hindustan petroleum corporation ltd....

of 52

HINDUSTAN PETROLEUM CORPORATION LTD. MUMBAI

DIESEL HYDROTREATER PROJECT

TITLE: ENGINEERING DESIGN BASIS PRESSURE VESSELS & HEAT EXCHANGERS

DOCUMENT NO : 44LK-5100-V.02-0001-A4

REV NO.

ISSUE DATE

PAGES REV DESCRIPTION PREPARED

BY

CHECKED

BY

APPROVED

BY

A 15.02.2008 52 Issued for Client’s approval SNK CR HSC

0 10.09.2008 52

Clients comments incorporated & issyed

SNK CR HSC

JACOBS

HPCL-MUMBAI Engineering Design basis for of 52

44LK5100 Pressure vessels & heat exchangers Date: 10.09.2008

DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

TABLE OF CONTENTS

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 TALL COLUMNS

3.2 STORAGE TANKS

3.3 HYDROGEN BULLETS

3.4 REACTORS

3.5 SHELL & TUBE HEAT EXCHANGERS

3.6 ADDITIONAL REUIREMENTS FOR SPECIAL TYPE HIGH PRESSURE HEAT EXCHANGERS 3.7 AIR COOLED HEAT EXCHANGERS 3.8 DOUBLE PIPE HEAT EXCHANGERS 3.9 PLATE HEAT EXCHANGERS

TABLE – 1 DETAIL & WEIGHT OF COLUMN ATTACHMENTS

TABLE – 2 ALLOWABLE STRESS FOR COMBINED LOADING

TABLE- 3 MATERIAL SELECTION CHART

Section B TRAYS AND TOWER INTERNALS

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

1.0 CODES & STANDARDS 1.1 CODES The following applicable codes, Licensor’s Global Practices (GP’s) Applicable rules and

regulations 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, Shell & Tube heat exchangers, High pressure heat exchangers, Air cooled heat exchangers, Double pipe exchangers, Plate heat exchanger, Steel Flare/ Vents 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 3 For very high pressure Vessel TEMA CLASS ‘R’, 1999 EDITION. For Shell & tube Heat Exchangers ASME SEC. VIII DIV. 2/PD 5500 Mounded Vessels / Bullets. ASME SEC.V For non-destructive testing TEMA, 1999 EDITION / IS 800 For double pipe exchanger (To the extent applicable) 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 / API 601 For gaskets ASME B 96.1 Welded Aluminum alloy storage tank 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 categorized under any

other code API 650 For Storage Tanks API Standard 661 / IS 800 Latest

edition For Air cooled exchangers

API 620 For Low Pressure Storage Tanks IS: 6533 For steel vent stacks etc

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

IS: 9178/DIN 1055 For Silos, Hoppers and, Bins IS: 875/ Site Data For wind load consideration IS: 1893/ Site Data For seismic design consideration IBR For steam producing, steam storage, catch water

vessels, condensate flash drums and similar vessels 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 Sulfide Stress Cracking Resistant Metallic Materials for Oil Field Equipment

NACE TM 0284 Evaluation of Pipeline and Pressure Vessel Steel for Resistance to Hydrogen Induced Cracking.

NACE TM 0177 Laboratory Testing of Metals for Resistance to Sulfide Stress Cracking in Hydrogen Sulfide 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

API-RP-945 Avoiding environmental cracking in Amine Units

API-950

Survey of construction Materials and corrosion in sour water stripper

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

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 Hydro test 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 (Minimum) 2.2.1 For columns of carbon and low alloy steel, minimum thickness shall be 8 mm (including

corrosion allowance up to 3.0 mm). 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 :

For diameter less than 2400mm:

Wall thickness = Dia + 1.5 + Corrosion Allowance. 1000

For diameter 2400mm and above: Wall thickness = Dia + 2.5 + Corrosion Allowance.

1000 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 3.0mm but shall

not be less than calculated as per following formula: For diameter more than 1500 mm Wall thickness = Dia + 2.5 + Corrosion Allowance.

1000 Corrosion allowance (if any) 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 tall column and designed accordingly.

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

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. 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.

Body flanges may be provided in lieu of Man holes for vessels with dia ≤ 760 mm. 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 m

3 3 inch

200-400 m3 4 inch

400-700 m3 6 inch

>700 m3 8 inch

2.3.7 All tower and drums will be provided with valved drain connections, terminating in a line

size block valve and blind. The drain will be provided from a bottom draw off line of at least equal size. Vessel drain sizing will be per the following :

Vessel volume (m^3 ) process drain inches Upto 200 m^3 3

200-400 m^3 3 400-700 m^3 4

>700 m^3 6

2.3.8 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.

