IPE-TM-510 Hydraulics
Typical Pump Spillback Hydraulics NHP
IPE-TM-510-13
1. Table of Contents
1. Table of Contents 1
2. Purpose 1
3. General Information 2
4. “Automatic Minimum Flow Spillback System” with Control Valve 2
4.1 Steps to Enable Spillback System 2
4.2 NHP automatic Creation of Equipment/Circuits 3
4.3 NHP Automatic Calculations 4
5. Column Total Overhead Pump with Minimum Flow Protection via Reflux 4
Example 5 Hydraulics of Column Total Overhead Pumps with Minimum Flow Protection via Reflux 7
6. Normal Flow Below Pump Minimum Flow, Spillback with Restriction Orifice 11
Example 6 Hydraulics of Pump with Single Discharge Flow Path and Continuous Spillback through a Restriction Orifice 13
Appendix A Hydraulics of Pump with Single Discharge Flow Path and Minimum Flow Protection via Control Valve 15
Appendix B Hydraulics of Pump with Single Discharge Flow Path and Minimum Flow Protection via Control Valve 17
2. Purpose
This procedure discusses the most common hydraulic circuits in NHP for pump minimum flow protection. In the hydraulic tabulations, for all flow scenarios in all process cases, the pump head and system frictional losses between the upstream vessel and spillback/splitter node must be based on a flow no lower than the minimum continuous flow of the pump. An automated spillback is required where the spillback flow controller adjusts the opening of the spillback flow control valve until the flow through the pump equals or exceeds the minimum continuous flow. If the forward flow control valve ever closes (due to a localized instrument air failure, for example), the spillback flow control valve must be capable of passing the minimum continuous flow of the pump.
NHP will automatically account for the existence of Minimum Flow Spillback Systems without the user needing to explicitly add the spillback equipment, piping and circuits. Each pump has a minimum flow criterion as one of its characteristics. If any one of the hydraulics flow scenarios has a volumetric flow rate that is lower than the pump’s minimum flow, then an “Automatic Minimum Flow Spillback System” would be applied after the user approves it. The user would have the capability of turning off this automatic system on a pump by pump basis.
A number of important factors must be considered by the Instrument Engineer when specifying a control valve. These factors include (but are not limited to): valve body size, commercially available rated valve coefficient (Cv), characteristic (linear or equal percentage), and metallurgy of control valve internals. For the Instrument Engineer to confidently specify a control valve, the hydraulic tabulations must reflect the true rangeability of the control valve.
3. General Information
- The best practice is to have the circuit design and alternate flow scenario factors match the pump flow scenario factors. This is not required if NHP performed the spillback calculations automatically.
- If a spillback is required, the pump circuit MUST include the alternate flow scenario. If the pump will not turndown flow, set the alternate flow scenario factor to 100%.
- If the amount of fluid spilling back from a column bottoms pump is less than 20% of the reboiler flow, then the column bottoms pump spillback can return to the reboiler inlet. Otherwise, discuss with the exchanger specialist if there is a concern for the reboiler with the on/off spillback during turndown.
- A spillback circuit will not be created; the spillback calculations will be performed without a dedicated circuit. Users must not put the spillback equipment in a circuit. A spillback circuit is not required for the EDI.
- Reference Procedure to determine if a spillback is required and the type of spillback.
4. “Automatic Minimum Flow Spillback System” with Control Valve
4.1 Steps to Enable Spillback System
After it has been determined that a spillback with control valve is required, follow the steps listed below in NHP to enable the “Automatic Minimum Flow Spillback System”.
1. The Design Engineer will create the pump circuit as if a spillback is not required. The default spillback selection for each pump will be “Not Sure”.
2. After running the pump circuit, NHP will issue an error message if any of the flow scenario flow rates are less than the pump minimum flow. There may be a message that NHP can make a pump selection since the rated flow is too low.
3. If a spillback is not required, open the pump form, select the Pump Selection tab and choose “No” for the Spillback Flow Control. The next time that the pump circuit is run, an informational message will be displayed indicating that the flow is less than the pump minimum flow. No further action is necessary.
4. If a spillback is required, open the pump form, select the Pump Selection tab, choose “Yes” for the Spillback Flow Control, select the Spillback Return Equipment and Port (the default is the pump suction source) and hit the “Add Spillback Equipments” button.
5. If a spillback is no longer required, then the spillback equipment can be removed by opening the pump form, selecting the Pump Selection tab and pressing the “Remove Spillback Equipments” button. Also, set the Spillback Flow Control to “No”.
6. If a spillback is required for process reasons and not for pump protection, manually enter the low flow that you want to design the spillback for in the pump minimum flow field and select “Yes” for the Spillback Flow Control and add the equipment.
4.2 NHP automatic Creation of Equipment/Circuits
Upon hitting the “Add Spillback Equipments” button, NHP will do the following steps automatically:
- Create a flow device. The tag will contain the last two numbers of the pump followed by an “S”.
- Copy the pump discharge pipe. The tag will be the same followed by an “S”. The equivalent length will be set to “Short Run”.
- Copy the pump discharge pipe again. The tag will be the same followed by an “SS”. The equivalent length will be set to “Typical Run”.
- Create a splitter. The tag will contain the last two numbers of the pump followed by an “S”.
- Edit the circuit. The new flow device, two pipes and splitter will be inserted in the pump circuit immediately downstream of the pump discharge pipe.
- Create a spillback control valve. The tag will contain the last two numbers of the pump followed by an “S”. This control valve will not participate in a circuit.
