 1.14 2.1 2.2 2.3 2.4 2.5 2.6 2.7
Alloy Steels Austenitic Steels
1/2Cr- 1Cr- Type
1/2Mo 1/2Mo 21/4 C 304L Types
C- Ni-Cr- 11/4Cr- r-1Mo5Cr- 9Cr- Type Type Type Type 347, Type Type
Temp.°F Carbon Steel 1/2Mo Mo 1/2Mo 1/2Mo 1Mo 304 316 316L 321 348 309 310
-20 to
100 740 750 695 620 695 750 750 750 750 750 720 720 600 720 720 670 670
200 675 750 655 560 680 750 710 715 750 750 600 620 505 610 635 605 605
300 655 730 640 550 655 730 675 675 730 730 530 560 455 545 590 570 570
400 635 705 620 530 640 705 660 650 705 705 470 515 415 495 555 535 535

500 600 665 585 500 620 665 640 640 665 665 435 480 380 460 520 505 505
600 550 605 535 455 605 605 605 605 605 605 415 450 360 435 490 480 480
650 535 590 525 450 590 590 590 590 590 590 410 445 350 430 480 465 465
700 535 570 520 450 570 570 570 570 570 570 405 430 345 420 470 455 455

750 505 505 475 445 530 530 530 530 530 530 400 425 335 415 460 445 445
800 410 410 390 370 510 510 510 510 500 510 395 415 330 415 455 435 435
850 270 270 270 270 485 485 485 485 440 485 390 405 320 410 445 425 425
900 170 170 170 170 450 450 450 450 355 450 385 395 ... 405 430 415 415

950 105 105 105 105 280 345 380 380 260 370 375 385 ... 385 385 385 385
1000 50 50 50 50 165 215 225 270 190 290 325 365 ... 355 365 335 350
1050 ... ... ... ... ... 190 140 200 140 190 310 360 ... 345 360 290 335
1100 ... ... ... ... ... ... 95 115 105 115 260 325 ... 300 325 225 290

1150 ... ... ... ... ... ... 50 105 70 75 195 275 ... 235 275 170 245
1200 ... ... ... ... ... ... 35 55 45 50 155 205 ... 180 170 130 205
1250 ... ... ... ... ... ... ... ... ... ... 110 180 ... 140 125 100 160
1300 ... ... ... ... ... ... ... ... ... ... 85 140 ... 105 95 80 120

1350 ... ... ... ... ... ... . . .. ... ... ... 60 105 ... 80 70 60 80
1400 ... ... ... ... ... ... ... ... ... ... 50 75 ... 60 50 45 55
1450 ... ... ... ... ... ... ... ... ... ... 35 60 ... 50 40 30 40
1500 ... ... ... ... ... ... ... ... ... ... 25 40 ... 40 35 25 25

Source: ASME/ANSI B16.5-1988, page 18. With permission from the American Society of Mechanical
Engineers.
Pressure/Temperature Ratings
Pressures are in psig, Class 300
Figure 10

Saudi Aramco DeskTop Standards 25

Engineering Encyclopedia Instrumentation
General Design Considerations

Example Problem 3
In Example Problem 2 the following was determined:

Design Pressure (DP) Design Temperature (DT)

Pump discharge line to cooler 410 psig 420°F

What pipe schedule and flange class would be required for this 10″ line with a corrosion
allowance of 1/16″ for carbon steel (Group 1.1) and a casting factor of 0.8?

From Figure 5, a 10″ line has 10.75″ outside diameter.

From Figure 6, S is 13.7 ksi (thousand psi) at 400°F and 13.0 ksi at 500°F.

Interpolation results in 13.56 ksi at 420°F.

Pipe Schedule

Calculate required thickness using Barlow’s Equation:

(DP)D (410)(10.75)
t= C 1/16 = 0.203 .062 = .265
2SE c 2(13.56x103 )(0.8)

From Figure 5: Schedule Thickness

20 0.25″
30 0.307″
40 0.365″

Schedule 30 would be adequate for this service. Schedule 40 would probably be used due to
availability and cost of standard Schedule 40 pipe.

Flange Class

From Figure 9, Class 150, flange group 1.1, at 400°F maximum pressure is 200 psig which is
less than DP of 410 psig. Must go to next class flange (Class 300) to check adequacy.

From Figure 10, Class 300 flange group 1.1, at 400°F maximum pressure is 635 psig and at
500°F maximum pressure is 600 psig giving 628 psig at 420°F interpolation. This is adequate
for 410 psig DP.

A Class 300 flange will be required.

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Piping and Tubing

Piping and tubing are two quite different pieces of equipment. Piping is manufactured to
ANSI B31.3 and is available in much heavier walls and larger diameters than tubing. For
example, the minimum nominal pipe size used in refineries is 1 in., whereas the maximum
size pressure tubing manufactured is 2 in. Even denotation of pipe and/or tubing size is
different. For example, 6 in. normal pipe size pipe has an O.D. (outside diameter) of 6.625 in.
(see Figure 5), whereas 1 in. tubing has an O.D. of 1 in. Also, tubing is manufactured in
accordance to Saudi Aramco Standard ASTM A-269 (stainless steel).

Except for heat exchangers, the use of tubing in refinery service is usually limited to
instrument leads, etc. Tubing services are usually equipped with isolation valves so that in the
event of a mechanical breakage, the leakage of a flammable fluid can be quickly stopped.
Tubing is quite susceptible to mechanical breakage, relative to piping, because of the
relatively small sizes and thin walled fabrication. Tubing is manufactured to ASTM Standard
with Birmingham Wire Gage (BWG) thickness.

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Valves, Fittings, and Gaskets

The following discussion of piping system valves will be limited to the valves that are
discussed in SAES-L-008 and SADP-L-008. Included are angle, ball, check, diaphragm,
needle, butterfly, gate, globe, choke, and plug valves; used for on/off services, for manual
control, and for prevention of reverse flow. All of these valve types are normally classified
under Saudi Aramco Materials System (SAMS) Class 7. Excluded are control, safety relief,
relief, surge relief, solenoid, pilot, and other valves classified under AMS Class 34. See
Figure 11 for a cross section view of some manually operated valve types.

The type of valve selected is greatly influenced by the valve service. If the valve is to be in a
manual flow control service, then the selection depends mainly on the system pressure rating,
fluid type, and expected pressure drop across the valve. If the valve is to be in an on/off
service, then the selection depends mainly on the seat tightness requirements. If a bubble
tight shutoff is required, then a soft seated valve is required; however, if a limited amount of
leakage can be tolerated, then a metal seated valve will probably be selected. Metal seated
valves may have small imperfections on the valve faces which will permit a limited amount of
leakage. The soft seated valve uses an elastomer or plastic to seal leakages from small
imperfections in the metal surfaces. Soft seated valves have relatively low temperature
limitation because elastomers tend to flow at higher temperatures. Fire will usually destroy
the soft seat and may limit application of soft seated valves.

The normal position of the valve also influences the selection process. For example, if the
valve is normally open, a gate valve may be selected to minimize pressure drop and collection
of the system debris. SADP-L-008 makes valve type recommendations for different types of
services (Tables I-III). SADP-L-008 also discusses the possible applications for different
types of valves, by valve type. Valve materials and pressure/temperature rating
considerations are also discussed. One of the valve selection tables in SADP-L-008 has been
reproduced and included in this module to illustrate how valve selection is accomplished (see
Figure 12). In addition to the information in SADP-L-008, SAES-L-008 contains extensive
guidance for the selection of the appropriate valve component parts and materials as a
function of valve service.

Pipe fittings are the preformed pieces of pipe that are used to alter the straight run pipe in
some manner (change direction, size, etc.). See Figure 13 for a pictorial index of some of the
seamless welding fittings available for constructing a piping system. There are two basic
types of fittings: seamless welding fittings (shown in Figure 13) and forged steel fittings
(shown in Figure 14). Forged fittings are usually used for the smaller piping systems (4 in.
and smaller), whereas the seamless welding fittings are available in very large sizes
(approximately 3 ft in diameter). Both types of fittings are manufactured to a standardized set
of dimensions and specifications that meet ASA and/or ASTM requirements. The plant
engineer should refer to SAES-L-007 and SADP-L-007 for special requirements instituted for
piping fittings by Saudi Aramco prior to designing a piping system. Refer to Figure 15 for
spiral wound gasketing and Figure 16 for the Basic Guide for Choice of Gasketing.