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

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

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

2.4 DESIGN PRESSURE Design pressure shall be calculated based on the following general guide lines unless

otherwise specified elsewhere. When specified in the Process Data Sheet same shall be followed: 1

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 70kg/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) to the calculated hydro-test pressure. 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 100 kPa (15 psi g) 1 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, unless otherwise specified elsewhere.

2.5 DESIGN TEMPERATURE 2.5.1 For vessels operating at 0

oC and above, if not specified in the Process Data Sheet, 1

Design temperature = maximum operating temp. + 15

oC (subject to a min of 65

oC)

2.5.2 For Vessels operating below 0

oC if not specified in the Process Data Sheet, 1

Design temperature = lowest operating temperature

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

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. 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% of design wind load.

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

equipment is new with 50% of design 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/lined 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. 44LK5100-00-V.02-0001-A4 Rev. 0

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 = 3.0 mm First shell course = 3 mm Subsequent shell courses = 1.5 mm Floating roof/fixed roof = 0.5mm 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? (stress analysis) 2.7.10 Corrosion allowance for nozzles including manholes shall be at least equal to that specified

for the vessel. No corrosion allowance is required for standard flange face. 2.7.11 Corrosion allowance for gasket faces of girth/ body flange or specially designed non

standard flanges 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. 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 (Mumbai) 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.

Values of K1 for mean probable design life of equipment shall be as follows: (i) 1.0 for 50 years mean return period (ii) 1.09 for 100 years mean return period (iii) K1 (columns and stacks height greater than 30 m ) = 1.09 2.8.1.2 Terrain, height and structure size factor, K2

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

These factors are to be taken from IS 875 (Part 3) – 1987 for relevant class of the

structures with respect to the actual height of the structures. Terrain category shall be considered as 2 for columns and stacks height greater than 30 m

and 3 for other equipment in units 2.8.1.3 Topography factor, K3 = 1 Surface area of piping, platforms and other attachments fixed to the equipment (Vessel /

Column) exposed to wind shall be accounted 2.8.2 Drag coefficient for cylindrical vessels shall be 0.7 minimum 2.8.3 Drag coefficient for spherical vessel shall be 0.6 minimum 2.8.4 Contingency factor of 1.1 shall be used on wind pressure if required. 2.9 SEISMIC LOADING CONSIDERATION Seismic loads shall be in accordance with design requirements for earthquake conditions

for Zone –III as per IS 1893. 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.

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

2.11 SUPPORTS

2.11.1 Skirt supports shall be provided for all l tall columns (refer cl.2.2.3) and reactors. Small

vertical vessels may be supported on legs (pipes or structural section) or brackets.

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

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 corrosion

allowance (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. 2.11.4 Columns with diameter larger than 900 mm shall be self supported unless the process data

sheet indicates a guide supported design. 2.11.5 Columns with diameter less than & including 900mm 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 900mm and height not exceeding 20m

(including skirt height) can be self-supported and heights exceeding 20m 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 anchoring bracket support at the centre line of the vessel.

2.11.10 All vertical equipments shall be provided with suitable lifting arrangements.

2.11.11 All skirt supported columns/equipments with height 20 m and above and weight 50 MT and above are to be provided with tailing lug.

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 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) manhole 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 may be provided with 600 NB man way. However, when inside diameter of manholes are specified, then Inside diameter shall be considered as minimum required & a mandatory requirement.

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

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 (if specified)

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 tank 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. 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 (due to construction limitations) 1

≥ 12 m < 60 m Pontoon type

≥ 60 m Double deck type (for proper balancing) 1

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

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

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 Specially designed flanges for process nozzles shall not be used. 2.15.5 Girth flanges and intermediate body flanges shall be of weld neck type only. 2.15.6 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 and design temperature. Change in basic constructional features of the flanges is not permitted.

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

specified otherwise. 2.17 GASKETS 2.17.1 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.

2.17.2 0 All SS spiral wound gaskets shall be provided with outer and inner rings

2.17.3 0 When RTJ type of facing is provided, gasket shape shall be round and not hexagonal, in order to avoid sharp edges in the groove

2.18 PIPE DAVIT All columns and Vertical vessels with internals & safety valve size 80 NB shall be provided

with pipe davit as per Jacobs standard. 2.19 SPARES Gaskets: Four (4) sets for manholes, two (2) sets for other gasketted joint. Fasteners: 10% (minimum 2 in each size) Sight / Light glass: 4 sets for each installed glass. Internals: (Valves for Trays, Bolts / Nuts, Clamp Assemblies)-10%, Sealing foils for

Cartridge Trays-200% 2.20 VENT / DRAIN / VENTILATION NOZZLE CONNECTIONS:

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

All vent and drain lines of light HC like MS, naphtha, LPG, propylene, and H2 shall be provided with double isolation valves with end flanges as per OISD. Dia. 15 NB and above drain lines should 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 m

3 - 50 NB 40NB

-

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. 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.

