hindustan petroleum corporation ltd. mumbai...

of 29

HINDUSTAN PETROLEUM CORPORATION LTD.

MUMBAI

DIESEL HYDROTREATER PROJECT

TITLE: GENERAL SPECIFICATION FOR PRESSURE VESSELS

DOCUMENT NO. : 44LK-5100-00-V.02-0101-A4

Rev No. Issue Date Pages Rev Description Prepared

By

Checked

By

Approved

By

0 18.08.2008 30 Issued as general specification SNK CR HSC

1 19.12.2008 29 Revised as marked and issued SNK CR HSC

Jacobs

HPCL-MUMBAI GENERAL SPECIFICATION FOR of 29

44LK-5100 PRESSURE VESSELS Rev.1

Doc. No. 44LK-5100-00-V.02-0101-A4 Date: 19.12.2008

TABLE OF CONTENTS

1.0 CODES & STANDARDS

1.1 CODES

1.2 STATUTORY REQUIREMENTS

1.3 INTERNATIONAL REQUIREMENTS

2.0 DESIGN BASIS – GENERAL

2.1 SIZING OF EQUIPMENT

2.2 SHELL/ HEAD THICKNESS

2.3 VESSEL END CLOSURES

2.4 DESIGN PRESSURE

2.5 DESIGN TEMPERATURE

2.6 HYDRO TEST PRESSURE

2.7 CORROSION ALLOWANCE

2.8 WIND LOADING CONSIDERATION

2.9 SEISMIC LOADING CONSIDERATION

2.10 CAPACITY

2.11 SUPPORTS

2.12 MANHOLES

2.13 FLOATING ROOF

2.14 NOZZLE SIZE

2.15 FLANGES

2.16 INTERNALS

2.17 GASKETS

2.18 PIPE DAVIT

2.19 SPARES

2.20 VENT/ DRAIN/ VENTILATION NOZZLE CONNECTION

2.21 IMPORTANT CONSIDERATIONS

3.0 DESIGN REQUIREMENTS – SPECIFIC APPLICATIONS

3.1 LPG STORAGE SPHERES

3.2 TALL COLUMNS

3.3 STORAGE TANKS

3.4 MOUNDED BULLETS

3.5 CRYOGENIC VESSELS & TANKS

3.6 HYDROGEN BULLETS

TABLE – 1 DETAIL & WEIGHT OF COLUMN ATTACHMENTS

TABLE – 2 ALLOWABLE STRESS FOR COMBINED LOADING

TABLE – 3 MATERIAL SELECTION CHART

TABLE – 4 NOZZLE LOCAL LOADS

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Doc. No. 44LK-5100-00-V.02-0101-A4 Date: 19.12.2008

44LK-5100-00-V.02-0101-A4-General Spec for Pressure vessels

1.0 CODES & STANDARDS 1.1 CODES The following applicable codes and laws of India and their applicable standards in their latest

edition including latest addenda shall be followed unless otherwise specified for the design, fabrication, inspection and testing of Vessels, Columns, Reactors, Storage Tanks, Steel Flare/ Vent Stacks :

ASME SEC. VIII DIV. 1 For Pressure Vessels ASME SEC. VIII DIV. 2 For Pressure Vessels (as specified in bid package for

high shell wall thickness of equipment) ASME SEC. VIII DIV. 2 Mounded Vessels /Bullets/Horton spheres ASME SEC.V For non-destructive testing ASME SEC. II Part A, B, C, D For material specification & allowable stresses ASTM/ IS For material specification for Tanks ASME Sec. IX For welding ASME B 16.5 For flanges ASME B 16.47 For large diameter flanges ASME B 16.20 / For gaskets ANSI B1.1/IS 4218 For bolting specification ASME B 16.28 For elbows & return bends ASME SEC. VIII Div. 1 For workmanship of Vessels not categorised under any

other code API 650 For Storage Tanks API 620 For Low Pressure Storage Tanks IS : 6533 For steel vent stacks etc IS: 875/ Site Data For wind load consideration IS : 1893/ Site Data For seismic design consideration

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IBR For steam producing, steam storage, catch water vessels,

condensate flash drums and similar vessels

SMPV Static and mobile pressure vessel(unfired) rules, 1981

1.2 STATUTORY REQUIREMENTS National laws and statutory requirements such as of Indian Boiler Regulations and

requirements of Department of Explosives, Nagpur, India together with any local by-laws for the state shall be complied with. Static and Mobile Pressure Vessel (SMPV) rules and Petroleum rules, Directorate (OISD) etc as applicable shall also be complied with.

1.3 INTERNATIONAL PUBLICATIONS NACE MR 0175 Sulphide Stress Cracking Resistant Metallic Materials for Oil Field

Equipment

NACE MR 0284 Evaluation of Pipeline and Pressure Vessel Steel for Resistance to

Hydrogen Induced Cracking NACE TM 0177 Laboratory Testing of Metals for Resistance to Sulphide Stress Cracking

in Hydrogen Sulphide Environment NACE RP 0472 Methods & controls to prevent in service cracking of CS welds in P1

materials in corrosive petroleum refining environments WRC Bulletin # 107 Local Stresses in Spherical & Cylindrical Shells due to External

Loadings WRC Bulletin # 297 Local Stresses in Cylindrical Shells due to External Loadings on Nozzles WRC Bulletin # 368 Stresses in intersecting Cylindrical Shells subject to pressure

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2.0 DESIGN BASIS – GENERAL All equipment shall be designed in accordance with the latest design codes, and

applicable standards/ specifications. Design calculations shall be made considering all loads for Erection, Operating and Hydrotest conditions (ref. Para.3.2.2)

2.1 SIZING OF EQUIPMENT All equipment columns, clad/lined vessels, vessels (including thickness ≥ 50 mm), tanks,

bullets & all others vessels shall be sized on the basis of internal diameter only. 2.2 SHELL/HEAD THICKNESS 2.2.1 For columns of carbon and low alloy steel, minimum thickness shall be 8mm (including

corrosion allowance up to 3mm). The minimum thickness of carbon and low alloy steel vessels shall be 6.0 mm (including

corrosion allowance not exceeding 3.0 mm) but shall not be less than calculated as per following formula:

Wall thickness = Dia / 1000 + 1.5 + Corrosion Allowance, for Dia. less than 2400 mm.

Wall thickness = Dia / 1000 + 2.5 + Corrosion Allowance, for Dia. 2400 mm and more.