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Source: Crane Technical Paper No. 410 - Flow of Fluids Through Valves, Fittings and Pipe, © 1988. With
permission from Crane Company.
Types of Valves
Figure 11

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Source: Crane Technical Paper No. 410 - Flow of Fluids Through Valves, Fittings and Pipe, © 1988. With
permission from Crane Company.

Types of Valves
Figure 11, Cont’d

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Application ∆P* NPS in. Rating Valve Paragrap Remarks

h

General High 1/8 - 1 all Needle 4.3.2 Fine flow

Purpose regulation

Mod/High 1/2 - 12 Up to ANSI Globe/Angle 4.3 04-AMSS-002

900 4.4

High 2 and Less than ANSI 4.8

above 600

High 2-8 API 2000 and Choke 4.4 Suitable for

above abrasive services

Mod 2 - 12 Up to ANSI Plug 4.6 Limited throttling

1500

Mod 2 - 72 Up to ANSI Butterfly 4.7

300

Steam (and Mod/High 1/2 - 12 Up to ANSI Glove/Angle 4.3 04-AMSS-002

other high 600 4.4
temp./press.
services)

Low 2 and ANSI 900 and Parallel slide 4.2.4 Short-term control
above above

*∆P: Required pressure drop across the valve.

Example SADP-L-008 Selection Table for Manual Control Valve Type Service
Figure 12

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Source: Ladish General Catalog No. 55 - Forged and Seamless Welding Pipe Fittings, © 1954. With
permission from Ladish Company.

Seamless Welding Fittings

Figure 13

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Source: Ladish General Catalog No. 55 - Forged and Seamless Welding Pipe Fittings, © 1954. With
permission from Ladish Company.
Forged Steel Fittings
Figure 14

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Gasketing material is used for bolted joints in piping systems to prevent the leakage of gas or
liquid from the interior of the pipe to the atmosphere. The gasketing is placed between the
pipe flanges, as shown in Figure 15. The picture shown in Figure 15 was deliberately
selected to illustrate the fact that very complex gaskets are available for special services. A
representative listing of gasket types and their recommended uses is shown in Figure 16. The
vendor supplied gasket selection information shown in Figure 16, combined with information
contained in Saudi Aramco SAES-L-009, will provide the plant engineer with a basis for
selecting a gasket type. For any unusual services, the plant engineer should contact the
assigned mechanical specialist in the Consulting Services Department.

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With permission from Garlock.

Spiral-Wound Gasket
Figure 15

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MEDIA
Alka-
Acids Gases Oils Solvents
lies

Refrigerants, Halocarbons

Contamination Required
Preferred

Aromatic, (Ben., etc.)

Water & Salt Solution

Aliphatic (Gas, etc.)
Synthetics, Diesters
Air & Dry Industry

Fluid Where Non-

Satisfactory

Bromine, Chlorine

Chlorinated
Petroleum
Corrosive

Corrosive

Oxygen

Steam
Mild

Mild
PRODUCT BASIC COMPOSITION COMMENTS
Compressed Asbestos White Asbestos, SBR Binder Prime General Service
*
Compressed Asbestos White Asbestos, SBR Binder Medium Grades
Compressed Asbestos White Asbestos, SBR Binder Hot Oil Resistant
Compressed Asbestos White Asbestos, Neoprene Binder Prime for Oils
Compressed Asbestos White Asbestos, Neoprene Binder Prime for Refrigerants
Compressed Asbestos White Asbestos, Nitrile Binder General Solvent Service
Compressed Asbestos Blue Asbetos, SBR Binder Acid Resistant
Wire Inserted, White Asbestos,
Compressed Asbestos Heavy Duty Steam
SBR Binder
Homogeneous Rubber Natural Rubber Soft Tan Gum Rubber
Homogeneous Rubber SBR
Homogeneous Rubber SBR
Homogeneous Rubber SBR Prime "Red Rubber"
Homogeneous Rubber SBR
Homogeneous Rubber Neoprene
Homogeneous Rubber Neoprene
Homogeneous Rubber Neoprene
Homogeneous Rubber Neoprene
Homogeneous Rubber Nitrile
Homogeneous Rubber Nitrile
Homogeneous Rubber Nitrile
Excellent Ozone
Homogeneous Rubber EPDM
Resistance
Excellent Ozone
Homogeneous Rubber EPDM Resistance
SBR Rubber, 10-oz Cotton 1/32", uses 5-oz
Reinforced Rubber
Chafer Cotton Sheeting
Heavy Cotton
Diaphragm SBR Rubber, 20-oz Hose Duck
Reinforcement

Diaphragm Heavy Cotton

Neoprene, 20-oz Hose Duck
Reinforcement
Diaphragm Neoprene, 13-oz Nylon Prime General Duty
Diaphragm Nitrile, 4.5-oz Nylon Very Sensitive
White Asbestos, White SBR Soft and Conforming
Woven Asbestos
Impregnated
Cellulose Fiber, Cork, Glue, Soft, Resilient,
Vegetable Fiber
Glycerine Non-water
Vegetable Fiber Cellulose Fiber, Glue, Glycerine Firm, Non-water
PTFE PTFE plus Inert Filler Low Cold Flow
Flexible Graphite Pure Graphite Very High Temperatures
Fiberglass Fiberglass, Elastomer Soft and Conforming
*Compressed Asbestos sheet has never been officially approved by any governmental or other independent laboratory for oxygen
service. Despite the fact that we have many satisfied customers who have used this product for years in oxygen service, we cannot
guarantee its fitness for such use.

Basic Guide for Choice of Gasketing

Figure 16

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Expansion/Contraction

Two topics will be covered in this section:

• Problems caused by the thermal expansion of liquid-filled systems.

• Problems caused by the thermal expansion or contraction of pipe.

Liquid-filled systems that are blocked in and then heated can often result in the build-up of
very high pressures that can occasionally rupture the pipe (see Saudi Aramco SADP-L-043).
The warming action generates these high pressures because the coefficient of expansion for
the liquid in the pipe is significantly higher than the coefficient of expansion for the pipe wall.
In other words, the contents of the pipe expand much faster than the walls of the pipe. The
following example problem shows why very high liquid pressures occur with the warming of
blocked-in liquid.

Example Problem 4
A 12 in. carbon steel pipe, 200 ft long, (distance between block valves) containing liquid
propane refrigerant at 40°F is blocked in. The propane filled line sits in the sun, blocked in,
and the temperature of the propane in the line rises to 130°F. The pressure in the pipe at the
time of the block in (40°F liquid) was 70 psig. For this example problem, the following
nomenclature is used: subscript "1" is used for the condition prior to the warming of the
liquid and subscript "2" is used for the warmed condition. The carbon steel coefficient of
expansion at the average temperature of 85°F is 6.5 x 10-6. Find expansion of length and
volume of pipe and volume of propane.
where: V = Volume of pipe or liquid, ft3
L = Length of pipe, ft.
r = Radius of pipe, in.
C = Coefficient of expansion for metal
T = Temperature of pipe or liquid, °F
Pipe Volume at 40°F:

2
V1 = πr12 L1 = 3.1416 6 200 = 157.08 ft3
12

Pipe Volume at 130°F:

 (r1 )(C)(T2 − T1 ) + r1 
2

V2 = 
 12


[(L )(C )(T
1 2 − T1 ) + L 1 ]

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Length Thermal Expansion for 12" CS Pipe 200 ft. at 40°F heated to 130°F

Exp = L C ∆T
= 200 (6.5 x 10-6)(130-40)
= 0.117 ft.
= 1.4"

Volume at 130°F

 ( )(6 )(6.5 × 10 -6 )
2
 6 
V2 = 
 12 12 
[ ]
(130 - 40 ) +    (200)(6.5 × 10 -6 )(130 - 40 ) + 200

= (3.1416)(0.0002925+ 0.5) (0.117 + 200)

2

= (3.1416) (0.2503) (200.117) = 157.55 ft3

Pipe volume expansion = V2 - V1 = 157.36 - 157.08 = 0.28 ft3

The change of pipe diameter with temperature in this case is small. The actual diameter
change and the volume change due to the diameter change is shown below:

R2 = R1 + (C∆T)(R1) = R1+(6.5 x10-6)(90) = 3.51 x 10-3 in. + R1

-3
3.51x10
R 2 = 0.5 + = 0.5 + .0002925 = 0.50002925
12

Volume change for radius expansion π[(0.50002925)2 - (0.5)2] 200 = 0.0184 ft3 (6.6% total)

Propane Volume 40°F:

V1 = Same as the pipe at 40°F = 157.08 ft3.