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 analyzed by using finite element analysis methods (FEM) as defined in job specifications & reports shall be submitted for Jacobs review. For allowable nozzle loads refer Jacobs standard specification attached with BID package.

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

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

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. 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.

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 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. 2.21.18 All ladders and platforms shall be galvanized. 2.22 CATHODIC PROTECTION: Impressed current cathodic protection system shall be designed and installed as per the

Jacobs specification

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

2.23 EXTERNAL COATING: Applied protection shall be designed and installed as per the Jacobs specification 2.24 INTERNAL COATING: Bottom 90-degree of internal surface of vessel shall be coated with anti-corrosion coating

suitable for stored product. 2.25 LOCATION/SPACING OF VESSELS: Minimum spacing of vessels and other safety regulations shall be as per OISD-STD-150. 3.0 DESIGN REQUIREMENTS-SPECIFIC APPLICATIONS 3.1 TALL COLUMNS Mechanical design of self-supporting column and its anchorage block shall be carried out

considering combination of various loads. 3.1.1 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. 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 IS 875 (latest edition)(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 localized and gross stresses due to attachment or mounting of reflux /

reboiler, condenser etc. 3.1.2. Loading condition 3.1.2.1 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.

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

(b)Operating condition: Column in (corroded condition) under design pressure, including welded items, trays, removable internals, packing/catalyst 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.

3.1.2.2 Earthquake and wind shall be considered not acting concurrently. 3.1.2.3 Cyclic loads if any to be considered. 3.1.3 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. 3.1.3.1 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.

3.1.3.2 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°. 3.1.3.3

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.

3.1.3.4 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

3.1.4 Stress Limits

The stresses due to design pressure, weights (erection/operating/hydrotest as the case

may be), wind/seismic loads shall be combined using maximum principal stress theory for ASME SECTION VIII Div.1. Thicknesses are accordingly chosen to keep the stresses within limits as per Table-2.

3.1.5 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 etc.

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

3.1.6 Hydro test pressure

Hydro test pressure shall be equal to Q (A factor depending on code of construction) x

design pressure x temperature correction factor as specified in ASME SEC. VIII DIV.1(Clause UG-99) / DIV 2 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.

3.1.7 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.

3.2 STORAGE TANKS 3.2.1 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). 3.2.2 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.

3.2.3 Shell thickness shall be calculated considering product liquid/water level up to top curb

angle for all tanks including floating roof tanks. 3.2.4 Seismic design as per API-650 (appendix-E) is mandatory for all storage tanks. 3.2.5 Annular bottom plates shall be provided for all storage tanks ≥ 12.0 m diameter. 3.2.6 All small tanks ≤ 10.0 m diameter shall be provided with anchor bolts to prevent uplift due

to wind. 3.2.7 Tanks having design temperature more than 100

0C shall have thermal isolation barrier

(Suitable insulating fire bricks) between tank bottom and foundation.

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

3.3 HYDROGEN BULLETS 3.3.1 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. 3.4 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 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..

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

3.5 SHELL & TUBE HEAT EXCHANGERS � DENOTES APPLICABILITY 3.5.1.0 THERMAL DESIGN CRITERIA Thermal design criteria shall be as per process design basis. 0 3.5.1.1 SELECTION OF TUBE SIZE Selection of tube size and tube length shall be as per process design basis 0 3.5.1.2 TEMA TYPE SELECTION Selection of TEMA type and preference shall be as per process design basis 0 Preferred exchanger for refinery services shall be horizontal, single pass shell, floating head

tube bundle (TEMA type “S”) arranged with two or more tube passes per shell. 3.5.1.3 OVERDESIGN MARGIN Over design margin shall be as per process data sheet 0 3.5.1.4 MINIMUM FLUID VELOCITY LIMITATIONS, IF ANY, shall be as per process data sheet 0 3.5.1.5 UTILITY SPECIFICATIONS shall be as per process data sheet 0 3.5.1.6 CORROSION ALLOWANCE CA is not applicable to tubes and baffles 0 3.5.1.7 OTHER REQUIREMENTS 3.5.1.7.1 MOC for Sea water cooled heat exchangers shall be as follows: 0 1) For exchangers where H2 / H2S is present