- The flow rate is set to pump minimum flow. NEVER insert the spillback control valve and its connected pipes in a circuit.
- Create a suction pipe for the spillback control valve.
- The flow rate is set to the pump minimum flow.
- The stream mapping is set the same as the pump discharge pipe.
- The maximum velocity is 700 ft/min and the maximum pressure drop per 100 ft is 10 psi.
- The equivalent length is “Typical Run”.
- Create a discharge pipe for the spillback control valve.
- The flow rate is set to the pump minimum flow.
- The stream mapping is set the same as the pump suction pipe.
- The maximum velocity is 700 ft/min and the maximum pressure drop per 100 ft is 10 psi.
- The equivalent length is “Typical Run”.
4.3 NHP Automatic Calculations
When the pump circuit is run, NHP will conduct the following calculations (See Appendix A for Circuit Report):
- If any flow scenario flow rate for any process case is less than the pump minimum flow, NHP will calculate the simulation stream factor and flow scenario factors and add them to the pump suction pipe, pump, pump discharge pipe, the pump discharge flow device and the pipe that ends with an “S”. This will increase the flow rate to equal the pump minimum flow.
- Flow scenario factor =
- Calculate the pressure drop and line size of the suction and discharge lines for the spillback control valve. The line size will be displayed on the pump summary report and the line size report.
- Calculate the alternate flow scenario pressure drop for the spillback control valve. This is only done for the process cases that require a spillback.
The results will be shown in the instrument report.
Control Valve DP = spillback splitter alternate flow scenario pressure - CV suction piping pressure drop - CV discharge piping pressure drop - Pressure at spillback return equipment alternate flow - Static head based on CV at grade and the elevation of the spillback return equipment port elevation
- If all pump flow rates are less than the pump minimum flow, NHP will add a continuous spillback with control valve. For example, there is an ASME pump with 11.3 gpm rated flow and 178 ft rated head. T-501-03 tool will show that there is no pump selection for this rated condition; the rated flow is too low. NHP will reference this tool and know to increase all the flows with a spillback to 13 gpm in order to make a pump selection. See Appendix B for Circuit Report.
5. Column Total Overhead Pump with Minimum Flow Protection via Reflux
This example involves a column total overhead pump with multiple process cases. At the normal (100%) flow scenario for each process case, the process flow exceeds the minimum continuous flow of the pump.
An automated spillback is not required in column total overhead liquid service when – for all process cases - the sum of the normal (100%) reflux flow and turndown flow of net overhead liquid exceeds the minimum continuous flow of the pump. The reflux can be as high as 100% at turndown conditions if the reboiler is heated by steam or hot oil and the reboiler is not turned down.
An automated spillback is required in column total overhead liquid service when – for any process case - the sum of the normal (100%) reflux flow and turndown flow of net overhead liquid is less than the minimum continuous flow of the pump. In addition, if the reboiler is heated by process fluid or the column is steam stripped, the reboiler will be turned down and the reflux must also be turned down. A spillback will be required if the total overhead liquid at turndown is less than the minimum continuous flow of the pump.
For this example, let’s assume the reboiler is heated by steam and the reflux will be increased to avoid an automated spillback. The Design Engineer shall adhere to the following (see Example 5 hydraulic tabulations):
1. Both the reflux and net overhead circuits shall include the pump. This ensures that sufficient differential pressure will be available to both the reflux and net overhead flow control valves.
2. Setup the two pump circuits the normal way as if no spillback is required (100%, 110%, 50/60%).
| Case 2 | Case 3 | |
|---|---|---|
| Reflux flow, gpm | 742.7 | 683.2 |
| Net Overhead flow, gpm | 605.8 | 633.9 |
| Pump minimum flow, gpm | 800 | 800 |
| Total Alternate flow at 50%, gpm | (742.7+605.8)*0.5 = 674.3 | (683.2+633.9)*0.5 = 658.6 |
3. As shown in the table above, the alternate flow is less than the pump minimum flow. Determine how much you need to increase the reflux in order to set the alternate flow equal to the pump minimum flow.
| Case 2 | Case 3 | |
|---|---|---|
| Net Overhead flow at 50%, gpm | 605.8*0.5 = 302.9 | 633.9*0.5 = 316.95 |
| Required reflux to increase pump alternate flow to pump min flow, gpm | 800-302.9 = 497.1 | 800-316.9 = 483.1 |
| Reflux alternate flow factor, % | 497.1/742.7*100 = 67 | 483.1/683.2*100 = 71 |
4. Since the reflux needs to be increased less than 100% to increase the alternate pump flow to the pump minimum flow, a spillback is not required. The reflux should be increased in order to avoid a spillback and prevent the alternate flow from going less than the pump minimum flow. Review the technology manual to see if there are any exceptions to this rule. If the calculated reflux alternate flow factor is greater than 100%, then an automated spillback is required.
5. Calculate the alternate flow factor for the total overhead streams.
| Case 2 | Case 3 | |
|---|---|---|
| Total overhead alternate flow factor, % | 800/(742.7+605.8)*100 = 59 | 800/(683.2+633.9)*100 = 61 |
6. Enter the total overhead alternate flow factors on the circuit and copy to all equipment and pipes (net overhead and reflux circuits). NHP will only accept whole numbers for the flow scenario factors currently.
7. Set the pipes and equipment after the reflux splitter back to 50% for the alternate flow factor in the net overhead circuit.
8. Enter the reflux alternate flow factors on all the pipes and equipment in the reflux circuit following the reflux splitter. NHP will only accept whole numbers for the flow scenario factors currently.