Propane Volume 130°F:

V2 =
(V1 )(sp.gr.1 ) = (157.08)(0.525) = 187.42ft3
sp.gr.2 0.44

(See Maxwell, Pg. 140 for sp. gr. values.)

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Propane Expansion = V2 - V1 = 187.42 - 157.08 = 30.34 ft3

 30.34ft3 
Percent volume increase for propane =   x100 = 19.3%
 157.08 

 0.28ft3 
Percent volume increase for the pipe=   x100 = 0.178%
 157.08

From the calculations in Example Problem 4, it can be seen that the propane liquid expands
65 times faster than the pipe. Since liquid has a compressibility almost equal to one (meaning
liquid is almost noncompressible), pressure in the pipe builds very quickly as the temperature
of the liquid rises. Typically, pressure rises (depending on the liquid involved) 10 to 100 psi
for every degree (°F) rise in temperature. To calculate the actual pressure use, see Saudi
Aramco Design Practice SADP-L-043. Thermal relief valves are normally provided for any
section of line that can be shut off to allow for greater expansion of the hydrocarbon than the
metal. These are normally 3/4x3/4” or 1x1” relief valves and may discharge around a block
valve if contamination of the fluid downstream of the valve is not a problem.

Problems can be caused by the thermal expansion or contraction by warming or cooling pipe.
From the calculations done for Example Problem 4, it can be seen that a 200 ft long pipe
heated 90°F (130 - 40) extends in length by 0.117 ft (1.4 in.). Not only does this growth in
the pipe cause great bending moments, but the pipe may slide off of its pipe support if the
proper allowance has not been made for the expansion. Typically, lines running between
major units, or connecting with tankage, could be 500 to 1000 ft long and in some cases could
carry liquids as hot as 500°F. For a line in this category, the growth when heating to
operating temperature for ambient temperature could be several ft, and would probably
require expansion loops to absorb some of the growth.

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USING PFD AND P&ID DRAWINGS

Figure 17 is a Process Flow Diagram (PFD) of a Depropanizer/Debutanizer system at Ras

Tanura. Note the following types of information on this drawing:

• Equipment symbols. • Distillation specs.

• Equipment sizes. • Molecular weight.

• Control scheme. • API gravities.

• Flow rates. • Pressure data.

• Heat duties. • Temperature data.

Another type of drawing frequently encountered by the plant engineer is the Piping and
Instrument Drawing (P&ID). An example of this type of drawing is shown in Figure 18.
Note that the P&ID is more complex than the PFD. These drawings show the actual piping
and instrument details. Line sizes, ratings, and materials are also included. There is less
emphasis placed on process items such as flow rates in these drawings. Note the following
types of information on this drawing: Another name for a P&ID is a Mechanical Flow
Diagram which may be more descriptive.

• Safety valve set pressures • Line sizes, ratings, materials

• Car sealed valves (chained) • Line numbers

• Corrosion probes • Instrumentation

• Emergency block valves • Demister pad (CWMS) locations

• Valve bypasses • Blind locations

• Control valve actions • Sample outlets

• Instrument numbers • Equipment numbers

• Equipment data, internals

Many variations of PFDs and P&IDs exist. Some of the items may appear on PFDs or P&IDs
depending on the owner's requirements. Standard drawings are often used to reduce the
complexity of P&IDs. An example of a standard drawing would be a standard level
transmitter installation including gage glasses, vents, drains, etc. as well as the level
transmitter.

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Process Flow Diagram Depropanizer and Debutanizer NGL Fractionating and Treating
Figure 17

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Typical P&ID
Figure 18

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Typical P&ID
Figure 18, Cont’d

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PLOT AREA CONSIDERATIONS

The distance between pieces of equipment is set by consideration of safety and operations.
for example an air cooled exchanger should not be set next to a process heater because the
intake air may be heated by the process heater. The air cooled exchanger should not be set
directly over a pump because a pump fire could melt the air cooled exchanger.

Therefore, the refinery space guide should be consulted for the proper buffer area and the
recommended limitation on what equipment can be under or over an air-cooled exchanger. A
sample equipment spacing guide is shown in Figure 19. To use this guide, enter the chart
from the equipment being located, read down to the row concerning the pieces of equipment
nearby, and read the minimum distance required between them. Use the basic spacing
indicated on the top of the spacing guide for any equipment or items not directly indicated on
the chart.

Figure 19 is a basic spacing guide and may be revised under specific circumstances. For
example, Figure 19 shows that a drum may be located as close as 50 feet from a control
house. However, if the drum contained LPG with the possibility of releasing a large vapor
cloud, the minimum distance would probably be 100 to 150 feet.

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Onsite Spacing Chart

Figure 19

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Example Problem 5
Introduction:

In this Exercise, the Participant will calculate the minimum plot area and dimensions required
for the air-cooled exchanger defined below. The plot area will include an allowance for the
exchanger face area plus adequate spacing between the air-cooled exchanger and adjacent
facilities.

Since all answers may be determined from Figure 19, a Work Aid is not provided for this
Exercise.

Directions:

The refinery wants to locate an airfin exchanger in the plot shown below. The Participant has
been asked to determine the minimum distances required to the existing equipment and to
calculate the minimum plot area to be reserved for the airfin. If the distance to existing
equipment exceeds these dimensions, the location will be acceptable. The information
available is as follows: the horizontal air-cooled exchanger has 30-ft tubes and a face area, af,
of 1200 ft2. Use Figure 19 (equipment spacing requirements) for this Exercise to determine
plot area. To the north of the air-cooled exchanger, assume that there will be a cooling tower;
to the south, a furnace; to the west, a pipe band (pipe rack); and to the east, an access road.
The exchanger tubes will run from east to west.

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Total plot area required _______________ ft2. Mark dimensions on the sketch:

Cooling Tower

Airfin
Exchanger
Pipe Band

N
Access Road

Furnace

Figure 20

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Answer:

North minimum spacing requirement (cooling tower) = 50 ft

South minimum spacing requirement (furnace) = 50 ft
West minimum spacing requirement (pipe band) = 10 ft
East minimum spacing requirement (basic spacing road) = 10 ft
af
Airfin dimensions = = 1200 = 40 x 30 ft
tube length 30

Plot width = 10 + 30 + 10 = 50 ft
Plot length = 50 + 40 + 50 = 140 ft
Plot area = 50 x 140 = 7000 ft2

Figure 20A

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RELIEF AND FLARE SYSTEMS

Safety Valves and Relief Valves

Process Design Basis

There are a number of standards for design of safety and safety relief valves. The Saudi
Aramco standards include the following:

1. SAES-J-600
2. SADP-J -600
3. SAES-A-005
4. SADP-A-005 - Safety and Facility Design (Section 12, Pressure Relief)
5. GI-447 (Form 3099A, Relief Valve Authorization)
6. 34-SAMSS-611
7. 8020-611-Eng Shts 1, 2, & 3

Industry standards which are also adhered to by Saudi Aramco include:

1. ASME Boiler and Pressure Vessel Code

• Section I (Boilers)
• Section VIII (Pressure Vessels)
• Certification Tests
• Capacity Calculation

2. API
• API- Recommended Practice(RP) -520
• API- Recommended Practice(RP) -521
• API-STD-526
• API-STD-527
• API-STD-2000

3. NACE
• MR-01-75

This section introduces Safety Valve Design and is not intended to thoroughly cover the
subject. API-RP-520 titled “Sizing, Selection and Installation of Pressure-Relieving Devices
in Refineries” is recommended for further reading on this subject. Saudi Aramco’s PEDP
course PCI 110 Pressure Relief Valves should be considered for more complete coverage.