All dimensions are in mm. Above formula is applicable for both columns & vessels. 2.2.2 For columns of stainless steel and high alloy steel, minimum thickness shall be 5mm.

Corrosion allowance shall be added in this minimum thickness as specified in process data sheet.

The minimum thickness of stainless steels & high alloy vessels shall be 3.0 mm but shall

not be less than calculated as per following formula: Wall thickness = Dia / 1000 + 2.5 + Corrosion Allowance, for Dia. more than 1500 mm.

Corrosion allowance shall be added to minimum thickness as specified. Above formula is applicable for both columns & vessels.

2.2.3 Tangent to tangent height (H) to diameter (D) ratio (H/D) greater than 5 shall be

considered as column and designed accordingly. 2.3 VESSEL END CLOSURES 2.3.1 Deep torispherical dished end with 80% crown radius and 15% knuckle radius or

alternatively 2:1 semi-ellipsoidal dished end shall be used for pressure vessels unless otherwise specified. Seamless dished ends shall be used for specific services as per process licensor requirement.

2.3.2 Unless specified otherwise, hemispherical ends shall be used when the thickness

of shell exceeds 70 mm. 2.3.3 For atmospheric vessels, flat covers may be used.

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2.3.4 For vessels diameter ≤ 600 mm, without any internals, pipe caps may be used.

2.3.5

Manholes will be provided for all process vessels over 36 inches (760 mm) in diameter. Smaller vessels will normally be provided with hand holes or a flanged head, depending upon access requirements for the particular service. Manhole where provided must have minimum 19 inch ID unless a larger dia manhole is indicated in the data sheet.

Columns ≤ 900 mm diameter shall be provided with intermediate body flanges. Number of intermediate flanges shall be decided based on column height and type of internals.

For Vessels/ Columns of Diameter ≤ 900 mm with internals, flanged covers may be used.

Vessels and columns with diameter 900 mm shall be provided with 450 NB manholes unless otherwise specified.

Vessels and columns ≥ 1000 mm and upto 1500 mm shall be provided with 500 NB man hole. Vessels and columns with diameter 1500 mm and above may be provided with 600 NB man hole. However when inside diameter of manholes are specified, then, inside diameter shall be considered as minimum required and a mandatory requirement.

Trays and other column internals installation shall be given consideration in deciding the

size and location of manholes, hand holes or body flanges as the requirements may be at the initial design itself.

2.3.6 All process vessels that have a manhole will also be specified to have a vessel vent to

provide ventilation for maintenance. This vessel vent will be located at the top, or a minimum distance from top of vessel. Size of this vent shall be as follows.

Vessel capacity Size of vent (NB)

Upto 200 m3 3 inch

200-400 m3 4 inch

400-700 m3 6 inch

>700m3 8 inch

2.3.7 If the equipment process data sheet indicates sour service (alkaline or wet H2S service),

the equipment materials, their testing, their post weld heat treatment and any other recommendations of the NACE materials recommended by the licensor and pertinent publications like NACE MR 175 shall be complied without exception.

2.4 DESIGN PRESSURE Design pressure shall be calculated as per the following unless otherwise specified

elsewhere or in Process Data Sheet.

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2.4.1 When operating pressure is up to and including 70 kg/cm2 g

Design pressure = operating pressure + 10% (minimum 2.0 kg/cm

2 g.)

2.4.2 When operating pressure is above 70 kg/cm

2 g

Design pressure = operating pressure + 5% (minimum 7 kg/cm

2 g)

Operating pressure should be maximum operating pressure for clause 2.4.1 and 2.4.2. 2.4.3 Design pressure shall be at the top of vertical vessel or at the highest point of horizontal

vessel. 2.4.4 The design pressure at any lower point shall be calculated by adding the highest

operating liquid head and any pressure drop within the vessel. 2.4.5 Equipment with steam out condition shall be designed for full vacuum condition. 2.4.6 Equipment operating under vacuum / partial vacuum shall be designed for an external

pressure of 1.055 kg/cm2 g (15 psi g)

2.4.7 Vessels shall be designed for steam out conditions if specified on process data sheet. 2.4.8 Minimum design pressure shall be 3.5 kg/cm

2 g for any equipment except API storage

tanks. 2.4.9 All storage tanks shall be designed as per code considering full height & using specific

gravity 1.0 if not specified. 2.4.10 Pressure chambers of combination units in equipment shall be designed for testing

independently without pressure in the adjacent chamber in corroded condition. 2.5 DESIGN TEMPERATURE 2.5.1 For vessels operating at 0

oC and above

Design temperature = maximum operating temperature + 15

oC (subject to a minimum of

65 oC)

2.5.2 For Vessels operating below 0 oC

Design temperature = lowest operating temperature. 2.5.3 Minimum Design Metal Temperature (MDMT) shall be lower of minimum atmospheric

temperature and minimum operating temperature encountered during operation. 2.5.4 Un-insulated vessels containing LPG and similar fluids shall be designed for maximum &

minimum temperature as recommended by SMPV rules.

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Doc. No. 44LK-5100-00-V.02-0101-A4 Date: 19.12.2008


2.6 HYDRO TEST PRESSURE 2.6.1 Equipment shall be hydro tested in the fabricator’s shop as per applicable design code &

specification requirements. However care shall be taken that hydrostatic temperature shall be at least 6 degree centigrade higher than critical exposure temperature (CET) for vessel thickness up to 50 mm and minimum 17 degree centigrade higher than the CET where CET is minimum design metal temperature (MDMT). However, if code requirement is found to be stringent, than the same shall be followed.

2.6.2 All vertical vessels, columns and horizontal vessels (in full corroded condition) shall also

be designed for site testing of the equipment with water at the test pressure on the top of the equipment considering 50% wind load.

2.6.3 All equipment foundation shall be designed and constructed for water full condition when

equipment is new with 50% wind load. 2.6.4 Open atmospheric vessels shall be tested by filling water up to the top curb angle. 2.6.5 Pressure chambers of combination units that have been designed to operate

independently shall be hydro tested to code test pressure as separate vessels i.e., each chamber shall be tested without pressure in the adjacent chamber.

When pressure chambers of combination units have their common elements designed for

maximum differential pressure, the common elements shall be subjected to test pressure equivalent to the differential pressure multiplied by a factor as per applicable design code.