Example 5 Hydraulics of Column Total Overhead Pumps with Minimum Flow Protection via Reflux
Inflection Point Engineering
Hydraulic Circuit Summary Report
Platforming Process Unit NOTE - THE INFORMATION IN THIS DOCUMENT IS Date 30 Jul 13 14:13
Case 2 CONFIDENTIAL AND PROPERTY OF Inflection Point Engineering, AND Proj 500078-C.1.0
MUST NOT BE DISCLOSED TO OTHERS OR REPRODUCED By Pam Watkins
IN ANY MANNER OR USED FOR ANY PURPOSE
500078-Case2.usc WHATSOEVER WITHOUT ITS WRITTEN PERMISSION. Version 3.2.29
TEC51013 Ex 5
Circuit 2 : Reformate Splitter Net Overhead
Normal Design Alternate
PRESS 100.0% 110.0% 59.0%
DROP ------------------- ------------------- -------------------
LINE 100 PER NOZL PRESS INLET PRESS INLET PRESS INLET
SIZE EQ 100ft ELEV DROP PRESS DROP PRESS DROP PRESS
EQUIPMENT IDENTIFICATION IN ft psi ft psi psig psi psig psi psig
Reformate Splitter Receiver 30.0 2.00 2.00 2.00
Liquid Level 1.0 -0.32 2.00 -0.32 2.00 -0.32 2.00
LN-XP309 12 5.77 0.10 0.59 2.32 0.71 2.32 0.21 2.32
Static Head 27.0 -8.53 1.73 -8.53 1.60 -8.53 2.10
Reformate Splitter Overhead Pumps *Gov* 3.0 -106.13 10.25 -101.79 10.13 -119.49 10.63
Pump Head,ft of fluid 335.66 321.94 377.92
Pump Capacity, gpm 1349 1484 810
Average Flowing ,SG 0.729
Operating Temperature,°F 169
Viscosity,cP 0.27
LN-XP310 8 3.93 0.82 3.21 116.38 3.88 111.92 1.16 130.12
Splitter Reflux Split 113.17 108.04 128.97
LN-XP313 (Alt=50%) 6 1.94 0.70 1.35 113.17 1.64 108.04 0.34 128.97
Reformate Splitter Net Overhead C (Tube) 9.04 111.82 10.94 106.40 2.26 128.63
(Alt=50%)
LN-317 (Alt=50%) 6 1.94 0.68 1.31 102.78 1.59 95.46 0.33 126.37
Splitter Net Ovhd Liq Flow Orifice: FD-1 6 1.15 101.47 1.39 93.87 0.29 126.04
(Alt=50%)
LN-319 (Alt=50%) 6 1.94 0.68 1.31 100.32 1.59 92.48 0.33 125.75
Splitter Net Ovhd Liq CV: CV-1614 24.99 99.01 16.04 90.90 54.42 125.43
(Alt=50%)
LN-XP321 (Alt=50%) 6 5.94 0.68 4.02 74.02 4.86 74.86 1.00 71.00
Battery Limit(Alt=50%) 70.00 70.00 70.00
Example 5 (Continued)
Inflection Point Engineering
Hydraulic Circuit Summary Report
Platforming Process Unit NOTE - THE INFORMATION IN THIS DOCUMENT IS Date 30 Jul 13 14:13
Case 2 CONFIDENTIAL AND PROPERTY OF Inflection Point Engineering, AND Proj 500078-C.1.0
MUST NOT BE DISCLOSED TO OTHERS OR REPRODUCED By Pam Watkins
IN ANY MANNER OR USED FOR ANY PURPOSE
500078-Case2.usc WHATSOEVER WITHOUT ITS WRITTEN PERMISSION. Version 3.2.29
TEC51013 Ex 5
Circuit 3 : Reformate Splitter Reflux
Normal Design Alternate
PRESS 100.0% 110.0% 59.0%
DROP ------------------- ------------------- -------------------
LINE 100 PER NOZL PRESS INLET PRESS INLET PRESS INLET
SIZE EQ 100ft ELEV DROP PRESS DROP PRESS DROP PRESS
EQUIPMENT IDENTIFICATION IN ft psi ft psi psig psi psig psi psig
Reformate Splitter Receiver 30.0 2.00 2.00 2.00
Liquid Level 1.0 -0.32 2.00 -0.32 2.00 -0.32 2.00
LN-XP309 12 5.77 0.10 0.59 2.32 0.71 2.32 0.21 2.32
Static Head 27.0 -8.53 1.73 -8.53 1.60 -8.53 2.10
Reformate Splitter Overhead Pumps *Gov* 3.0 -106.13 10.25 -101.79 10.13 -119.49 10.63
Pump Head,ft of fluid 335.66 321.94 377.92
Pump Capacity, gpm 1349 1484 810
Average Flowing ,SG 0.729
Operating Temperature,°F 169
Viscosity,cP 0.27
LN-XP310 8 3.93 0.82 3.21 116.38 3.88 111.92 1.16 130.12
Splitter Reflux Split 113.17 108.04 128.97
LN-311 (Alt=67%) 6 1.94 1.04 2.01 113.17 2.44 108.04 0.90 128.97
Splitter Reflux Flow Orifice: FD *Swage* 8 1.48 111.16 1.79 105.60 0.67 128.06
(Alt=67%)
LN-325 (Alt=67%) 6 1.94 1.04 2.01 109.68 2.44 103.81 0.90 127.40
Splitter Reflux CV: CV-1616(Alt=67%) 46.95 107.66 37.93 101.37 74.83 126.49
LN-XP327 (Alt=67%) 6 3.34 1.04 3.47 60.71 4.20 63.44 1.56 51.66
Static Head -139.9 44.18 57.25 44.18 59.25 44.18 50.11
Reformate Splitter 139.9 -6.00 13.07 -6.00 15.07 -6.00 5.93
Example 5 (Continued)
Inflection Point Engineering
Hydraulic Circuit Summary Report
Platforming Process Unit NOTE - THE INFORMATION IN THIS DOCUMENT IS Date 30 Jul 13 14:13
Case 3 CONFIDENTIAL AND PROPERTY OF Inflection Point Engineering, AND Proj 500078-C.1.0
MUST NOT BE DISCLOSED TO OTHERS OR REPRODUCED By Pam Watkins