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Required Relief Rate

Figure 21 lists the basis for relief capacities. The safety relief device is sized for the
maximum of these basis. The usual case is that the maximum loading is due to fire or utility
failure. The utility failure is usually associated with cooling and can be caused by either a
general power failure or failure of the cooling water system. A control system failure that
controls flow from a high pressure system to a low pressure system can also be the cause of
relieving the low pressure system and should be sized accordingly. One such basis would be
sonic flow through an open control valve.

Pressure Pressure
Item Relief Device Relief Device
No. Condition (Liquid Relief) (Vapor Relief)a

1 Closed outlets on vessels Maximum Total incoming steam and vapor plus that
liquid generated therein at relieving conditions
pump-in rate

2 Cooling water failure to condenser — Total vapor to condenser at relieving

conditions

3 Top-tower reflux failure — Total incoming steam and vapor plus that
generated therein at relieving conditions
less vapor condensed by sidestream reflux

4 Sidestream reflux failure — Difference between vapor entering and

leaving section at relieving conditions

5 Lean oil failure to absorber — None, normally

6 Accumulation of noncondensables — Same effect in towers as found for Item 2; in

other vessels, same effect as found for Item
1

7 Entrance of highly volatile material

Water into hot oil — For towers, usually not predictable
Light hydrocarbons into hot oil — For heat exchangers, assume an area twice
the internal cross-sectional area of one tube
to provide for the vapor generated by the
entrance of the volatile fluid due to tube
rupture.

Basis for Relief Capacities Under Selected Conditions

From API-RP-250
Figure 21

a
Consideration may be given to the suppression of vapor production as the result of the device’s relieving
pressure being above operating pressure, assuming constant heat input.

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Pressure Pressure
Item Relief Device Relief Device
No. Condition (Liquid Relief) (Vapor Relief)a

8 Overfilling storage or surge vessel Maximum —

liquid
pump-in rate

9 Failure of automatic controls — Must be analyzed on a case-by-case basis.

10 Abnormal heat or vapor input — Estimated maximum vapor generation

including non-condensables from
overheating

11 Split exchanger tube — Steam or vapor entering from twice the

cross-sectional area of one tube; also same
effects found in Item 7 for exchangers

12 Internal explosions — Not controlled by conventional relief

devices but by avoidance of circumstances.

13 Chemical reaction — Estimated vapor generation from both

normal and uncontrolled conditions.

14 Hydraulic expansion
Cold fluid shut in See C.2 —
Lines outside process area shut in See C.2 —

15 Exterior fire — Estimate by the method given in D.5

16 Power failure (steam, electric, or — Study the installation to determine the effect
other) of power failure; size relief valve for the
worst condition that can occur
Fractionators — All pumps could be down, with the result
that reflux and cooling water would fail
Reactors — Consider failure of agitation or stirring,
quench or retarding stream; size valves for
vapor generation from a runaway reaction
Air-cooled exchangers — Fans would fail; size valves for the
difference between normal and emergency
duty
Surge vessels — —

Basis for Relief Capacities Under Selected Conditions

From API-RP-250
Figure 21, Cont’d

a
Consideration may be given to the suppression of vapor production as the result of the device’s relieving
pressure being above operating pressure, assuming constant heat input.

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Fire Vapor Rate

The relief rate required by a fire is equal to the amount of vapor generated by the fire.

Fire on the wetted surface will generate vapors by vaporizing the liquid. The amount of vapor
produced can be calculated from the following:

W = Q/∆h

where:
W = mass rate of vapor generated, lbs/hr
Q = total heat absorbed to the wetted surface, Btu/hr
∆h = latent heat at relief conditions, Btu/lb

The total heat absorbed to the wetted surface can be found from the following:

Q = Constant F A0.82
where:
Constant = 21000 for prompt fire fighting and adequate drainage of
flammable materials away from vessel.
= 34500 when adequate drainage and fire fighting do not exist
F = Environmental factor, Btu/hr- ft2
A = Total effective wetted surface, ft2

A partial definition of the environmental factor F is:

Condition F
Bare Wall 1.0
Insulation k(1660 - Tf )
F=
21000 t

where:
k = insulation thermal conductivity, Btu/hr- ft2-°F/in
Tf = temperature at relieving conditions, °F
t = insulation thickness, in

A, the total effective wetted surface is described in Figure 22.

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Class of Vessel Portion of Liquid Inventory Remarks

Liquid-full, such as treaters All up to the height of 25 feet —

Surge drums, knockout Normal operating level up to —

drums, process vessels the height of 25 feet

Fractionating columns Normal level in bottom plus Level in reboiler is to be

liquid holdup from all trays; included if the reboiler is an
total wetted surface up to the integral part of the column
height of 25 feet

Working storage Average inventory level up to For tanks of 15 psig

the height of 25 feet operating pressure or less;
see API Standard 2000

Spheres and spheroids Up to the maximum —

horizontal diameter or up to
the height of 25 feet,
whichever is greater

Total Effective Wetted Surface

Figure 22

Safety Valves/Safety Relief Valves

Safety valves are spring-loaded pressure relief devices designed to provide full opening with
minimum over-pressure. Static pressure retained in the huddling chamber and the kinetic
energy of the gas or vapor are utilized to overcome the spring force on the disk as it lifts,
resulting in pop action. the closing pressure will be at a point below the set pressure and will
be reached after the blowdown phase is completed.

Figure 23 shows the pressure level relationship for pressure relief valves. The overpressure
allowed for sizing depends on the basis and will range from 10% for a non-fire basis to 21%
for a fire exposure basis. For multiple pressure relief valves on a vessel. the additional valves
may be set at a maximum of 5% higher than the maximum allowable working pressure which
is the set point for a single valve.

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Relief Valve Pressure-Level Relationship

API-RP-520
Figure 23

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A safety relief valve is a spring-loaded pressure relief device that provides the characteristics
of a safety valve in gas or vapor service and the characteristics of a relief valve when used in
liquid service. Safety relief valves are generally provided with bonnets that enclose the spring
and provide a pressure tight housing for use in conventional or balanced types, depending on
the effect of back pressure on their performance.

Blowdown is the difference between the set pressure and the closing pressure of the pressure
relief valve expressed either as a percent of the set pressure or in pressure units. This value is
important to make sure the valve resets properly.

Back pressure is the pressure that exists on the outlet of the pressure relief and is the sum of
the superimposed and built-up back pressures. Superimposed back pressure is the static
pressure at the outlet of a pressure relief device at the time the device is required to operate.
Built-up back pressure is the reverse at the outlet as a result of relieving. Back pressure can
cause an instability or harmonic resonance and the valve may start to flutter or chatter. Flutter
refers to the abnormally rapid reciprocating motion of the movable parts of the pressure relief
valve in which the disk does not contact the seat. Chatter refers to flutter when the disk does
contact the seat. Chatter can lead to damage of the valve and associated piping

Figure 24 shows a conventional safety relief valve. The adjusting screw is used to adjust the
spring tension or set pressure. The adjusting ring is used to adjust blowdown. Figure 25
shows how back pressure can effect the set pressure. Venting the bonnet to atmosphere
maintains safety of the equipment but can release hazardous materials to the atmosphere.
Most conventional relief valve bonnets are unvented to atmosphere but are vented internally
to the valve discharge.

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Conventional Safety Relief Valve

API-RP-520
Figure 24

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Back Pressure Effect on Conventional Valve Set Pressure

API-RP-520
Figure 25

The set pressure is set with an atmospheric back pressure. If the bonnet is vented (to
atmosphere), back pressure will result in the valve opening at less than set pressure because
the back pressure will reduce the net force on the disk as shown in Figure 25. If the bonnet is
not vented, back pressure will result in the valve opening at greater than the set pressure
because the back pressure will increase the net force on the disk as shown in Figure 25.