Tubes, Tube sheets, Floating head, Super Duplex Baffles, Support Plates, tie rod, spacers etc. Super Duplex 2) For exchangers where H2 / H2S is not present

Tubes Welded Titanium (0.9mm wall thk) Tube sheet, floating head, baffle, tie rod Ni-Al-Br Spacers

3.5.2.7.2 Do not stack exchangers when individual shell isolation and bypasses are provided. 3.5.2.7.3 Minimum design metal temperature (MDMT) � 0

0C

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

� ………. (specify) 3.5.2.0 MECHANICAL DESIGN CRITERIA 3.5.2.1 Bolting ( except nozzle bolting ) : � Inch � TEMA Metric 3.5.2.2 Bolt loads : � Full � Average 3.5.2.3 Main Girth Flange : � Forged (hubbed) � Plate 3.5.2.4 Bundle interchangeability : � Shall be considered (in the same unit

only) to the extent possible. � Not required 3.5.2.5 Radius of U-bends : � 2 x Tube OD (Preferred) � 1.5 x Tube OD (Min.) 3.5.2.6 Pulling of removable bundle (at both

fixed and floating tubesheets) : � Eyebolts for pulling out bundle shall be

provided. 3.5.2.7 Min. flange connection size (except

Multi-Purpose connection) : � 1 ½” NB

� 2” NB

3.5.2.8 Nozzles from Seamless pipe upto : � 8” NB � _____ NB Nozzles may be rolled from plate

(with 100% X-ray) � 10” NB & above

� _____ NB 3.5.2.9 Tubesheet type for Floating head and

U tube exchangers : � Extended

� Non-extended � Non-extended for Stab-in-bundles of “B”

type stationary head. 3.5.2.10 Multi-Purpose (MP) Connection for

PG/TI : � For CLAD EXCHANGERS

One 2” NB connection on each process nozzle with blind flange

For OTHERS One 1½” NB connection on each process

nozzle with blind flange

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

3.5.2.11 Minimum rating for Multi-Purpose /Instrument connection

: � Same as Process nozzle

� Same as Process nozzle with minimum # 300.

3.5.2.12 Vent and Drain : � 1 ½” NB nozzle

(Separate vent and drain will not be provided if vented/drained by other nozzles or through MP connection, unless required by process datasheet / P&ID. In case MP connection provided on piping separate vent & drain on shell to be provided.

3.5.3.0 MISCELLANEOUS ASPECTS 3.5.3.1 Davits : � Shall be provided for channel cover and

shell covers for exchangers � Not required 3.5.3.2 Spares (Mandatory) : � 400% Gaskets � 20% Bolting (Min. 4 studs and 8 nuts per

joint) � Client to indicate additional requirement

(if any) 3.5.3.3 Testing Accessories : � Test rings shall be provided on all

floating “S” & “T” type head type exchangers.

� Dummy shell shall be provided for fixing

test ring for exchangers such as kettle type or floating head without shell covers or stab in bundle where shell side design pressure is higher than tube side pressure.

� Test flanges shall be provided. For exchangers with removable bundle

and bonnet (type channel) For exchanger with removable bundle

and channel with flat cover if tube side pressure is greater than shell side pressure

� Minimum number of test rings/test

flanges/dummy shells shall be one per bundle.

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

� For shell side interconnected and stacked exchangers the minimum number of test rings shall be equal to the number of exchangers in one stack.

� For “U” tube & floating head exchanger

with Bonnet type channel, number of test flanges shall be equal to number of exchanger in one stack.

3.5.3.5 Cathodic protection � Yes as applicable (Water coolers are to

be provided with sacrificial anodes. Inside channel box, channel cover and floating head covers to be painted with two coats of epoxy zinc phosphate primer and two coats of coal tar epoxy painting as per finish. For Duplex tubes use Aluminum sacrificial anode.

3.5.3.6 Vendor selection : � As per Bidder Qualification Criteria Notes 1) Hydro testing of stacked exchangers shall be carried out in stacked condition. 2) All the tube bundles of heat exchangers, coolers, and condensers should have

impingement plate at the inlet side wherever possible. 3) Admiralty brass/Cupro nickel tube bundles should be used in case of coolers and

condensers. If brass tube bundle is not suitable due to process medium containing ammonia, hydrogen sulphide or due to temperature limitation, then duplex stainless steel or other suitable metallurgy shall be considered depending upon service.