IN ANY MANNER OR USED FOR ANY PURPOSE
500078-Case3.usc WHATSOEVER WITHOUT ITS WRITTEN PERMISSION. Version 3.2.29
TEC51013 Ex 5
Circuit 2 : Reformate Splitter Net Overhead
Normal Design Alternate
PRESS 100.0% 110.0% 61.0%
DROP ------------------- ------------------- -------------------
LINE 100 PER NOZL PRESS INLET PRESS INLET PRESS INLET
SIZE EQ 100ft ELEV DROP PRESS DROP PRESS DROP PRESS
EQUIPMENT IDENTIFICATION IN ft psi ft psi psig psi psig psi psig
Reformate Splitter Receiver 30.0 2.00 2.00 2.00
Liquid Level 1.0 -0.32 2.00 -0.32 2.00 -0.32 2.00
LN-XP309 12 5.77 0.10 0.57 2.32 0.69 2.32 0.21 2.32
Static Head 27.0 -8.59 1.75 -8.59 1.63 -8.59 2.11
Reformate Splitter Overhead Pumps 3.0 -107.90 10.34 -103.71 10.22 -120.51 10.70
Pump Head,ft of fluid 338.68 325.53 378.27
Pump Capacity, gpm 1318 1450 804
Average Flowing ,SG 0.735
Operating Temperature,°F 159
Viscosity,cP 0.27
LN-XP310 8 3.93 0.79 3.09 118.24 3.74 113.93 1.15 131.20
Splitter Reflux Split 115.15 110.19 130.05
LN-XP313 (Alt=50%) 6 1.94 0.77 1.49 115.15 1.80 110.19 0.37 130.05
Reformate Splitter Net Overhead C (Tube) 10.00 113.66 12.10 108.39 2.50 129.68
(Alt=50%)
LN-317 (Alt=50%) 6 1.94 0.75 1.45 103.66 1.76 96.29 0.36 127.18
Splitter Net Ovhd Liq Flow Orifice: FD-1 6 1.27 102.21 1.54 94.53 0.32 126.82
(Alt=50%)
LN-319 (Alt=50%) 6 1.94 0.75 1.45 100.93 1.76 92.99 0.36 126.50
Splitter Net Ovhd Liq CV: CV-1614 25.04 99.48 15.86 91.23 55.03 126.14
(Alt=50%)
LN-XP321 (Alt=50%) 6 5.94 0.75 4.44 74.44 5.38 75.38 1.11 71.11
Battery Limit(Alt=50%) 70.00 70.00 70.00
Example 5 (Continued)
Inflection Point Engineering
Hydraulic Circuit Summary Report
Platforming Process Unit NOTE - THE INFORMATION IN THIS DOCUMENT IS Date 30 Jul 13 14:13
Case 3 CONFIDENTIAL AND PROPERTY OF Inflection Point Engineering, AND Proj 500078-C.1.0
MUST NOT BE DISCLOSED TO OTHERS OR REPRODUCED By Pam Watkins
IN ANY MANNER OR USED FOR ANY PURPOSE
500078-Case3.usc WHATSOEVER WITHOUT ITS WRITTEN PERMISSION. Version 3.2.29
TEC51013 Ex 5
Circuit 3 : Reformate Splitter Reflux
Normal Design Alternate
PRESS 100.0% 110.0% 61.0%
DROP ------------------- ------------------- -------------------
LINE 100 PER NOZL PRESS INLET PRESS INLET PRESS INLET
SIZE EQ 100ft ELEV DROP PRESS DROP PRESS DROP PRESS
EQUIPMENT IDENTIFICATION IN ft psi ft psi psig psi psig psi psig
Reformate Splitter Receiver 30.0 2.00 2.00 2.00
Liquid Level 1.0 -0.32 2.00 -0.32 2.00 -0.32 2.00
LN-XP309 12 5.77 0.10 0.57 2.32 0.69 2.32 0.21 2.32
Static Head 27.0 -8.59 1.75 -8.59 1.63 -8.59 2.11
Reformate Splitter Overhead Pumps 3.0 -107.90 10.34 -103.71 10.22 -120.51 10.70
Pump Head,ft of fluid 338.68 325.53 378.27
Pump Capacity, gpm 1318 1450 804
Average Flowing ,SG 0.735
Operating Temperature,°F 159
Viscosity,cP 0.27
LN-XP310 8 3.93 0.79 3.09 118.24 3.74 113.93 1.15 131.20
Splitter Reflux Split 115.15 110.19 130.05
LN-311 (Alt=71%) 6 1.94 0.89 1.72 115.15 2.09 110.19 0.87 130.05
Splitter Reflux Flow Orifice: FD *Swage* 8 1.26 113.42 1.53 108.10 0.64 129.18
(Alt=71%)
LN-325 (Alt=71%) 6 1.94 0.89 1.72 112.16 2.09 106.57 0.87 128.55
Splitter Reflux CV: CV-1616(Alt=71%) 50.12 110.43 41.60 104.49 75.79 127.68
LN-XP327 (Alt=71%) 6 3.34 0.89 2.97 60.32 3.59 62.89 1.50 51.89
Static Head -139.9 44.51 57.35 44.51 59.30 44.51 50.39
Reformate Splitter 139.9 -6.00 12.84 -6.00 14.78 -6.00 5.88
6. Normal Flow Below Pump Minimum Flow, Spillback with Restriction Orifice
This example involves a pump with a single discharge flow path and multiple process cases. At normal and design flow scenarios for both process cases, the net forward flow is below the minimum flow of the centrifugal pump; therefore, the minimum flow of the pump will spillback continuously. Reference Procedure to determine if a restriction orifice (due to its lower cost) in the spillback line is a better option than a control valve. The restriction orifice sizing is generally left to the contractor. All flow scenarios for all process cases are set equal to the pump minimum flow plus the net forward flow.