2.6.6 Coils shall be hydro tested to code test pressure separately. 2.6.7 Unless otherwise specified in applicable design code allowable stress during hydro test in

tension shall not exceed 90% of yield stress point. 2.6.8 Storage tanks shall be tested as per applicable code. 2.7 CORROSION ALLOWANCE 2.7.1 3.0 mm minimum corrosion allowance for carbon steel columns, vessels and atmospheric

vessels shall be used unless otherwise specified. 2.7.2 1.5 mm minimum corrosion allowance for low alloy steel columns and vessels shall be

used unless otherwise specified. 2.7.3 No corrosion allowance for stainless steel columns & vessels shall be used unless

otherwise specified. 2.7.4

For cladded vessels, no corrosion allowance is required on the base material. Minimum 3.0 mm cladding (undiluted) shall be considered as corrosion allowance unless otherwise specified.

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Doc. No. 44LK-5100-00-V.02-0101-A4 Date: 19.12.2008


2.7.5 If it is agreed to develop the cladding by weld overlay method, then it shall be ensured to have undiluted chemistry of the cladding upto specified thickness of cladding. Surface texture requirement if applicable shall also be ensured.

Code requirements of PWHT and any specified NDT shall also be complied.

2.7.6 For storage tanks, minimum corrosion allowance shall be as follows unless otherwise specified: bottom plate – 3 mm, shell courses- First shell course 3 mm, subsequent shell courses 1.5 mm, floating roof/fixed roof – 0.5 mm.

2.7.7 Buried vessels shall have 1.5mm external corrosion allowance. Vessel shall also be

applied with a proven external corrosion resistant coating. 2.7.8 Spheres/mounded bullets shall have 1.5 mm corrosion allowance. 2.7.9 Cladding or lining thickness shall not be included in strength calculations. 2.7.10 Corrosion allowance for nozzles including manholes shall be equal to that specified for the

vessel. No corrosion allowance is required for standard flange face. 2.7.11 Corrosion allowance for girth/ body flange faces shall be used equal to that specified for

vessel. 2.7.12 Corrosion allowance for support skirts of columns & vertical vessels shall be 1.0 mm

(minimum) unless specified otherwise. 2.8 WIND LOADING CONSIDERATION 2.8.1 Design basis for wind loads shall be as per IS: 875 (Part-3) – 1987. As per IS-875 (Part-

3), 1987 definition of basic wind speed shall be peak gust velocity averaged over 3 second time interval at 10 m height above mean ground level with 50 years mean return period.

Values of coefficients K1, K2 (or K2 for gust factor method of wind load calculation), K3 (as

in IS: 875 – Part –3) for the project site shall be considered as under. 2.8.1.1 Probability Factor K1

The design life of all equipment shall be taken as 50 years. The mean return period of all equipment shall be 50 years except for flare stack/ chimney for which the mean return period shall be taken as 100 years.

Wind load shall be calculated in accordance with Indian Standard IS 875-1987 Part 3 as

follows; Wind load (kg) F = C x Ae x Pd

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Where

C = Shape factor for cylinders Refer to Table D-2 (Table 23 IS 875) Ae = Effective Area D x H (m2) D = Maximum of (1.2Do or Do+0.6) m Do = Outside diameter of insulated shell m H = Height of the section (m) Pd = Design Wind Pressure at height H Refer to Table D-1 (kg/m2) 2.9 Requirements for Earthquake Design

Seismic design shall be as per IS 1893 part IV Zone = III

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2.10 CAPACITY 2.10.1 Tank Capacity shall be specified as Nominal capacity and stored capacity. Nominal capacity for fixed roof tanks shall be volume of cylindrical shell.

Stored capacity for fixed roof tanks shall be equal to nominal capacity minus free board volume (equivalent to 500mm of shell height) or location of fixing of lowest roof structure member

Nominal capacity (also the stored capacity) for floating roof tanks shall be volume of cylindrical shell minus free board volume. (Equivalent to minimum 1500mm of shell height).

Nominal capacity (also the stored capacity) for fixed cum floating roof tanks shall be volume of cylindrical shell minus free board volume. (equivalent to minimum 2500 mm of shell height).

2.10.2 Bullets (above ground or under ground) Nominal capacity is the geometric capacity of bullet. Stored capacity shall be 85% of nominal capacity at maximum design temperature. 2.10.3 Sphere Nominal capacity is the geometric capacity of sphere. Stored capacity shall be 85% of nominal capacity at maximum design temperature. 2.11 SUPPORTS

2.11.1 Skirt supports shall be provided for all vertical vessels, columns and reactors. Small vertical vessels may be supported on legs or brackets.

2.11.2 All Cr-Mo steel reactors shall be supported on skirts.

Welding of external cleats on Cr-Mo steel reactors shall be avoided wherever possible. 2.11.3 Skirt thickness The minimum thickness for the skirts shall be greater of: a) The thickness required by stress analysis with a minimum of 6 mm inclusive of CA) b) 1/3 of the shell wall thickness with a maximum of 30 mm Corrosion allowance of 1.0 mm minimum shall be considered for skirts unless otherwise

specified

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2.11.4 Columns with diameter ≥ 900 mm shall be self supported unless the process data sheet indicates a guide supported design.

2.11.5 Columns with diameter less than 900 mm shall be supported by superimposed structure

around the column covering the entire height. Guy wires shall not be used to support any equipment. Supporting of columns by superstructure require prior approval from Jacobs

2.11.6 In special cases, columns with diameter up to 900 mm and height not exceeding 20m

(including skirt height) can be self-supported and heights exceeding 20 m shall be supported by super imposed structure around the column covering the entire height.

2.11.7 Flare and vent stacks shall be supported structurally by superimposed structure around for

complete height. 2.11.8 Storage spheres shall be supported on pipe leg supports with tie rod bracing and turn buckles. 2.11.9 Buried vessels shall be suitably anchored to prevent the uplift due to water table. Anchor bolts

shall have corrosion allowance of 6mm. Buried vessels shall be supported on concrete saddles with bracket support at the centerline of the vessel.

2.12 MANHOLES 2.12.1 Manhole size less than 480 mm ID shall be avoided. If the dia of vessel is small, check if a

hand hole or a body flange can be considered. However, Vessels with less than 900 mm ID shall be provided with hand holes or flanged heads,

depending upon access requirement for the particular service. Vessels and columns with diameter 900mm shall be provided with 450 NB (Min ID 432 mm)

man hole unless otherwise specified. Vessels and column with diameter greater than 1000mm and upto 1500mm shall be

provided with 500 NB (Min ID 480 mm) man way. Vessels and columns with diameter 1500mm and above can be provided with 600 NB man way. However, when inside diameter of man holes is specified, then same shall be considered as minimum required. Size of manholes shall be as per licensor drawing.