All licensor requirements shall be complied with. However in case of any contradiction

same to be resolved in consultation with the Owner/PMC/Licensor. 3.6 ADDITIONAL REQUIREMENTS FOR SPECIAL TYPE HIGH PRESSURE EXCHANGERS 3.6.1 Heat exchangers can be Screw Plug or Breech-Lock type or modified TEMA DEU type. 3.6.2 CORROSION ALLOWANCE: 1. Corrosion allowance for pressure retaining parts shall conform to Process Data sheet. 2. Weld overlay or cladding thickness shall be considered corrosion allowance. Unless

otherwise specified on process data sheet, undiluted thickness of weld overlay shall be minimum 3 mm. Cladding minimum thickness shall not be less than 3 mm.

3. No credit for strength shall be taken for cladding/weld overlay in the design. 4. Corrosion allowance as specified on Process data sheet shall be added to all exposed

surfaces of channel internals. 3.6.3 VACCUM CONSIDERATIONS: The exchanger including the channel internals shall be designed for full vacuum when

specified.

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

3.6.4 All inlet and outlet nozzles shall be designed as self reinforced nozzles with integral flanges. 3.6.5 Exchanger shall be designed considering external loads due to piping. 3.6.6 Nozzle flanges of higher ratings which are not covered in ASME B16.5 shall be designed as

per ASME Sec. VIII Div. I. 3.6.7 Where units are stacked, the lower shell shall be designed to carry super-imposed load (full

of water) of the upper shell. The corrosion allowance shall be deducted from the shell thickness before determining the external loading. In addition to the normal design loads, exchangers shall be designed to withstand a horizontal pulling load of twice the bundle weight.

3.6.8 U-bend radius shall be 2 times the tube OD minimum. The minimum thickness at U-bend

after thinning shall not be less than the minimum thickness required by code. Tube thickness specified in data sheet for the exchangers is minimum to be adopted. Tube thickness if required for thinning allowances at U-Bend shall be increased.

3.6.9 Tube to tube sheet joint for all exchangers shall be strength welded. 3.6.10 Wherever applicable, longitudinal Baffle to tubesheet joint shall be full penetration weld with

groove in tubesheet. 3.6.11 HYDROSTATIC TESTS 3.6.11.1 Procedure for hydro testing of the exchangers designed with differential pressure shall be as

follows:

a) Pressurize only shell side to Q (A factor depending on code of construction) x differential design pressure x temperature correction factor as specified in ASME SEC. VIII DIV.1 (Clause UG-99 / DIV 2) and check tube to tube sheet joint and tube sheet to shell gasket leakage.

b) Pressurize only tube side to Q (A factor depending on code of construction) x

differential design pressure x temperature correction factor as specified in ASME SEC. VIII DIV.1 (Clause UG-99) / DIV 2 and check for tube to tube sheet joint leakage and tube sheet to shell gasket leakage.

c) Pressure both shell side and tube side simultaneously to Q (A factor depending on

code of construction) x design pressure x temperature correction factor on each side ensuring their differential pressure between the two sides, at no time to exceed Q (A factor depending on code of construction) times the differential design pressure corrected for temperature.

3.6.11.2 All vertical exchangers shall be tested in vertical position. Alternately, exchanger may be

tested in horizontal position with test pressure modified with prior approval of Designer. 3.6.11.3 Stacked exchangers with nozzles interconnected shall be hydro tested in stacked condition

except when the hydro test pressure of the individual exchanger is different. 3.6.12 Vendor shall supply required accessories for handling & maintenance including accessories /

attachments for shell/ bundle pulling and accessories required for dismantling of High-pressure channel internals of all exchangers. Vendor shall supply fixtures required for dismantling channel cover.

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

3.6.13 Vendor to supply one set of torque wrenches for bolt size M38 (1 ½ “) to M56 (2 ¼”) and a set of hydraulic bolt tensioner for bolt sizes greater than M56 (2 ¼”) in case these bolt sizes are being used in exchangers covered in the requisition.

3.6.14 SPARES. BOLTING : 20% set screws, studs and nuts but not less than 4 studs (with 2

nuts for each stud) for each joint. PUSH RODS : 100% push rods (In case of Screw plug / Breech Lock exchangers) SEALING STRIPS : 100% Lamiflex sealing strips as applicable. GASKETS : 400% gaskets other than those used for hydro-testing and

dispatch for each joint. Spare bolting and gaskets shall be provided for all joints of girth flanges, channel cover,

tubesheet, interconnecting nozzles, nozzles with blind flange etc. 3.6.15 Gasket Register for high pressure exchangers shall be maintained. All licensor requirements shall be complied with. However in case of any

contradiction same to be resolved in consultation with the Owner/PMC/Licensor.