This example assumes that the heat and weight balance does not include a stream number to model the pump minimum flow plus the net forward flow.
The Design Engineer shall adhere to the following (see Example 6 hydraulic tabulations):
- Set the Spillback Flow Control to “No” since this type of spillback must be done manually.
- A spillback splitter shall be added to the circuits which contain the pump.
- A spillback circuit is not required.
- Simulation stream factors and flow scenario factors need to be entered for the suction and discharge piping and the pump in order for the flow through the pump to equal the pump minimum flow plus the net forward flow. Enter separate flow factors for each process case since the net forward flows are different for each process case. This forces the hydraulics program to apply the correct pump head and system frictional losses to all flow scenarios. This will also correctly calculate the valve coefficients (Cvs) of the forward flow control valve.
- There is a chance that hydraulics will pick a different pump type and, subsequently, a different minimum flow after the rated flow has been increased to pump minimum flow plus net forward flow. If this happens, manually enter the original pump minimum flow (calculated when the normal flow was only equal to the net forward flow) in hydraulics.
| SOR | EOR | |
|---|---|---|
| Pump Minimum flow, gpm | 21.67 | 21.67 |
| Net Forward flow, gpm | 9.66 | 10.26 |
| Desired flow through pump, gpm | 21.67+9.66 = 31.33 | 21.67+10.26 = 31.93 |
| Simulation Stream factor, % | (21.67+9.66)/9.66*100 = 324.3 | (21.67+10.26)/10.26*100 = 311.2 |
| Design flow factor, % | (21.67+9.66*1.10)/31.33*100 = 103 | (21.67+10.26*1.10)/31.93*100 = 103 |
| Alternate flow factor, % | (21.67+9.66*0.6)/31.33* 100 = 88 | (21.67+10.26*0.6)/31.93*100 = 87 |
- Enter the simulation stream factors on the pump suction and discharge lines.
- Enter the design and alternate flow factors on the circuit and copy to all equipment and pipes. NHP will only accept whole numbers for the flow scenario factors currently.
- Set the design and alternate factors back to 110%/60% for all pipes and equipment downstream of the spillback splitter.
Example 6 Hydraulics of Pump with Single Discharge Flow Path and Continuous Spillback through a Restriction Orifice
Inflection Point Engineering
Hydraulic Circuit Summary Report
Butamer Process NOTE - THE INFORMATION IN THIS DOCUMENT IS Date 30 Jul 13 15:12
SOR CONFIDENTIAL AND PROPERTY OF Inflection Point Engineering, AND Proj 970112-C.1.0
MUST NOT BE DISCLOSED TO OTHERS OR REPRODUCED By Maria Hernandez
IN ANY MANNER OR USED FOR ANY PURPOSE
01May13-YE16960-SOR-Butamer.usc WHATSOEVER WITHOUT ITS WRITTEN PERMISSION. Version 3.2.29
TEC51013 Ex 6 RO
Circuit 22 : Degassed Caustic to Effluent Treatment
Normal Design Alternate
PRESS 100.0% 103.0% 88.0%
DROP ------------------- ------------------- -------------------
LINE 100 PER NOZL PRESS INLET PRESS INLET PRESS INLET
SIZE EQ 100ft ELEV DROP PRESS DROP PRESS DROP PRESS
EQUIPMENT IDENTIFICATION IN ft psi ft psi psig psi psig psi psig
Degassing Drum 8.5 2.90 2.90 -0.23
Liquid Level 0.5 -0.23 2.90 -0.23 2.90 -0.23 -0.23
LN-493 (Strm=324.30%) 3 1.93 0.13 0.25 3.13 0.27 3.13 0.20 0.00
Static Head 6.0 -2.83 2.88 -2.83 2.87 -2.83 -0.20
Transfer Pumps 2.5 -147.57 5.71 -146.85 5.70 -149.78 2.64
Pump Head,ft of fluid 313.91 312.37 318.60
Pump Capacity, gpm 31 32 28
Average Flowing ,SG 1.084
Operating Temperature,°F 86
Viscosity,cP 1.09
LN-494 (Strm=324.30%) 2 1.45 1.25 1.82 153.29 1.93 152.55 1.41 152.41