2.12.2 For storage tanks minimum number of manholes (size 600mm) shall be as follows:

Tank diameter Shell manhole

Flush type clean out fittings

Roof manhole

Dia. ≤ 12 m 1 NIL 1

> 12m <Dia. ≤ 45m dia 2 1 2

45m < Dia. ≤ 61m 3 2 2

Dia. >61m 4 2 2

For floating roof tanks, 1no 750 mm NB manhole with internal ladder shall be provided as per

fabricators standard. 2.12.3 Size of clean out doors fittings for tanks shall be 900mm x 1200mm.

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2.13 FLOATING ROOF 2.13.1 Floating roof shall be of following construction unless specified otherwise. Tank diameter Type of roof ≤ 12 m Double deck type

≥ 12 m < 60 m Pontoon type

≥ 60 m Double deck type

2.13.2 a. Primary and secondary seal to be provided for Naphtha, MS & Diesel service floating

type roof tanks. Internal floating roof shall have single seal. b. The roof drain shall be pivot master type. 2.14 NOZZLE SIZE 2.14.1 Minimum nozzle size = 40 NB Minimum nozzle size for clad vessels / columns = 80 NB Safety valve nozzle = Based on I.D. Self reinforced nozzle neck = Based on I.D. 2.14.2 Nozzles and manholes including self-reinforced type shall be “set in” type attached to

vessel with full penetration welds unless otherwise specified. 2.15 FLANGES 2.15.1 Nozzle flanges upto 600 NB shall be as be ASME / ANSI B16.5 and above 600 NB shall be

as per ASME / ANSI B 16.47 (SERIES ‘B’). 2.15.2 Nozzle flanges shall be welding neck flanges unless specified otherwise. Nozzles less than

50 NB shall be of long weld neck type. 2.15.3 Slip on flanges shall not be used in Lethal, Hydrogen, Amine, Caustic, severe cyclic

service, sour service, HIC (Hydrogen induced cracking) service and corrosive service where corrosion allowance is more than 3 mm.

2.15.4 Girth flanges and intermediate body flanges shall be of weld neck type only. 2.15.5 Flange rating shall be established based on design pressure, design temperature and

considering all external loads (moments and axial force). Nozzle flanges 900# rating & above shall also be designed as per ASME SEC. VIII DIV.1 appendix-2 considering design pressure, design temperature and all external loads. Change in basic constructional features of the flanges is not permitted.

2.15.6 For ratings ≥ 900 and for hydrogen service, flange face shall be RTJ

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2.16 INTERNALS All removable internals shall be bolted type and bolting shall be SS type 304 unless

specified otherwise. 2.17 GASKETS Service gaskets supplied shall not be used for hydro testing purpose. Gasket used for

hydro testing of equipment shall be of same specification as that of service gaskets for all nozzles, manholes and body/girth flanges. Gasket seating face of flanges shall have finish as per gasket specified.

2.18 PIPE DAVIT All columns and Vertical vessels with internals & safety valve shall be provided with pipe

davit as per Jacobs standard. Weight of the valve or item to be handled shall be advised for selection of configuration.

2.19 SPARES For mandatory, Erection & Commissioning spares refer spares list attached elsewhere in

the tender / amendment document. 1 2.20 VENT / DRAIN / VENTILATION NOZZLE CONNECTIONS: All vent and drain lines of light Hydrocarbons like MS, naphtha, LPG, propylene, and H2

shall be provided with double isolation valves with end flanges as per OISD. Dia11/2”NB (40 NB) and above drain lines shall be provided with end flanges.

All vessels shall be provided with one number vent / drain connection as per following

unless otherwise specified in process data sheet. Vessel Volume Length (Horizontal

Vessel) Vent nozzle Drain nozzle Ventilation

nozzle Less than 6.0 m3 - 40 NB 40 NB -

6.0 – 15.0 m3 - 50 NB 50 NB

-

More than 15 m3 - 50 NB 80 NB -

- 3000mm – 4500mm - 100 NB

- 4500mm – 7500mm - 150 NB

- ≥ 7500mm - 200 NB

All vertical vessels not having any nozzle on the top shall be provided with 50 NB nozzles

for conducting hydro test in vertical conditions.

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2.21 IMPORTANT CONSIDERATIONS 2.21.1 All vessels and columns shall be designed considering design pressure; maximum

operating liquid head and any pressure drop within the vessels/columns. 2.21.2 All columns and vessels shall be capable of withstanding water full condition during system

testing. 2.21.3 Vessels and columns shall be hydro tested at shop at pressure calculated as per applicable

code in new and cold condition. 2.21.4 Seismic design shall be carried out based on design requirement for earthquake. 2.21.5 Equipment covered under the purview of IBR (Indian Boiler Regulations) shall be designed

as per IBR regulations. However, design of components not covered in IBR Regulations shall be designed in accordance with ASME SEC. VIII Div-1 by multiplying the allowable stress at design temperature by 0.8667 (1.3/1.5 which is the ratio of minimum multiplying factor for hydro test for ASME sec VIII div-1 and IBR). This way the equipment can be safely tested to meet ASME as well as IBR requirements.

2.21.6 Detail stress analysis, local load analysis for loads due to piping and supported equipment

etc. shall be carried out for all equipment. Critical equipment shall be analysed by using finite element analysis methods (FEM) as defined in job specifications & reports shall be submitted for Jacobs review.

2.21.7 All nozzle necks, all nozzle flanges and blind flanges shall be of weld overlay construction

for clad equipment. Loose liners on nozzle necks and blind flanges are not permitted. 2.21.8 All vertical vessels and columns shall be provided with 2 lifting lugs/Lifting trunions. Lifting

lugs shall be designed with impact factor of two. 2.21.9 Mechanical design of self supporting Tall columns / tower shall be carried out for various

load combinations as per Clause 3.2 2.21.10 Material of various parts of equipment shall be selected as per table given in TABLE– 3

unless otherwise stated on process data sheets. In case the suggested basic material system for equipment does not meet the temperature applicability requirement, it shall be brought to the notice of Jacobs and clarification obtained at enquiry stage itself.