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

3.7 AIR COOLED HEAT EXCHANGERS 3.7.1.0 THERMAL DESIGN CRITERIA 3.7.1.1 Design air temperature : � As per process package � As per basic engineering design basis 3.7.1.2 Type of Draft : Forced 0 3.5.1.1.2

TUBE MATERIAL

TUBE DIAMETER

TUBE THICKNESS

TUBE THICKNESS

FOR IBR TUBE LENGTH

Carbon Steel 25 2.77 2.77 8.5/10.5/12.5 m Stainless Steel 20 2.11 2.3 8.5/10.5/12.5 m High alloy Steel 20 2.11 2.3 8.5/10.5/12.5 m

Higher tube OD may be used where design constraints exist. 3.7.1.4 Tube Length (TL) : � If on piperack, TL = piperack width +

0.5m � If on technological structure, suitable

tube length shall be adopted. Note : Standard lengths are 8.5m, 10.5m and 12.5m 3.7.1.5 Fin Data : Aluminium “G” type (embedded) fins upto

4000C fin design temperature (maximum 9

fins/inch) 0 3.7.1.6 Width of bundle (Max.) : 3.0 m 3.7.1.7 Type of Header : Cover Type Header to be used for design pressure < 50 Kg/cm

2g and fouling resistance ≥

0.0004 Hr m2

0C/K.Cal. For all other cases and H2 service (H2 partial pressure > 7

kg/cm2g), plug type header to be used.

3.7.1.8 Split Header : If inter pass temperature difference

exceeds 1100C or if design temperature

exceeds 1800C.

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

3.7.1.9 Corrosion Allowance : 3mm for Carbon steel/Low alloy steel NIL for Stainless steel/High Alloy Steel (Note : Higher/lower value for CA to be considered if specified in process datasheet). 3.7.1.10 Provision of Louvre : � As per Process data sheet & P&ID. Auto-variable fans � As per Process data sheet & P&ID. Variable speed motors � As per Process data sheet & P&ID. 3.7.1.11 Maximum fan horsepower : 40 kW 3.7.2.0 MECHANICAL DESIGN CRITERIA 3.7.2.1 Bolting (except nozzle bolting) : � Metric � Inch 3.7.2.2 Construction of Header : � Plate 3.7.2.3 Minimum flange connection size (except

Multi-Purpose connection) : � 1 ½” NB

3.7.2.4 Construction of nozzles Upto 12” NB : From seamless pipe 14” NB and above : When made from plate, weld seam of

nozzle to be 100% radiographed 3.7.2.5 Nozzle Flanges : Forged weld neck. 3.7.2.6 Multi-Purpose connections : One on one of the inlet & one on one of the

outlets of each header size 1.5”NB flanged with BF, rating will be same as process nozzle. If it is not possible to provide on process nozzle then it shall be provided on header. One nozzle at inlet and one nozzle at outlet of the shell /channel box to be provided for hydro testing of the shell in addition to MP connection

Note : Any special recommendation regarding vent & drain connection shall be followed as

per process data sheet requirement/P&ID’s. 3.7.2.7 Tube to tubesheet joint : Expanded (into two grooves) upto design

pressure of 70 kg/cm2g for non lethal

service. : For design pressure above 70 kg/cm

2g and

for lethal service, tube to tubesheet joint shall be “Strength welded with contact expansion”.

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

3.7.2.8 Noise Level : The noise level shall be limited to 85 dB(A) max. measured at the header access platform walkways and one meter from the bay limit on motor maintenance platform. The noise level within the air cooler bay shall be 90 dB(A) maximum, at locations defined as per API.

3.7.2.9 Positioner for Autovariable fan : Integral type positioner shall be provided. 3.7.2.10 Loss of signal air to Auto fan : Blades of the fan shall lock in the

maximum flow condition unless specified otherwise.

3.7.2.11 Type of Drives (Speed Reducers) : HTD/PGGT of GATES or Torque Drive

Plus belts of FENNER, UK upto 40 kW. 3.7.2.12 Access Platform : Shall be provided wherever possible on all

the four sides, (width=900mm) with stair on one side and ladder on other side.