Spillback Splitter 151.46 150.62 151.00
LN-494A (Des=110%,Alt=60%) 1.5 1.26 0.51 0.65 151.46 0.78 150.62 0.23 151.00
Liquid to Refinery: FD-1727 1.50 1.64 150.82 1.99 149.83 0.59 150.77
(Des=110%,Alt=60%)
LN-495 (Des=110%,Alt=60%) 1.5 0.90 0.51 0.46 149.18 0.56 147.85 0.17 150.18
Control Valve : CV-1627 26.21 148.71 24.25 147.29 29.11 150.01
(Des=110%,Alt=60%)
LN-XP496 (Des=110%,Alt=60%) 1.5 4.90 0.51 2.51 122.51 3.04 123.04 0.90 120.90
Battery Limits 120.00 120.00 120.00
Example 6 (continued)
Inflection Point Engineering
Hydraulic Circuit Summary Report
Butamer Process NOTE - THE INFORMATION IN THIS DOCUMENT IS Date 30 Jul 13 15:12
EOR CONFIDENTIAL AND PROPERTY OF Inflection Point Engineering, AND Proj 970112-C.1.0
MUST NOT BE DISCLOSED TO OTHERS OR REPRODUCED By Maria Hernandez
IN ANY MANNER OR USED FOR ANY PURPOSE
01May13-YE16961-EOR-Butamer.usc WHATSOEVER WITHOUT ITS WRITTEN PERMISSION. Version 3.2.29
TEC51013 Ex 6 RO
Circuit 22 : Degassed Caustic to Effluent Treatment
Normal Design Alternate
PRESS 100.0% 103.0% 87.0%
DROP ------------------- ------------------- -------------------
LINE 100 PER NOZL PRESS INLET PRESS INLET PRESS INLET
SIZE EQ 100ft ELEV DROP PRESS DROP PRESS DROP PRESS
EQUIPMENT IDENTIFICATION IN ft psi ft psi psig psi psig psi psig
Degassing Drum 8.5 2.90 2.90 -0.23
Liquid Level 0.5 -0.23 2.90 -0.23 2.90 -0.23 -0.23
LN-493 (Strm=311.20%) 3 1.93 0.13 0.26 3.13 0.28 3.13 0.20 0.00
Static Head 6.0 -2.83 2.87 -2.83 2.86 -2.83 -0.20
Transfer Pumps *Gov* 2.5 -147.03 5.71 -146.29 5.69 -149.60 2.63
Pump Head,ft of fluid 312.92 311.36 318.40
Pump Capacity, gpm 32 33 28
Average Flowing ,SG 1.084
Operating Temperature,°F 87
Viscosity,cP 1.07
LN-494 (Strm=311.20%) 2 1.45 1.30 1.88 152.73 2.00 151.98 1.42 152.23
Spillback Splitter 150.85 149.98 150.81
LN-494A (Des=110%,Alt=60%) 1.5 1.26 0.57 0.72 150.85 0.87 149.98 0.26 150.81
Liquid to Refinery: FD-1727 1.50 1.85 150.13 2.24 149.11 0.67 150.55
(Des=110%,Alt=60%)
LN-495 (Des=110%,Alt=60%) 1.5 0.90 0.57 0.51 148.28 0.62 146.87 0.18 149.88
Control Valve : CV-1627 24.98 147.77 22.88 146.25 28.69 149.70
(Des=110%,Alt=60%)
LN-XP496 (Des=110%,Alt=60%) 1.5 4.90 0.57 2.79 122.79 3.38 123.38 1.00 121.00
Battery Limits 120.00 120.00 120.00
Appendix A Hydraulics of Pump with Single Discharge Flow Path and Minimum Flow Protection via Control Valve
(Automatic Generation)
Platforming Process Unit NOTE - THE INFORMATION IN THIS DOCUMENT IS Date 31 Jul 13 07:23
Case 2 CONFIDENTIAL AND PROPERTY OF Inflection Point Engineering, AND Proj 500078-C.1.0
MUST NOT BE DISCLOSED TO OTHERS OR REPRODUCED By Pam Watkins
IN ANY MANNER OR USED FOR ANY PURPOSE
500078-Case2.usc WHATSOEVER WITHOUT ITS WRITTEN PERMISSION. Version 3.2.29
TEC51013 Typical
Circuit 4 : Reformate Splitter Net Bottoms
Normal Design Alternate
PRESS 100.0% 110.0% 50.0%
DROP ------------------- ------------------- -------------------
LINE 100 PER NOZL PRESS INLET PRESS INLET PRESS INLET
SIZE EQ 100ft ELEV DROP PRESS DROP PRESS DROP PRESS
EQUIPMENT IDENTIFICATION IN ft psi ft psi psig psi psig psi psig
Reformate Splitter 40.0 19.07 21.07 11.93
Liquid Level 1.5 -0.47 19.07 -0.47 21.07 -0.47 11.93
LN-XP330 24 1.80 0.07 0.13 19.54 0.16 21.54 0.03 12.40
Static Head 40.0 -12.57 19.41 -12.57 21.38 -12.57 12.37
Splitter Reboiler Split 31.98 33.95 24.93
LN-335 (Alt=56.23%) 10 4.74 0.11 0.52 31.98 0.63 33.95 0.17 24.93
Static Head -3.0 0.94 31.45 0.94 33.32 0.94 24.77
Reformate Splitter Bottoms Pumps *Gov* 3.0 -107.77 30.51 -103.37 32.37 -122.32 23.82
(Alt=56.23%)