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Figure 26 shows a balanced-bellows safety relief valve which is one type of balanced pressure
safety relief valve. Figure 27 shows how the back pressure will no longer effect the set
pressure of a balanced pressure safety relief valve. The bonnets of balanced pressure safety
relief valves must be vented to atmosphere to operate properly.

Balanced-Bellows Safety Relief Valve

API-RP-520
Figure 26

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Back Pressure Effects on Balanced-Pressure Safety Relief Valve

API-RP-520
Figure 27

Figure 27 shows two types of balanced pressure safety relief valves: the vented piston and
vented bellows. The net pressure on the disk is independent of back pressure in both cases.
The net pressure on the disk is atmospheric pressure over the nozzle area plus the spring
pressure. When the valve is set (atmospheric pressure) in the shop, the differential pressure
on the disk should be the same as that required to start flow in service.

The back pressure must not exceed the critical pressure so that critical (sonic) flow can be
maintained through the valve orifice. If the orifice velocity is subsonic the capacity will be
reduced.

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Figure 28 shows a typical pilot operated safety relief valve.

Modulating Pilot-Operated Valve (Flowing Type)

API-RP-520
Figure 28

A pilot operated valve should not be used in a service in which the pilot lines could plug.

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The nozzle in a safety relief valve is sized to operate at critical (sonic) flow. If the back
pressure is greater than the critical pressure the capacity is reduced. The critical pressure is
found from the following:
k
Pc  2 k −1
= 
P1  k + 1

where:
Pc = Critical pressure, psia
P1 = Upstream set pressure, psia
k = Ratio of specific heats (cp/cv), dimensionless

If the back pressure is greater than the critical pressure refer to API-RP-520 for sizing the
nozzle area for subcritical flows.

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Critical flow nozzle area requirements for gases and vapors can be determined by any of the
following formulas:

W TZ
A=
C K d P1 Kb M

V TZM
A=
6.32 C K d P1 Kb

V TZG
A=
1.175 C Kd P1 Kb

where:
A = required effective discharge area of the valve, in square inches.
W = required flow through the valve, in pounds per hour.
C = coefficient determined from an expression of the ratio of the specific heats
of the gas or vapor at standard conditions. This can be obtained from
Figure 29.
Kd = effective coefficient of discharge
= 0.975 for use in the above equations.
P1 = upstream relieving pressure, in pounds per square inch absolute. This is
the set pressure plus the allowable overpressure plus atmospheric
pressure.
Kb = capacity correction factor due to back pressure. This can be obtained
from the manufacturer's literature or estimated from Figure 30. The back-
pressure correction factor applies to balanced-bellows valves only.
T = relieving temperature of the inlet gas or vapor, in degrees Rankine
(degreesFahrenheit + 460).
Z = compressibility factor for the deviation of the actual gas from a perfect
gas, a ratio evaluated at inlet conditions.
M = molecular weight of the gas or vapor. Various handbooks carry tables of
molecular weights of materials, but the composition of the flowing gas or
vapor is seldom the same as that listed in tables. This value should be
obtained from the process data.
V = required flow through the valve, in standard cubic feet per minute at 14.7
pounds per square inch absolute and 60°F.
G = specific gravity of gas referred to air
= 1.00 for air at 14.7 pounds per square inch absolute and 60°F.

The value of the coefficient C can be evaluated from the ratio of the specific heats (k) of the
gas vapor by using Figure 29.

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Values of Coefficient C
API-RP-520
Figure 29

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Use Word 6.0c or later to

view Macintosh picture.

Back Pressure Sizing Factor, Kb for Balanced-Bellows Pressure Relief Valves

API-RP-520
Figure 30

Orifice Orifice Orifice Orifice

Letter Area Letter Area
Square Inch Square Inch
D 0.110 P 6.38
E 0.196 Q 11.05
F 0.307 R 16.0
G 0.503 T 26.0
H 0.785 W 57.26
J 1.287 W2 93.6
K 1.838 X 101.8
L 2.853 Y 128.8
M 3.60 Z 159.0
N 4.34
Standard Orifice Letter/Area
Farris Engineering Catalog 193C
Figure 31

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Example Problem 6
In this example, the following relief requirements are given:

a. Required hydrocarbon vapor flow, W, caused by an operational upset, of 53,500 pounds

per hour.

b. Molecular weight of hydrocarbon and vapor [a mixture of butane (C4) and pentane (C5)],
M, of 65 and k of 1.09.

c. Relief temperature, T, of 627°R (167°F).

d. Relief valve set at 75 pounds per square inch gauge, the design pressure of the
equipment.

e. Back pressure of 0 pounds per square inch gauge.

In this example, the following data are derived:

a. Permitted accumulation of 10 percent.

b. Relieving pressure, P1, of 75 x 1.1 + 14.7 = 97.2 pounds per square inch absolute.

c. Calculated compressibility, Z, of 0.84. (If a calculated compressibility is not available,

Z = 1.0 should be used.)

d. Critical back pressure of 97.2 x 0.59 = 57.3 pounds per square inch absolute (42.6
pounds per square inch gauge).
Note: Since the back pressure (0 pounds per square inch gauge) is less than the critical back pressure
(42.6 pounds per square inch gauge), the relief valve capacity is based on the critical flow equation and
Kb=1.

e. Capacity correction due to back pressure, Kb = 1.0 (Figure 30 may be used for Kb for
balanced pressure relief valves).

f. Cp/Cv = k of 1.09. From Figure 29, C = 326.

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Answer:

The size of a single pressure relief valve is derived from the following equation:

W TZ
A=
C K d P1 Kb M

53500 627 x 0.84

A=
326 x 0.975 x 97.2 65

See API Standard 526, which also provides a purchase specification sheet for flanged steel
safety relief valves.

From Figure 31, select a "P" letter orifice size (6.38 square inches) since orifice letter “N” is
undersized at 4.34 square inches.

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Single Pressure Relief Device for Several Components in a Process System

In some situations, a single pressure relief device may be desirable to protect several
components in a process system. For this system to meet ASME Code, the following criteria
must be satisfied.

1. No means can exist for blocking any of the equipment components being protected from
the installation of the single pressure relief device.

2. The set pressure of the first pressure relief device to be actuated must be at or below the
lowest design pressure of any equipment component being protected in the system.

3. The accumulated pressure when the pressure relief device is discharging may be as high
as 10 percent (or 21 percent for fire) above the lowest design pressure for any equipment
component in the system. If multiple relief devices are used in a single installation, then
accumulated pressure may be as high as 16 percent (or 21 percent for fire) above the
lowest design pressure for any equipment component in the system.

4. The operating pressure in any equipment component must never exceed its design
pressure when the pressure relief device protecting the system is not discharging.

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A typical flow scheme of a system involving a single pressure relief device serving
components in a process system is shown in Figure 32. Typical pressure profiles developed
for design of the pressure relief system are also shown. For further details on this type of a
system see API Recommended Practice 520 Appendix B.

Typical Pressure Profile for a System Involving a Single Pressure Relief Device
API-RP-520
Figure 32

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Block Valves

A full area block valve may be installed on the inlet or outlet of a safety relief valve for
inspection and repair purposes only. Saudi Aramco normally designs for a redundant (extra
safety relief valve) with inlet and outlet block valves so that safety relief valves can be tested
and inspected annually where required. When such a valve is provided it must be locked or
sealed in the open position. It shall not be closed except by an authorized person.

Flare Systems

The flare system will include the flare lines/manifolds, blowdown drum, vapor recovery, and
the flare itself. Not all of these will be included in all flare systems.

Flare Lines/Manifolds
The flare lines within a unit need to be designed so that all liquid drains away from the safety
relief valves. Flare lines may require special metallurgy for high temperatures or corrosive
materials. Flare lines may need special metallurgy when relieving flashing liquids because of
low temperatures that may be generated. Flare lines need to be purged (swept) with gas
(about 0.1-0.15 ft/sec) which cannot go to dew point under operating conditions to prevent air
leakage into the system. Steam tracing and insulation may be necessary if there is a
possibility of heavy liquids being released . The lines should be sized sufficiently large to
accommodate releases from several sources without creating excessive back pressure (about
200 ft/sec maximum).