3.7.2.13 Maintenance Platform : Shall be provided full length for

fans/motors (min. width 1000mm). 3.7.2.14 Fan blade material : FRP 3.7.3.0 MISCELLANEOUS ASPECTS 3.7.3.1 Spares (Mandatory) : � 400% gasket for header cover &

nozzles � 200% gasket for plugs � 20% plugs � 100% belts, 100% bearings � One set of blade for each size/type

of fan � 20% bolts & nuts for all nozzle with

BF & cover plate � One set of diaphragm actuator with

positioner for each type of auto variable pitch fan

3.7.3.2 Spares(Additional) : � Additional fan spares (as per

supplier recommendations). � Motor spares (as per engineering

design basis) 3.7.3.3 Roof of bundle � Required

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

� Not required 3.7.3.4 Hot dip galvanizing of air cooler

structurals : Air cooler structurals shall be hot dip

galvanised for the following :- i. Plenum chambers, bundle frames. ii. Motor suspension structure, fan

guards, gratings for stairs and platforms.

iii. All bolts/nuts for structures. (Main structure and all other surfaces not

indicated above shall be given one coat of primer).

Note: Whenever hot dip galvanizing is used, additional hot dip coat shall be provided on

the surfaces. 1 3.7.3.5 Final Painting : All header boxes shall be finally painted as

per JE spec. at vendor’s shop. 3.7.3.6 Protective Covering (for finned tubes) on

bundle bottom/top : Yes

3.7.3.7 Vendor selection : � As per Bidder Qualification Criteria All licensor requirements shall be complied with. However in case of any


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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

3.9 PLATE HEAT EXCHANGERS 3.9.1.0 GENERAL REQUIREMENT 3.9.1.1 Plate heat exchangers shall be designed and fabricated as proprietory equipment meeting

the thermal, material and end connections requirement of the data sheet. Vendor shall be fully responsible for all aspects of design and construction of the plate heat exchanger as per the governing code.

3.9.1.2 End nozzles of the exchanger shall conform to ASME B 16.5 standard. Gasket surface for

the end connection nozzle shall be suitable for specified gasket compatible soft gaskets between the plate pack shall be provided by vendor meeting fluid compatibility requirement.

3.9.1.3 Endoscopy with VCR and camera control shall be supplied along with the equipment for

inspection of plate type heat exchangers. 3.9.1.4 Close circuit cleaning facility to be provided. 3.9.2.0 PROCESS REQUIREMENT 3.9.2.1 In general, the exchanger shall be a single pass, counter flow design to facilitate access to

the plate pack for maintenance. 3.9.2.2 The frame of the exchanger shall be designed to permit future installation of a minimum of

20% additional plates. 3.9.2.3 Ports shall be sized so that combined entrance and exit plus nozzle losses do not exceed

30% of the total pressure drop. 3.9.2.4 Vendor shall use the specified fouling factor. If it is not specified in the data sheet, he shall

indicate the fouling factor used by him in arriving at the offered design before award of contract.

All licensor requirements shall be complied with. However in case of any


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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

TABLE – 1 DETAILS AND WEIGHT OF COLUMN ATTACHMENTS

1. Shape factor for shell (for wind load

calculations) : 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. 1) Equivalent height of platform (for wind load

computation) : 1000 mm.

2) Shape factor for platform : 1.0 10. Weight of platforms : 100 kg/m

2.

11. Platform shall be considered as below: Top and bottom : All around Intermediate : Half

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 KxSxE KxSxE 0.90xY.P.xE

Longitudinal compressive stress K x B K x B B

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

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.

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:-

PRESSURE PARTS NON PRESSURE PARTS

DESIGN

TEMP.-C

PLATE

PIPE

(SEE NOTE

8)

TUBES,

SPACERS (SEE

NOTE-11)

FORGING

(SEE NOTE 12)

BOLTS/

STUDS/

NUTS

EXTERNAL

(SEE NOTE

13)

STRUCTURAL

ATTACHMENT

WELDED TO

PRESSURE

PARTS,

BAFFELS,

SUPPORTS,

TIE RODS,

SEALING,

SLIDING

STRIPS ETC.

INTERNAL

PIPES

STUDS BOLTS

NUTS

INTERNAL

TIE RODS

CRYOGEN IC

FROM

-254 UPTO

-196

SA240

GR.304L,

304, 316,316L

347 (IMPACT

TESTED)

SA312 TYPE

304

304L,316,

316L,347

SA213 TYPE

304 304L,316,

316L,347

SA 182,GR F

304,304L,316

347,316L

ABOVE

-196 UPTO

–80

SA240

GR.304L,

304,

316,316L

321,347

SA 353/553

GR.A

SA312 TYPE

304

304L,316,

316L,321,

347

SA333GR.8

SA213 TYPE

304 304L,316,

316L,321,

347

SA334 GR.8

SA 182,GR F

304,F304L,

F316L,316 321

347,

SA522

SA320 GR

B8,8C,8T

STRAIN

HARDENED

SA194GR.8,

8C,8T

SAME AS PRESSURE PARTS

SS GRADE

SAME AS

TUBES

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DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

LOW TEMP.