Pump Head,ft of fluid 342.54 328.53 388.78
Pump Capacity, gpm 889 978 500
Average Flowing ,SG 0.726
Operating Temperature,°F 352
Viscosity,cP 0.17
LN-XP337 (Alt=56.3%) 6 3.16 1.45 4.57 138.28 5.53 135.74 1.45 146.15
FD-1708S Reformate Splitter Bott *Swage* 8 1.38 133.71 1.67 130.21 0.44 144.70
(Alt=56.28%)
LN-XP337S(Alt=56.3%) 6 0.47 1.45 0.69 132.33 0.83 128.53 0.22 144.26
Reformate Splitter Bottoms Pumps Spillba 131.64 127.70 144.04
LN-XP337SS 6 1.94 1.45 2.81 131.64 3.40 127.70 0.70 144.04
Reformate Splitter Bottoms Trim C (Tube) 10.00 128.83 12.10 124.31 2.50 143.34
LN-341 6 1.94 1.30 2.52 118.83 3.05 112.21 0.63 140.84
Splitter Net Bottoms Flow Orific *Swage* 8 1.43 116.31 1.73 109.15 0.36 140.21
LN-343 6 1.94 1.30 2.52 114.88 3.05 107.42 0.63 139.85
Splitter Net Bottoms CV: CV-1618 39.64 112.36 20.58 104.37 124.04 139.22
LN-XP347 6 5.94 1.30 7.72 72.72 9.34 83.79 1.93 15.18
Battery Limits 65.00 74.45 13.25
LN-XP347R 6 34.63 1.30 45.00 65.00 54.45 74.45 11.25 13.25
Storage Tank 20.00 20.00 2.00
Appendix A (continued)
Platforming Process Unit NOTE - THE INFORMATION IN THIS DOCUMENT IS Date 31 Jul 13 07:23
Case 3 CONFIDENTIAL AND PROPERTY OF Inflection Point Engineering, AND Proj 500078-C.1.0
MUST NOT BE DISCLOSED TO OTHERS OR REPRODUCED By Pam Watkins
IN ANY MANNER OR USED FOR ANY PURPOSE
500078-Case3.usc WHATSOEVER WITHOUT ITS WRITTEN PERMISSION. Version 3.2.29
TEC51013 Typical
Circuit 4 : Reformate Splitter Net Bottoms
Normal Design Alternate
PRESS 100.0% 110.0% 50.0%
DROP ------------------- ------------------- -------------------
LINE 100 PER NOZL PRESS INLET PRESS INLET PRESS INLET
SIZE EQ 100ft ELEV DROP PRESS DROP PRESS DROP PRESS
EQUIPMENT IDENTIFICATION IN ft psi ft psi psig psi psig psi psig
Reformate Splitter 40.0 18.84 20.78 11.88
Liquid Level 1.5 -0.47 18.84 -0.47 20.78 -0.47 11.88
LN-XP330 24 1.80 0.07 0.13 19.31 0.15 21.26 0.03 12.35
Static Head 40.0 -12.58 19.18 -12.58 21.10 -12.58 12.32
Splitter Reboiler Split 31.76 33.69 24.90
LN-335 (Alt=62.24%) 10 4.74 0.09 0.43 31.76 0.52 33.69 0.17 24.90
Static Head -3.0 0.94 31.33 0.94 33.17 0.94 24.73
Reformate Splitter Bottoms Pumps 3.0 -111.81 30.39 -108.19 32.22 -122.50 23.79
(Alt=62.24%)
Pump Head,ft of fluid 354.87 343.38 388.78
Pump Capacity, gpm 803 884 500
Average Flowing ,SG 0.727
Operating Temperature,°F 351
Viscosity,cP 0.17
LN-XP337 (Alt=62.32%) 6 3.16 1.19 3.75 142.20 4.53 140.41 1.46 146.29
FD-1708S Reformate Splitter Bott *Swage* 8 1.13 138.45 1.37 135.88 0.44 144.83
(Alt=62.3%)
LN-XP337S(Alt=62.32%) 6 0.47 1.19 0.56 137.32 0.68 134.51 0.22 144.39
Reformate Splitter Bottoms Pumps Spillba 136.76 133.83 144.18
LN-XP337SS 6 1.94 1.19 2.30 136.76 2.79 133.83 0.58 144.18
Reformate Splitter Bottoms Trim C (Tube) 8.18 134.46 9.89 131.05 2.04 143.60
LN-341 6 1.94 1.07 2.08 126.28 2.51 121.15 0.52 141.56
Splitter Net Bottoms Flow Orific *Swage* 8 1.17 124.20 1.42 118.64 0.29 141.04
LN-343 6 1.94 1.07 2.08 123.03 2.51 117.22 0.52 140.74
Splitter Net Bottoms CV: CV-1618 57.55 120.96 42.19 114.71 127.37 140.22
LN-XP347 6 5.94 1.07 6.36 63.41 7.69 72.52 1.59 12.85
Battery Limits 57.05 64.83 11.26
LN-XP347R 6 34.63 1.07 37.05 57.05 44.83 64.83 9.26 11.26
Storage Tank 20.00 20.00 2.00
Appendix B Hydraulics of Pump with Single Discharge Flow Path and Minimum Flow Protection via Control Valve
Continuous Spillback
(Automatic Generation)
Butamer Process NOTE - THE INFORMATION IN THIS DOCUMENT IS Date 31 Jul 13 07:39
SOR CONFIDENTIAL AND PROPERTY OF Inflection Point Engineering, AND Proj 970112-C.1.0
MUST NOT BE DISCLOSED TO OTHERS OR REPRODUCED By