2.21.11 Local Stress analysis shall be carried out for nozzle to shell junction using maximum shear

stress theory for vessels and columns. Allowable stress intensity shall be as per ASME SEC. VIII Div. 2 and non-destructive examinations shall be carried out for shell to nozzle junction as per ASME SEC. VIII Div. 2.

2.21.12 Stress analysis of shell to skirt junction shall be carried out using maximum shear stress

theory for vessels and columns designed as per ASME Sec. VIII Div. 2. In case skirt shell joint is of butt-welded construction, the same shall be 100% radiographed.

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2.21.13 All vessel, columns and tanks shall be provided with earthing bosses as per Jacobs standard. Body flanges of equipment shall have provision to provide jumpers for earthing.

2.21.14 Permanent fixed ladders shall be provided inside the skirt of columns/vertical vessels for

inspection of dome / dished end. 2.21.15 ODC / Very heavy equipment shall require special considerations for handling,

transportation and erection by Contractor. 2.21.16 All equipment shall be painted as per Jacobs painting specification. 2.21.17 All equipment requiring insulation shall be provided with insulation support rings /cleats

as per Jacobs specifications. 3.0 DESIGN REQUIREMENTS-SPECIFIC APPLICATIONS 3.1 LPG STORAGE SPHERES 3.1.1 The design pressure shall be established based on the composition and vapor pressure

of LPG at design temperature, but in no case it shall be less than 14.50 kg/cm2.g at the

top of the sphere. 3.1.2 Selection of material of construction for various LPG storage applications shall be as per

following: i. For refinery and gas processing plants: SA-516 Gr. 60 ii. For design temperature lower than minus 40 deg. C and thickness over 50mm:

SA-537 Cl.1 3.1.3 All LPG spheres shall be post weld heat treated irrespective of storage application and

adopted shell thickness. 3.2 TALL COLUMNS Mechanical design of self-supporting column and its anchorage block shall be carried

out considering combination of various loads. 3.2.1 Loadings: The loadings to be considered in designing a self supporting column / tower shall

include: a. Internal and or external design pressure specified on process data sheets. b. Self weight of column inclusive of piping, platforms, ladders, manholes, nozzles,

trays, welded and removable attachments, insulation and operating liquid etc. The weight of attachments to be considered shall be as per Table–1

c. Other loadings as specified in UG-22 of ASME SEC. VIII Div. 1 wherever applicable

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d. Seismic forces and moments shall be computed in accordance with design requirement for earthquake. Unless otherwise specified importance factor and damping coefficient shall be considered as 2 and 2% respectively.

e. Basic wind pressure and wind velocity (including that due to winds of short duration

as in squalls) for the computation of forces / moments and dynamic analysis respectively shall be in accordance with site data for the project (Refer Clause 2.8 above). Additional wind loading on column due to external attachments like platforms, ladders, piping and attached equipment should be given due consideration.

Loadings resulting in localised and gross stresses due to attachment or mounting of

reflux / reboiler, condenser etc 3.2.2. Loading condition Analysis shall be carried out for following conditions: (a) Erection condition: Column (uncorroded) erected on foundation without insulation,

platforms, trays, removable internals etc., but with welded attachments plus full wind on column.

(b) Operating condition: Column in (corroded condition) under design pressure,

including welded items, trays, removable internals, piping, platforms, ladder, reboiler mounted on column, insulation and operating liquid etc., plus full wind on insulated column with all other projections open to wind or earthquake forces.

(c) Test conditions Column (in corroded condition) under test pressure, filled with

water plus 33% of specified wind load on uninsulated column including all attachments shall be considered.

Earthquake and wind shall be considered not acting concurrently. 3.2.3 Deflection of column: Maximum allowable deflection at top of column shall be equal to total height (including

skirt height) of the column divided by 200 but shall not exceed 300 mm in any case. 3.2.3.1 If the deflection of column exceeds the above allowable limit, the thickness of skirt shall

be increased as first trial upto a maximum value equal to the column thickness and this exercise shall be stopped if the deflection falls within allowable limit.

3.2.3.2 If the above step is inadequate, skirt shall be gradually flared to reduce the deflection.

Flaring of skirt shall be stopped if the deflection falls within limits or half angle of

cone reaches maximum limit of 9°°°°. 3.2.3.3 If the above two steps prove inadequate in limiting the deflection within allowable limits,

the thickness of shell courses shall be increased one by one starting from bottom course above skirt and proceeding upwards till the deflection falls within allowable limits.

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Doc. No. 44LK-5100-00-V.02-0101-A4 Date: 19.12.2008


3.2.3.4 For tall equipment fabricated from stainless steels and other exotic materials, it shall be examined if an external guide will be helpful in controlling the required thickness such that the equipment along with its guide structure cost is economical than a free standing design

3.4 Stress Limits The stresses due to design pressure, weights, wind/seismic loads shall be combined

using maximum principal stress theory for ASME SECTION VIII Div.1. Thickness is accordingly chosen to keep the stresses within limits as per Table-2.

3.2.5 Skirt support base Base supporting including base plate, anchor chairs, compression ring, foundation bolting

etc., shall be designed based on over-turning moment (greater of seismic or wind). Minimum size of anchor bolts shall be M24.

A minimum number of 8 foundation bolts shall be provided. Numbers of foundation bolts

shall be in multiple of four. Skirt thickness shall also be checked to anchor chair reaction forces. Anchor bolts shall be so spaced that there is no interference between fixing arrangement, Anchor bolt sleeves and tailing lug etc.

SA 193 materials shall not be used for anchor bolts. In general anchor bolts made from

SA 36 / IS 2062 Gr B shall be considered 3.2.6 Hydro test pressure Hydro test pressure shall be equal to 1.3 x design pressure x temperature correction

factor as specified in ASME SEC. VIII DIV.1 (Clause UG-99) at top of column unless specified otherwise.

If column is tested in horizontal position, hydro test pressure shall be increased in order

to take the effect of water head .After taking precautions as suggested in para 2.21.5, an IBR equipment may be tested to meet IBR’s hydrostatic test requirements.

3.2.7 Dynamic analysis of column / Tower Dynamic analysis of each column shall be carried out for stability under transverse wind

induced vibrations as per standard design practice and calculations for each column shall be submitted to Jacobs for approval. The recommended magnification factor for unlined towers / column shall be taken as 70 and allowable dynamic amplitude shall be limited to tower diameter divided by 5.