The design of pipe anchors and supports on discharge manifolds may require special
consideration. Sudden changes in flow rate and temperature can produce large reaction
forces. If liquids are present in the relief system, the momentum forces can be significant.
API Recommended Practice 520, Part II, discusses this subject in more detail.

Blowdown Drum
The blowdown drum is a vapor-liquid separator to prevent liquids from entering the flare.
Flares are designed to burn vapors. Flammable liquids entering a flare may result in a
flaming fountain of liquid which can be quite hazardous. The blowdown drum may include a
liquid level control system to keep the liquid level under control.

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Vapor Recovery
Flaring of gases may be minimized by installing a vapor recovery system such as shown in
Figure 33. The reason for vapor recovery may be economical or environmental.

AHH

O AH
PC 2

FU EL G AS
C omp resso r TR EA TI NG
K no c k Ou t
D rum

Va p or
Recovery
co mpr e ss or
Op ti on a l
Su rge
Gas
Stor age
TO FL AR E

F LA RE HLA
H EAD ER
2'
LLA

6'
LIQUID
SEAL
M AK E U P

Back
Pressure
Seal

Vapor Recovery System

Figure 33

The flare back pressure seal provides a minimal back pressure so that the vapor recovery
system can operate. The vapor recovery system pressure control is set significantly below the
pressure to blow the back pressure seal. The back pressure seal would only be blown during a
major release. The back pressure seal normally contains water. Some relief systems may
operate at low temperatures because of flashing of LPG materials which could freeze water.
For this reason some relief systems have substituted kerosene for water in the back pressure
seal.

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Flare
There are two general types of flare: elevated and ground level.

The elevated flare has the advantage of being clearly visible so that operation can readily be
observed and usually costs less than a ground level flare. Elevated flares require more plot
space because of limits on heat radiation, are noisier, and maintenance may be more difficult.

Ground level flares have the advantage of minimum plot space requirements because they are
surrounded by radiation shields and have less noise and light pollution.

All flares can be smokeless but this requires monitoring or a good control system for steam to
the flare. Steam acts both as a catalyst for combustion (water-gas-shift reactions produce
hydrogen) and promotes turbulence which aids in the mixing of vapors with air which is
necessary for good combustion.

Flares must have pilots to keep the flare lit. Most pilots can be relit automatically from
ground level by a flame front generator. Molecular seals in flares prevent air leakage into the
flare which could result in an explosive mixture within the flare. Some elevated flare designs
incorporate a back pressure seal in the base of the flare.

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KEY FORMULAS

The following is a brief summary of the more important/useful formulas in this module. Note
that many of these items can be easily programmed for personal computer use.

Equation for Thermal Expansion

Pipe:
 (r )(C)(T2 − T1)
2

V2 =  1
 12
+ r1

[(L )(C )(T − T )+ L ]
1 2 1 1

Liquid:
V1 sp. gr. 1
V2 =
sp. gr. 2
where:
r = Pipe inside radius, in.
C = Coefficient of expansion.
T2 = Final temperature.
T1 = Initial temperature.
L1 = Original pipe length, ft.
V2 = Final volume, ft3.

Equation for Pipewall Thickness:

(DP)D
t= +c
2SEc

where:
t = Wall thickness, in.
DP = Design pressure, psig (Internal pressure, psia - atmospheric pressure,
psia)
D = Outside diameter, in.
S = Design stress, psi.
Ec = Quality factor.
c = Corrosion allowance, in.(1/8” corrosive service, 1/16” non corrosive
service)
(See Figure 8 for "S" values. See Figure 9 for "E" values.)

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Safety Relief Valves

Critical Pressure
k

Pc  2  k + 1
= 
P1  k + 1 

where:
Pc = Critical pressure, psia
P1 = Upstream set pressure, psia
k = Ratio of specific heats

Critical Flow Nozzle Area

V TZM
A=
6.32 C K d P1 Kb

V TZG
A=
1.175 C Kd P1 Kb

where:
A = required effective discharge area of the valve, in square inches.
W = required flow through the valve, in pounds per hour.
C = coefficient determined from an expression of the ratio of the specific heats the
gas or vapor at standard conditions. This can be obtained from Figure 29.
Kd = effective coefficient of discharge.
= 0.975 for use in the above equations.
P1 = upstream relieving pressure, in pounds per square inch absolute. This is the set
pressure plus the allowable overpressure plus atmospheric pressure.
Kb = capacity correction factor due to back pressure. This can be obtained from
manufacturer's literature or estimated from Figure 30. The back- correction
factor applies to balanced-bellows valves only.
T = relieving temperature of the inlet gas or vapor, in degrees Rankine (Fahrenheit +
460).
Z = compressibility factor for the deviation of the actual gas from a perfect gas ratio
evaluated at inlet conditions.
M = molecular weight of the gas or vapor. Various handbooks carry tables of
molecular weights of materials, but the composition of the flowing gas or vapor
is seldom the same as that listed in tables. This value should be obtained from
the process data.
V = required flow through the valve, in standard cubic feet per minute at 14.7 pounds
per square inch absolute and 60°F.
G = specific gravity of gas referred to air.
= 1.00 for air at 14.7 pounds per square inch absolute and 60°F.

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NOMENCLATURE

∆h Latent heat, Btu/lb

∆P Differential pressure, psi
A Area, ft2
C Coefficient of expansion for metal
C Nozzle discharge coefficient
c Corrosion allowance, in.
D Outside diameter, in.
DP Design pressure, psia
D.P. Design pressure, psia
D.T. Design temperature, °F
Fc Casting quality factor
F Environmental factor
G Specific gravity returned to air
Kb Back pressure correction
Kd Effective coefficient of discharge
L Length of pipe, ft
M Molecular weight, lb/lb mole
p pressure, psi
Q Heat absorbed, Btu/hr
r Radius of pipe
S Design stress, psi
T Temperature, °F
t Insulation thickness, in.
t Wall thickness of pipe, in.
V Volume, ft3
V Volumetric flow, SCFM
W Mass rate, lbs/hr
Z Compressibility factor

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REFERENCES

1. ANSI Code B31, Piping Code

2. API Publication 941, April 1990, Fourth Edition. (Steels in Hydrogen Service)

3. National Assoc. of Corrosion Engrs., Corrosion Data Survey

4. Swandby, Chemical Engineering, Nov. 12, 1962

5. Crane Technical Paper No. 410, Flow of Fluids

6. Standards of the Tubular Exchanger Manufacturers Association (TEMA) 7th Edition,

1988)

7. ANSI B16.5, Pressure/Temperature flange ratings

8. Data Book on Hydrocarbons, J. B. Maxwell

9. MEX 101.03, Material Selection

10. Aramco Specifications:

SADP-L-002 Design Conditions for Pressure Piping

SADP-L-003 Design Stress Criteria, Pressure Piping
SADP-L-006 Metallic Pipe Selection
SADP-L-007 Selection of Metallic Pipe Fittings
SADP-L-008 Selection of Valves
SADP-L-011 Flexibility, Support, Anchoring Piping
SADP-L-030 Material for Low-Temperature Service
SADP-L-032 Materials Selection for Piping Systems
SADP-L-043 Thermal Expansion Relief in Piping
SAES-A-004 Pressure Testing
SAES-L-002 Design Conditions for Pressure Piping
SAES-L-003 Design Stress Criteria, Pressure Piping
SAES-L-006 Metallic Pipe Selection
SAES-L-007 Design Stress Criteria, Pressure Piping
SAES-L-008 Selection of Valves
SAES-L-011 Flexibility, Support, Anchoring Piping
SAES-L-030 Material for Low-Temperature Service
SAES-L-032 Materials Selection for Piping Systems
SAES-N-001 Basic Criteria External Insulation

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11. Safety and Relief Valves

There are a number of standards for design of safety and safety relief valves. The
Aramco standards include the following:

SAES-J-600

SADP-J -600

SAES-A-005

SADP-A-005 - Safety and Facility Design (Section 12, Pressure Relief)

GI-447 (Form 3099A, Relief Valve Authorization)

34-SAMSS-611

8020-611-Eng Shts 1,2,& 3

Industry standards which are also adhered to by Aramco include:

ASME Boiler and Pressure Vessel Code

• Section I (Boiler)
• Section VIII (Pressure)
• Certification Tests
• Capacity Calculation

API
• API-Recommended Practice-520
• API-Recommended Practice -521
• API-STD-526
• API-STD-527
• API-STD-2000

NACE
• MR-01-75

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WORK AID 1: ADEQUACY OF ALLOY IN HYDROGEN SERVICE

This Work Aid is designed to assist the Participant in Exercise 1: Determine Adequacy of
Selected Materials.