IN ANY MANNER OR USED FOR ANY PURPOSE
01May13-YE16960-SOR-Butamer.usc WHATSOEVER WITHOUT ITS WRITTEN PERMISSION. Version 3.2.29
TEC51013 Cont SB CV
Circuit 22 : Degassed Caustic to Effluent Treatment
Normal Design Alternate
PRESS 100.0% 110.0% 50.0%
DROP ------------------- ------------------- -------------------
LINE 100 PER NOZL PRESS INLET PRESS INLET PRESS INLET
SIZE EQ 100ft ELEV DROP PRESS DROP PRESS DROP PRESS
EQUIPMENT IDENTIFICATION IN ft psi ft psi psig psi psig psi psig
Caustic Degassing Drum 8.5 2.90 2.90 2.90
Liquid Level 0.5 -0.23 2.90 -0.23 2.90 -0.23 2.90
LN-493 3 1.93 0.03 0.05 3.13 0.05 3.13 0.05 3.13
(Strm=134.52%,Des=100%,Alt=100%)
Static Head 6.0 -2.83 3.08 -2.83 3.08 -2.83 3.08
Spent Caustic Pumps(Des=100%,Alt=100%) 2.5 -87.88 5.91 -87.88 5.91 -87.88 5.91
Pump Head,ft of fluid 186.94 186.94 186.94
Pump Capacity, gpm 13 13 13
Average Flowing ,SG 1.084
Operating Temperature,°F 86
Viscosity,cP 1.09
LN-494 1.5 1.26 0.88 1.11 93.80 1.11 93.80 1.11 93.80
(Strm=134.52%,Des=100%,Alt=100%)
FD-1712S Spent Caustic Pumps Discharge 1.50 1.75 92.68 1.75 92.68 1.75 92.68
(Des=100%,Alt=100%)
LN-494S 1.5 0.24 0.88 0.21 90.93 0.21 90.93 0.21 90.93
(Strm=134.52%,Des=100%,Alt=100%)
Spent Caustic Pumps Spillback 90.73 90.73 90.73
LN-494SS 1.5 0.93 0.51 0.47 90.73 0.57 90.73 0.12 90.73
Spent Caustic to Refinery: FD-1727 1.50 1.64 90.25 1.99 90.15 0.41 90.61
LN-495 1.5 0.90 0.51 0.46 88.61 0.56 88.17 0.12 90.20
Spent Caustic to Refinery : CV-1627 25.64 88.15 24.57 87.61 29.46 90.08
LN-XP496 1.5 4.90 0.51 2.51 62.51 3.04 63.04 0.63 60.63
To Neutralisation System-normal/sulfidic 60.00 60.00 60.00
Appendix B (continued)
Butamer Process NOTE - THE INFORMATION IN THIS DOCUMENT IS Date 31 Jul 13 07:39
EOR CONFIDENTIAL AND PROPERTY OF Inflection Point Engineering, AND Proj 970112-C.1.0
MUST NOT BE DISCLOSED TO OTHERS OR REPRODUCED By
IN ANY MANNER OR USED FOR ANY PURPOSE
01May13-YE16961-EOR-Butamer.usc WHATSOEVER WITHOUT ITS WRITTEN PERMISSION. Version 3.2.29
TEC51013 Cont SB CV
Circuit 22 : Degassed Caustic to Effluent Treatment
Normal Design Alternate
PRESS 100.0% 110.0% 50.0%
DROP ------------------- ------------------- -------------------
LINE 100 PER NOZL PRESS INLET PRESS INLET PRESS INLET
SIZE EQ 100ft ELEV DROP PRESS DROP PRESS DROP PRESS
EQUIPMENT IDENTIFICATION IN ft psi ft psi psig psi psig psi psig
Caustic Degassing Drum 8.5 2.90 2.90 2.90
Liquid Level 0.5 -0.23 2.90 -0.23 2.90 -0.23 2.90
LN-493 3 1.93 0.03 0.05 3.13 0.05 3.13 0.05 3.13
(Strm=126.65%,Des=100%,Alt=100%)
Static Head 6.0 -2.83 3.08 -2.83 3.08 -2.83 3.08
Spent Caustic Pumps *Gov* 2.5 -87.83 5.91 -87.83 5.91 -87.83 5.91
(Des=100%,Alt=100%)
Pump Head,ft of fluid 186.94 186.94 186.94
Pump Capacity, gpm 13 13 13
Average Flowing ,SG 1.084
Operating Temperature,°F 87
Viscosity,cP 1.07
LN-494 1.5 1.26 0.88 1.11 93.75 1.11 93.75 1.11 93.75
(Strm=126.65%,Des=100%,Alt=100%)
FD-1712S Spent Caustic Pumps Discharge 1.50 1.75 92.64 1.75 92.64 1.75 92.64
(Des=100%,Alt=100%)
LN-494S 1.5 0.24 0.88 0.21 90.89 0.21 90.89 0.21 90.89
(Strm=126.65%,Des=100%,Alt=100%)
Spent Caustic Pumps Spillback 90.68 90.68 90.68
LN-494SS 1.5 0.93 0.57 0.53 90.68 0.64 90.68 0.13 90.68
Spent Caustic to Refinery: FD-1727 1.50 1.85 90.15 2.24 90.04 0.46 90.55
LN-495 1.5 0.90 0.57 0.51 88.30 0.62 87.80 0.13 90.09
Spent Caustic to Refinery : CV-1627 25.00 87.79 23.81 87.18 29.26 89.96
LN-XP496 1.5 4.90 0.57 2.79 62.79 3.38 63.38 0.70 60.70
To Neutralisation System-normal/sulfidic 60.00 60.00 60.00
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