3.3 STORAGE TANKS 3.3.1 Tank shell thickness calculation shall be carried out by the one - foot method as per API

650 for tank diameters less than and equal to 60m (200 feet). 3.3.2 Maximum height of un-stiffened shell shall be calculated based on the corroded thickness

of shell courses. Section modulus of wind girders shall also based on corroded thickness of shell courses.

Jacobs



Doc. No. 44LK-5100-00-V.02-0101-A4 Date: 19.12.2008


3.3.3 Shell thickness shall be calculated considering product liquid/water level up to top curb angle for all tanks including floating roof tanks.

3.3.4 Seismic design as per API-650 (appendix-E) is mandatory for all storage tanks. 3.3.5 Annular bottom plates shall be provided for all storage tanks ≥ 12.0 m diameter. 3.3.6 All small tanks ≤ 10.0 m diameter shall be provided with anchor bolts to prevent uplift due

to wind. 3.3.7 Tanks having design temperature more than 100

0C shall have thermal isolation barrier

(Suitable insulating fire bricks) between tank bottom and foundation. 3.5 CRYOGENIC VESSELS & TANKS 3.5.1 Apart from metallurgical suitability for equipment and its supporting structures , following

special considerations are required: 3.5.1.1 Expansion & contraction of the equipment affecting foundation design and piping 3.5.1.2 For cryogenic tanks, bottom insulation using foam glass requires special consideration. 3.5.1.3 Insulation of complete storage system requires special consideration from the point of

heat ingress from various sources affecting the selection of refrigeration system and tank safety system settings.

3.5.1.4 Bare surface of cryogenic equipment is a safety hazard and should be given special

consideration 3.6 HYDROGEN BULLETS 3.6.1 Hydrogen bullets shall be designed as ASME Sec VIII div.1. However, all fabrication and

inspection requirements shall as per ASME Sec. VIII div.2.

Jacobs



Doc. No. 44LK-5100-00-V.02-0101-A4 Date: 19.12.2008


TABLE – 1

DETAILS AND WEIGHT OF COLUMN ATTACHMENTS

1. Minimum Shape factor for shell (for wind load calculations) (Also refer para 2.8.1.1 for column design)

: 0.7

2. Weight of trays (with liquid) to be considered : 120 kg / m

2

3. Weight of plain ladder : 15 kg / m 4. Weight of caged ladder : 35 kg / m 5. Equivalent projection to be considered for wind

load on caged ladder. : 300 mm

6. Distance of platform below each manhole : Approx. 1000 mm 7. Maximum distance between consecutive platforms : 5000 mm 8. Projection of platform : 900 mm up to 1.0 m dia. Column and

1.2 m for column dia.>1m from column insulation surface

9. Equivalent height of platform (for wind load

computation) : 1000 mm.

10. Weight of platforms : 100 kg/m

2

11. Platform shall be considered all around.

Jacobs



Doc. No. 44LK-5100-00-V.02-0101-A4 Date: 19.12.2008


TABLE-2 ALLOWABLE STRESS FOR COMBINED LOADING

Conditions Vessel condition / temperature – type of stresses

Erection Operating Test

New or corroded New Corroded Corroded

Temperature Ambient Design Ambient

Longitudinal K x S x E K x S x E 0.90 x Y.P. x E

Longitudinal compressive stress K x B K x B B

Where

S = Basic allowable tensile stress as per Clause UG 23(a) of ASME SEC.VIII Div.1

B = ‘B’ value calculated as per clause UG-23 (b)

E = Weld joint efficiency of circumferential weld, depending on extent of radiography

K = Factor for increasing basic allowable value when wind or seismic load is present

Y.P. = Yield point stress

Note: Allowable stresses in skirt to shell joint shall be as per following:

0.49S, if joint is shear type.

0.70S, if joint is compression type.

Jacobs



Doc. No. 44LK-5100-00-V.02-0101-A4 Date: 19.12.2008


TABLE- 3 MATERIAL SELECTION CHART The following table gives general guidelines for material selection chart for various pressure parts / non pressure parts of the equipment:

Design Temp.

0C

Plate Pipe (See note 8)

Forging Bolts / Studs / Nuts External

Structural attachment welded to pressure parts

Internal pipes

Studs / Bolts / Nuts Internal

C R Y O G E N I C

From –254 up to –195

SA240 Gr.304L, 304, 316, 316L, 347 (impact tested)

SA312 Type 304 304L, 316, 316L, 347

SA182, Gr. F 304, 304L 316, 347, 316L

SA320, Gr.B8, 8C, 8T strain hardened SA 194 Gr.8 ,8C,8T

Above –195 up to –80

SA240, Gr.304L, 304, 316, 316L, 321, 347. SA 353, 553, Gr.A

SA312, Type 304, 304L, 316, 316L, 321, 347. SA333, Gr.8

SA182 Gr.F 304 F304L, F316L SA522

SA320, Gr.B8, 8C, 8T strain hardened SA194 Gr.8, 8C, 8T

Same as pressure parts

L O W T E M P E R A T U R E

Above –80 Up to –60

SA203 Gr.E impact tested (see note-1)

SA 333 Gr.3, 4

SA 350 Gr. LF3

SA 320 L7 SA 194 Gr.4 or Gr.7

SA 203 Gr.E SA333 Gr.3 , 4

SA193 Gr.B8 SA194 Gr.8

Above –60 Up to –45

SA537 Cl.1 impact tested (see note-1)

SA333 Gr.3

SA350 Gr.LF3

SA320 L7 SA194 Gr.4 Or GR 7

SA537 Cl.1 SA333 Gr.3

SA193, Gr.B8, SA194 Gr.8

Above-45 upto –29

SA516 (All grades) impact tested (see note-1)

SA333 Gr.6 or Gr.1

SA350 Gr.LF2

SA320 Gr.L7 SA194 Gr.4 or Gr.7

SA516 (in all grades)

SA333 Gr.6 , 1

SA193, Gr.B8, SA194 Gr.8

Above -29 upto 0

SA516 (all grades) (See note 3)

SA106, Gr.B (see note 3)

SA105 / SA266 (see note 3)

SA193 Gr.B7 SA194 Gr.2H

SA516 (in all grades)

SA106, Gr.B

SA-193, Gr.B8, SA194, Gr.8

Jacobs



Doc. No. 44LK-5100-00-V.02-0101-A4 Date: 19.12.2008


Design Temp. 0C

Plate Pipe (See note 8)