Use Figure 1 to determine adequacy of material for hydrogen service.

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WORK AID 2: CALCULATION OF EQUIPMENT DESIGN TEMPERATURE AND

PRESSURE

This Work Aid is designed to assist the Participant in calculating design temperature and
pressure. Use with Exercise 2: Determine Design Pressure and Temperature.

To calculate the design pressure and temperature for Exercise 1.2 use the following steps:

1. Determine tower design pressure. (Operating pressure + 10%) round up to nearest 5 psig.

2. Determine tower design temperature. (Operating temperature plus 50°F.)

3. Determine pump design pressure using the formula:

Pump Design Pressure = Maximum Suction + Shutoff ∆P

4. Determine pump design temperature. (Operating plus 50°F.)

5. Determine exchanger design pressure:

(Maximum Pump Suction + Normal ∆P) or (Normal Suction + Shutoff ∆P)

6. Determine exchanger design temperature. (Operating temperature plus 50°F.)

7. Determine piping design pressure:

- From tower to pump (maximum suction pressure).
- Pump suction block valve (75% of discharge).
- From pump to exchanger (same as exchanger).
- From exchanger to tankage (same as exchanger).
- From pump to just downstream of discharge block valve (same as pump).

8. Determine piping design temperature:

- From tower to pump (same as tower).
- From pump to exchanger (same as pump).
- From exchanger to tankage (exchanger outlet + 50°F)

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WORK AID 3: ADEQUACY OF CARBON STEEL IN HYDROGEN SERVICE AND

CALCULATION OF PIPEWALL THICKNESS

This Work Aid is designed to assist the Participant in determining adequacy of carbon steel
and calculating pipewall thickness. Use with Exercise 3: Determine Requirements for a New
Pipe.

Step 1: Plot the process conditions on Figure 1. Determine if carbon steel is acceptable.

Step 2: Calculate pipewall thickness using the formula:

(DP)D
t= + Corrosion Allowance
2SEc

Step 3: Determine pipe schedule using Figure 7

Step 4: Use Figures 5 and 6 to determine flange rating.

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WORK AID 4: PLOT AREA CONSIDERATIONS

1. Find distances from control house in Figure below.

Onsite Spacing Chart

Figure 19

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WORK AID 5: CALCULATE SAFETY RELIEF VALVE CONDITION AND SIZE

This work aid is designed to assist the participant in calculating the safety relief valve
conditions and size for Exercise 5.

To calculate relief valve conditions and size for Exercise 4, use the following:

1. Fire causes a relief of 100,000 lbs/hour propane

2. Permitted accumulation determined by fire

3. Relieving pressure = Set pressure x (1 + Accumulation/100)

4. Relieving temperature - Relieving temperature is the temperature at which the vapor

pressure of the contained liquid equals the relieving pressure (see Maxwell p. 29 for
propane vapor pressure).

5. Critical Pressure, Pc

 k 
Pc  2   k −1 
= 
P1  k +1

6. Coefficient Kb=1 if backpressure is less than Pc

7. Orifice area, in2

w Tz
A=
CK d P1 K b M

Propane MW on Maxwell, page 2

8. Select orifice size

Use Figure 31 to select orifice size

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GLOSSARY

accumulation The pressure increase over the maximum allowable pressure

during discharge through the relieving device.

B/CD Barrels per calendar day.

B/SD Barrels per stream day.

back pressure Downstream pressure at outlet. Sum of the superimposed and

built-up back pressures.

balanced pressure A spring-loaded pressure relief valve that incorporates a means for
relief valve minimizing the effect of back pressure (downstream) on
performance characteristics.

blowdown The difference between the set pressure and the closing pressure of
a pressure relief valve.

built-up back pressure The increase in pressure at the outlet of the relieving device as the
result of flow through the device

chatter Flutter when the disk does contact the seat and damage the valve
and associated piping.

closing pressure The inlet static pressure at which the valve disk reestablishes
contact with the seat or at which lift becomes zero.

coincident To occur at the same time.

CW rise The CW temperature rise across a CW exchanger.

embrittlement A type of attack on metal by substances such as caustic and

hydrogen, where the whole piece of metal becomes very brittle
(breaks very easily).

flutter Abnormally rapid reciprocating motion of the movable parts of the

pressure relief valve in which the disk does not contact the seat.

grain boundaries Metal is made up of grains that are tightly bound together. Each
grain has a boundary layer between itself and adjacent grains.

hydrolysis A chemical process of decomposition.

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impact testing A steel sample is tested to see how much of a blow by a sharp
wedge the metal can take before it breaks. Usually done at
temperatures below 160°F.

incipient attack The beginning of the attack when it first shows signs of the attack
taking place.

Inlet size Nominal pipe size of valve at inlet connection

ion content Some contaminants in water polarize (+ charges, - charges) as a

result of disassociating and forming ions.

lift The actual travel of the relief valve disk away from the closed
position when the valve is relieving

maximum allowable The maximum gauge pressure permissible at the top of the vessel
working pressure for the designated temperature and the basis for the maximum
pressure setting of the relief device.

maximum operating The maximum pressure expected during system operation

pressure

nozzle area The cross-sectional flow area of a nozzle at the minimum nozzle
diameter

opening pressure The inlet static pressure at which there is a measurable lift of the
disk or at which discharge of fluid becomes continuous.

outlet size Nominal pipe size of valve at outlet connection

overpressure The pressure increase over the set pressure of the relieving device.
This is equal to accumulation when the set pressure is the
maximum allowable pressure.

P&ID Piping and instrument diagram.

partial pressure Portion of total pressure in a gas phase that is attributable to any
one compound of the gas.

permeate To spread and diffuse into the metal.

PFD Process flow diagram.

post-weld heat A completed metal weld is uniformly heated to a defined

treatment temperature level for a defined period of time, thereby releasing
the stress in the metal created by the original weld.

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pressure relief device A device actuated by inlet pressure and designed to open during
abnormal conditions to prevent rise in internal pressure

Q Heat duty, Btu/hr.

relief valve A spring-loaded pressure relief valve actuated by inlet pressure

usually for incompressible fluids. The valve opens normally in
proportion to the pressure increase aver the opening pressure.

safety valve Spring-loaded pressure relief valve characterized by rapid opening

or pop action. Normally used with compressible fluids.

set pressure Inlet gage pressure at which pressure relief valve is set to open
under service conditions.

shutoff pressure Pump discharge pressure at the top of pump pressure flow curve
where the flow goes to zero.

simmer The audible or visible escape of compressible fluid between the

seat and disk at an inlet static pressure below the set pressure and
at no measurable capacity.

stamped capacity The rated relieving capacity that appears on the device nameplate.

superimposed back The static pressure at the outlet of a pressure relief device at the
pressure time the device is required to operate.

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DESCRIPTIONS OF APPLICABLE SAES AND SAMSS REQUIREMENTS

Standard Pipe Fittings (1) Flanges (2) Valves Bolting

SAES-L-005 X X X X X
SAES-L-006 X
SAES-L-007 X
SAES-L-008 X
SAES-L-009 X X
SAES-L-030 X X X X
SAES-L-031 X
SAES-L-032 X X X X
SAES-L-060 X X X X
SAES-L-061 X X X
01-SAMSS-001 X X X
01-SAMSS-005 X X X X
01-SAMSS-010 X X X X
01-SAMSS-016 X
01-SAMSS-017 X X
01-SAMSS-022 X
01-SAMSS-029 X X X X
01-SAMSS-033 X
01-SAMSS-034 X X X X
01-SAMSS-035 X
01-SAMSS-036 X
02-SAMSS-001 X X X
02-SAMSS-005 X
02-SAMSS-010 X X
04-SAMSS-001 X
04-SAMSS-002 X
04-SAMSS-003 X
04-SAMSS-041 X
04-SAMSS-042 X
04-SAMSS-048 X
04-SAMSS-050 X
04-SAMSS-051 X
04-SAMSS-052 X

Notes:
(1) Standard Drawings for Fittings:
• AE-036175 - used for fittings in Service Groups A, D, H, and L.
• AE-036643 - used for fittings in Service Groups A, H, and L.
• AE-036768 - used for fittings in Service Group 2E3A.