Forging Bolts / Studs / Nuts External

Structural attachment welded to pressure parts

Internal pipes

Studs / Bolts / Nuts Internal

I N T E R M E D I A T E T E M P E R A T U R E

Above 0 Upto 343

SA516 (all grades) SA240 type 304L, 316L, 321 (see note 4)

SA106 Gr.B SA312 TP304L, 316L, 321, A376 TP321

SA105 SA266 SA182 F 304L, 316L, 321

SA193 B7 SA194 Gr.2H SA193 B7 SA194 Gr.2H

IS2062 (plates) Same as Pressure parts

SA106 Gr.B Same as Pressure parts

SA193 Gr.B8 SA194,Gr.4 SA193, Gr.B8, SA194 Gr.8

Above 343 upto 427

SA387 Gr.11 Cl.1 / Cl.2 SA240 type 304L, 316L, 321 (see note 4)

SA335, Gr.P11 SA312 type 304L, 316L, 321,SA 376 Type 321

SA182 Gr.F11 SA182F 304L, 316L 321

SA193 Gr.B7 SA194 Gr.4 SA-193, B7 SA194 Gr.4

Same as Pressure parts Same as Pressure parts

Same as Pressure parts Same as Pressure parts

SA193 Gr.B8 SA194 Gr.8 SA193 Gr.B8 SA-194 Gr.8

E L E V A T E D T E M P E R A T U R E

Above 427 Up to 538

SA387 Gr.11, Cl.1/ Cl.2, SA387 Gr.12, Cl.1/ Cl.2

SA335 P11 SA335 P12

SA182 Gr.F11, SA182 Gr.F12

SA193 Gr.B16 SA194 Gr.4

Same as Pressure parts


SA193 Gr.B8. SA194 Gr.8

Above 427 Upto 500

SA240 type 304, 316, 321, (See note 4).

SA312, SA376 type 304, 316, 321

SA182 F 304, 316, 321

SA193 Gr.B16 SA194 Gr.4



SA193 Gr.B8. SA194 Gr.8

Above 538 Upto 593

SA387 Gr.22 Cl.1/ Cl.2 SA387 Gr.21, Cl.1/ Cl.2

SA335 P22 SA182 Gr.F22, SA336 Gr.F22

SA193 Gr.B5, SA194 Gr.3


Above 500 Upto 815

SA240, Gr.304H, 316H, 321H

SA312/ SA376 Type 304H, 316H, 321H

SA182 Grs. 304H, 316H, 321H

SA193, Gr.B8 SA194, Gr.8 (strain hardened)


Jacobs



Doc. No. 44LK-5100-00-V.02-0101-A4 Date: 19.12.2008


NOTES

1. Pressure vessel steel plates are purchased to the requirement of the standard ASME SA-20 which requires testing of individual plates for low temperature service. Carbon steel material is ordered to meet the impact requirements of supplement S5, of standard ASME SA 20. Typical material specification is as follows. SA516 Gr.60 normalised to meet impact requirements per supplement S5 of SA 20 AT -50

oF.

2. All permanent attachments welded directly to 9% nickel steel should be of the same material

or of an austentic stainless steel type which can not be hardened by heat treatment. 3. Check for impact testing requirement as per UCS-66 for coincident temperature and part

thickness. 4. Selection of stainless steel material shall be based on process recommendation / process

licensor. 5. This table is not applicable for atmospheric / low pressure storage tanks. Materials shall be

selected as per API 650 / API 620 as applicable. 6. Materials for caustic service, sour service, or sour service + HIC shall be selected based on

specific recommendation of process licensor & considering chemical composition, hardness, vacuum degassing requirements & heat treatment requirements.

7. Material for pressure vessels designed according to ASME SEC VIII DIV. 2 shall be given

special consideration as per code. 8. All pipes shall be of seamless construction. 9. Non-ferrous material and super alloys are not covered above and shall be selected based on

specific recommendation. 10. Material for vessel / column skirt shall be the same material as of vessel / column shell for

upper part with a minimum of 1000mm (2000 mm in case of design temp > 400 0C) 1 11. Materials used for IBR equipment shall meet all requirements of Indian Boiler Regulations.

All licensor requirements shall be complied with. However, in case of any contradiction same to be resolved in consultation with the Owner/Jacobs

12. REACTORS

(a) The design shall be done based on process licensors specifications. (b) Material selection shall be strictly as per licensors specification. (c) Minimum thickness shall be strictly be as per Licensors specification (d) MDR and UDS as per ASME code shall be obtained by the fabricator. (e) FEM analysis shall be done for all process nozzles, shell to head junction Y shaped

skirt, welded/weld overlayed support rings and any other stressed point as defined in

Jacobs



Doc. No. 44LK-5100-00-V.02-0101-A4 Date: 19.12.2008


licensors specification (f) All internals shall have minimum thickness as given in process licensors specification

and shall be designed for loads defined in licensors drawings. (g) Thermal analysis for HOT box shall be conducted. (h) Reactors as well as internals shall be fabricated by process Licensors approved

vendors, HPCL/Jacobs approved vendors. (i) Lifting arrangement shall be as defined by process Licensors drawings. (j) Floating type insulation support shall generally be provided. (k) Reactor to be designed for minimum 25 years of life..

Jacobs



Doc. No. 44LK-5100-00-V.02-0101-A4 Date: 19.12.2008


TABLE 4 : NOZZLE LOADING DATA FOR NOZZLES ON CYLINDRICAL SHELLS (For high pressure vessels refer Doc. No. 44LK5100-00-V.02-0113-A4 Nozzle loadings on HP vessels)

FLANGE RATING NOZZLE SIZE NB

FORCES AND

MOMENTS 150# 300# 600# 900# 1500# 2500#

1” FA (kg) FL (kg) FT (kg) ML (kg.m) MT (kg.m) MC (kg.m)

120 120 90 7.8 9 6

140 140 10.5 9.1 10.5 7.5

160 160 120 10.5 12 8

180 180 135 11.7 13.5

9

200 200 150 13 15 10

220 220 165 14.5 16.5 10

1½” FA (kg) FL (kg) FT (kg) ML (kg.m) MT (kg.m) MC (kg.m)

180 180 135 17.5 20

13.5

210 210 158 20.5 24 16

240 240 180 23 27 18

270 270 203 26 30 20

300 300 225 29 34 23

330 330 248 32 37 25


240 240 180 31 36 24

280 280 210 37 42 28

320 320 240 42 48 32

360 360 270 47 54 36

400 400 300 52 60 40

440 440 330 57 66 44


360 360 270 70 81 54

420 420 315 82 95 63

480 480 360 94 108 72

540 540 405 106 122 81

600 600 450 117 135 90

660 660 495 129 148 99


480 480 360 125 144 96

560 560 420 146 168 112

640 640 480 167 192 128

720 720 540 187 216 144

800 800 600 208 240 160

880 880 660 229 264 176

FA (kg) 720 840 960 1080 1200 1320

FL (kg) 720 840 960 1080 1200 1320

FT (kg) 540 630 720 810 900 990

ML (kg.m) 281 328 375 421 468 515

MT (kg.m) 324 378 432 486 540 594

6”

MC (kg.m) 216 252 288 324 360 396

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Doc. No. 44LK-5100-00-V.02-0101-A4 Date: 19.12.2008


FA (kg) 960 1120 1280 1440 1600 1760

FL (kg) 960 1120 1280 1440 1600 1760

FT (kg) 720 840 960 1080 1200 1320

ML (kg.m) 499 583 665 749 832 915

MT (kg.m) 576 672 768 864 960 1056

MC (kg.m) 384 448 512 576 640 704

8”

FA (kg) 1200 1400 1600 1800 2000 2200

FL (kg) 1200 1400 1600 1800 2000 2200

FT (kg) 900 1050 1200 1350 1500 1650

ML (kg.m) 780 910 1040 1170 1300 1430

MT (kg.m) 900 1050 1200 1350 1500 1650

MC (kg.m) 600 700 800 900 1000 1100

10”

FA (kg) 1440 1680 1920 2160 2400 2640

FL (kg) 1440 1680 1920 2160 2400 2640

FT (kg) 1080 1260 1440 1620 1800 1980

ML (kg.m) 1123 1310 1498 1685 1872 2060

MT (kg.m) 1296 1512 1728 1944 2160 2376

MC (kg.m) 864 1008 1152 1296 1440 1584

12”

FA (kg) 1680 1960 2240 2520 2800 3080

FL (kg) 1680 1960 2240 2520 2800 3080

FT (kg) 1260 1470 1680 1890 2100 2310

ML (kg.m) 1530 1784 2038 2293 2548 2803

MT (kg.m) 1764 2058 2352 2646 2940 3235

MC (kg.m) 1176 1372 1568 1764 1960 2156

14”

FA (kg) 1920 2240 2560 2880 3200 3520

FL (kg) 1920 2240 2560 2880 3200 3520

FT (kg) 1440 1680 1920 2160 2400 2640

ML (kg.m) 1997 2330 2663 2995 3328 3660

MT (kg.m) 2304 2688 3072 3456 3840 4224

MC (kg.m) 1536 1792 2048 2304 2560 2816

16”

FA (kg) 2160 2520 2880 3240 3600 3960

FL (kg) 2160 2520 2880 3240 3600 3960

FT (kg) 1620 1890 2160 2430 2700 2970

ML (kg.m) 2527 2949 3370 3791 4212 4633

MT (kg.m) 2916 3402 3888 4374 4860 5346

MC (kg.m) 1944 2268 2592 2196 3240 3564

18”

Jacobs



Doc. No. 44LK5100-00-V.02-0101-A4 Date: 19.12.2008


FA (kg) 2400 2800 3200 3600 4000 4400

FL (kg) 2400 2800 3200 3600 4000 4400

FT (kg) 1800 2100 2400 2700 3000 3300

ML (kg.m) 3120 3640 4160 4680 5200 5720

MT (kg.m) 3600 4200 4800 5400 6000 6600

MC (kg.m) 2400 2800 3200 3600 4000 4400

20”

FA (kg) 2640 3080 3520 3960 4400 4840

FL (kg) 2640 3080 3520 3960 4400 4840

FT (kg) 1980 2310 2640 2970 3300 3630

ML (kg.m) 3775 4405 5034 5663 6292 6921

MT (kg.m) 4356 5082 5808 6534 7260 7986

MC (kg.m) 2904 3388 3872 4356 4840 5324

22”

FA (kg) 2880 3360 3840 4320 4800 5280

FL (kg) 2800 3360 3840 4320 4800 5280

FT (kg) 2160 2520 2880 3240 3600 3960

ML (kg.m) 4493 5242 5991 6739 7488 8237

MT (kg.m) 5184 6048 6912 7776 8640 9504

MC (kg.m) 3546 4032 4608 5184 5760 6336

24”

FA (kg) 3120 3640 4160 4680 5200 5720

FL (kg) 3120 3640 4160 4680 5200 5720

FT (kg) 2340 2730 3120 3510 3900 4290

ML (kg.m) 5273 6152 7031 7909 8788 9667

MT (kg.m) 6084 7098 8112 9126 10140 11154

MC (kg.m) 4056 4732 5408 6084 6760 7436

26”

FA (kg) 3360 3920 4480 5040 5600 6160

FL (kg) 3360 3920 4480 5040 5600 6160

FT (kg) 2520 2940 3360 3780 4200 4620

ML (kg.m) 6115 7135 8154 9173 10192 11211

MT (kg.m) 7056 8232 9408 10584 11760 12936

MC (kg.m) 4704 5488 6272 7056 7840 8624

28”

FA (kg) 3600 4200 4800 5400 6000 6600

FL (kg) 3600 4200 4800 5400 6000 6600

FT (kg) 2700 3150 3600 4050 4500 4950

ML (kg.m) 7020 8190 9360 10530 11700 12870

MT (kg.m) 8100 9450 10800 12150 13500 14850

MC (kg.m) 5400 6300 7200 8100 9000 9900

30”

Jacobs



Doc. No. 44LK5100-00-V.02-0101-A4 Date: 19.12.2008


NOZZLE LOADING OF CYLINDRICAL, DISHED / FORMED END

MB

DISHED / FORMED ENDS

CYLINDRICAL ENDS

Z

FZ=FT

Z

FX=FL

FY=FA

Y

X

X

FR = RESULTANT

FLFT

FA

Y MT

MT

ML

FA

MC

(NOTE: LOADS INDICATED IN THE TABLES TO BE CHECKED FOR BOTH POSITIVE AND NEGATIVE

CONDITIONS)

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