(2) Standard Drawing for Flanges:

Saudi Aramco Standard SAES-L-005 references the specific drawings required for each Service Group.

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Covers the selection of compatible pipeline material items used together in a specific system
or service, and listed in a piping specification under a code number.

SAES-L-006, "Metallic Pipe Selection"

Covers limitations on the selection of metallic pipe and tubing for pressure services in plant
piping and transportation piping.

SAES-L-007, "Selection of Metallic Pipe Fittings"

Covers limitations on the selection of metallic pipe fittings for pressure services in plant
piping and transportation piping.

SAES-L-008, "Selection of Valves"

Covers limitations on the selection of all valves normally classified under Saudi Aramco
Materials System Class 04. This standard contains tables of applicable materials for valves.
It also contains a section (Section 8) on materials limitations.

SAES-L-009, "Metallic Flanges, Gaskets, and Bolts"

Covers limitations on the selection of metallic pipe flanges, gaskets, and bolting for pressure
services in plant piping and transportation piping. Paragraph 3 of this standard references the
following ASTM material specifications:

• ASTM A126 Grade B or better: gray cast iron flanges in accordance with ANSI B16.1
Limited to nonhazardous service.

• ASTM A105: limits the use of this material for carbon steel flanges based on
industry standards, sizes, and pipe materials.

• ASTM A694 Grade F60: for use with API 5L Grade X52 or higher pipe in
transportation pipelines.

• ASTM 6A Type 4 and Type materials.

• ASTM A350 Grade LF3, or LF2 per 02-SAMSS-001: preferred material for low
temperature service in the range of 0°C to -46°C (32°F to -50°F).

SAES-L-030, "Material for Low-Temperature Service"

Covers toughness requirements for carbon steels used in the refrigerated fluid service at a
minimum design temperature below 0°C (32°F). The requirements supplement ANSI B31.3
and are more restrictive.

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SAES-L-031, "Fracture Control of Line Pipe"

Covers supplementary material toughness requirements to control crack propagation at
temperature above 0°F (32°F) in carbon steel pipe used for cross country and submarine
pipelines. Applies to line pipe, 6 in. or larger NPS, with wall thicknesses of 6.35 to 38.1 mm
(0.25 to 1.5 in.).

SAES-L-032, "Materials Selection for Piping Systems"

Indicates the basic materials of construction for piping systems based upon the material to be
transported. Contains a table that lists service fluid (environment), concentration of the
material transported, service temperature, and whether air is present.

SAES-L-060, "Nonmetallic Piping"

Covers requirements and limitations for the design, installation, and testing of nonmetallic
piping, except for plumbing.

SAES-L-061, "Technically Acceptable RTR Piping"

Lists specific RTR pipe and fittings, in accordance with 01-AMSS-029 or 01-AMSS-034 that
have undergone and passed an evaluation by Saudi Aramco and are acceptable for use in
Saudi Aramco installations.

01-SAMSS-001, "Asbestos-Cement Pipe, Fittings, and Gaskets"

Covers the requirements for the manufacture, classification, dimensions, and testing of
asbestos-cement pipe, pipe fittings, and gaskets for pressure and non-pressure service.
Asbestos-cement lined pipe is used only in the repair of existing systems. It is no longer
allowed in new installations.

01-SAMSS-005, "Pipe, Cement-Lined, Shop Applied"

Provides references, including material specifications, covering the manufacture, inspection,
and testing of cement-lined pipe.

01-SAMSS-010, "Fabricated Carbon Steel Piping"

Covers the minimum requirements for the fabrication of regular carbon steel pipe spools,
including applicable material standards.

01-SAMSS-016, "Sour, Wet Service Line Pipe"

Defines additional requirements necessary to obtain welded line pipe that is resistant to
Hydrogen Induced Cracking (HIC) in wet, sour environments.

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01-SAMSS-017, "Auxiliary Piping for Mechanical Equipment"

Defines the minimum requirements governing the design, fabrication, installation, and
inspection of auxiliary piping associated with compressors, pumps, fans, turbines, engines,
and gears.

01-SAMSS-022, "Fracture Control Testing Procedures for Line Pipe"

Defines the mandatory fracture control testing procedure applicable to line pipe with wall
thicknesses of 6.3 to 38 mm (0.25 to 1.5 in.) and intended for use in cross country and
offshore pipelines at temperatures between 0°C and 120°C (32°F and 250°F).

01-SAMSS-029, "Unrestrained Gasketed Joint RTR Sewer Pipe Fittings"

Covers the requirements for Reinforced Thermosetting Resin (RTR) pipe, couplings, and
fittings using polyester or epoxy resin and unrestrained gasketed joints for 300 - 1200 mm (12
- 48 in.) nominal size.

01-SAMSS-033, "API 5L Electric Resistance Welded Line Pipe"

Defines the requirements, supplemental to API Specification 5L, for plain end electric
resistance-welded steel pipe four inches and above in nominal diameter.

01-SAMSS-034, "RTR Pressure Pipe and Fittings"

Defines the requirements for RTR pipe, couplings, and fittings using epoxy resin with
adhesive bonded joints from, 25 - 400 mm (1 - 16 in.) nominal size, or with restrained
gasketed joints for 25 - 1200 mm (1 - 48 in.) nominal size.

01-SAMSS-035, "API Line Pipe"

Defines the requirements, supplemental to API Specification 5L, for beveled end, seamless, or
submerged arc-welded, (straight seam or spiral seam) carbon steel pipe 6 in. and above in
nominal diameter.

01-SAMSS-036, "Low-Temperature Pipe"

Covers the requirements for seamless pipe, 1 in. nominal size or larger, and for straight seam,
submerged arc-welded pipe, 16 in. nominal size and larger, for service with minimum design
temperatures between 0°C and -46°C (32°F and -50°F).

02-SAMSS-001, "Piping Components for Low-Temperature Service"

Covers the requirements that apply to piping components for use in refrigerated natural gas
liquid (NGL) service with minimum design temperatures of 0°C and -46°C (32°F and -50°F).
This specification supplements ANSI B16.11 and ANSI B16.14.

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02-SAMSS-005, "Butt-Welded Pipe Fittings"

Supplements the requirements of ANSI B16.9 and ASTM A234 Grade WPB for wrought
carbon steel pipe fittings. Also supplements the requirements for MSS SP-75 for high test
fittings. In addition, it covers carbon steel fittings suitable for low-temperature service and
fittings suitable for wet, sour service. Does not include cast fittings, or corrosion alloy steel
pipe fittings.

02-SAMSS-010, "Flanged Insulating Joints/Spools for Cathodic Protection"

Describes the requirements for insulating joints and spools with bolted flanges and any
standard pressure rating and pipe diameter.

04-SAMSS-003, "Additional Requirements for Low-Temperature Valves"

Contains specific information concerning material requirements for valves in low-temperature
service.

In addition, each of the major valve types used by Saudi Aramco has an SAMSS that lists the
necessary industry standards for the particular valve type.

• SAES-L-005, "Limitations on Piping Components."

• SAES-L-008, "Selection of Valves."
• 04-SAMSS-001, "Gate Valves."
• 04-SAMSS-002, "Globe Valves."
• 04-SAMSS-041, "Expanding Plug Valve."
• 04-SAMSS-042, "4-Way Diverter Valve."
• 04-SAMSS-048, "Valve Inspection and Testing Requirements."
• 04-SAMSS-050, "Gate Valves, Through-Conduit Type, API 6D."
• 04-SAMSS-051, "Ball Valves, API 6D."
• 04-SAMSS-052, "Ball Valves, API 6A."

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