ABOVE

-80 UPTO -

60

SA 203 GR E

IMPACT

TESTED (SEE

NOTE-1)

SA333GR.3

SA334GR.3

SA350 GR.LF3

SA 320 L7

SA194GR.4

OR GR7

SA 203 GR E

SA333GR.3

SA193GR.B8 SA

194 GR.8

CS KILLED

ABOVE

-60 UPTO -

45

SA537CL.1

IMPACT

TESTED

(SEE NOTE-1)

SA333GR.3

SA334GR.3

SA350 GR.LF3

SA 320 L7

SA194GR.4

OR GR7

SA 537 CL.I

SA333GR.3

SA193GR.B8 SA

194 GR.8

CS KILLED

ABOVE

-45 UPTO

-29

SA 516 (ALL

GRADES)

IMPACT

TESTED

(SEE NOTE-I)

SA333GR.6

OR GR.I

SA334GR.6 OR

GR.I

SA350 GRLF2

SA 320

GRL7 SA194

GR.4 OR

GR7

SA-516(INALL

GRADES)

SA333GR.6

SA193GR.B8 SA

194 GR.8

CS KILLED

ABOVE

-29 UPTO

0

SA 516 (ALL

GRADES)

(SEE NOTE-

3)

SA 106 GR.B

(SEE NOTE

3)

SA334GR.6 OR1

(SEE NOTE 3)

SA105/ SA266

(SEE NOTE 3)

SA-193 GRB7

SA-194 GR2H

SA-516(INALL

GRADES)

SA 106 GR.B

SA-193GR.B8

SA-194GR.8

CS KILLED

INTERMEDIATE TEMPERATURE

ABOVE 0

UPTO 343

SA 516 (ALL

GRADES),

SA 240 TYPE

304L,316, 321

(SEE NOTE 4)

SA 106GR.B

SA-312 TP

304L, 316L,

321 SA-376

TP321

SA179,

SA 210 Gr. A1

SA-213 TP 304L

316L, 321

SA-105 SA-266,

SA182F

304L,316L,

321

SA-193B7

SA-194 GR2H

SA-193B7

SA-194GR2H

IS-2062

(PLATES)

SAME AS

PRESSURE

PARTS

SA 106GR.B

SA 106GR.B

SA-193GR.B7

SA-194GR.2H

SA-193GR.B8

SA-194GR.8

IS- 2062

(WELDABLE

QUALITY)

SAME GRADE

AS PRESSURE

PARTS

ABOVE

343 UPTO

427

SA 204GR.B

SA387GR11

CL.1/CL.2

SA 240

TYPE

304L,316L,

321(SEE

NOTE 4)

SA335GRP1

SA335

GR.P11

SA312 TYPE

304L, 316L,

321 SA376

TYPE 321

SA 209 GR T1

SA213 GR.T11

SA 213 TYPE

304L, 316L, 321

SA182GR.F1

SA182 GR.F11

SA182F 304L,

316L, 321

SA193GR.B7

SA194GR.4

SA193GR.B7

SA194GR.4

SA193GR.B7

SA194GR.4

SAME AS

PRESSURE

PARTS

SAME AS

PRESSURE

PARTS

SAME AS

PRESSURE

PARTS

SAME AS

PRESSURE

PARTS

SAME AS

PRESSURE

PARTS

SAME AS

PRESSURE

PARTS

SA-193GR.B8

SA 194 GR.8

SA-193GR.B8, B8M

SA 194 GR.8, 8M

SA-193GR.B8, B8T

SA 194 GR.8, 8T

C-V-, Mo

(COMML.

QLTY)

1%Cr.1/2Mo

(COMML.

QLTY)

SA479

Gr.304L,

316L, 321

ELEVATED TEMPERATURE

ABOVE

427 UPTO

538

SA387GR.11

CL.1/CL.2

SA387GR.12

CL.I/CL.2

SA335P11

SA335P12

SA213T11

SA213T12

SA182GR F11

SA182 GR.F12

SA193

GR.B16

SA194GR.4

SAME AS

PRESSURE

PARTS

SAME AS

PRESSURE

PARTS

SA-193GR.B8

SA 194 GR.8

V/»a-VMo

(COMML.

QTLY)

ABOVE

427 UPTO

500

SA 240

TYPE

304,316,321

(SEE NOTE

4)

SA312/

SA376 TYPE

304,316,321

SA213TP

304,316,321

SA182F304,

316,321

SA193

GR.B16

SA194GR.4

SAME AS

PRESSURE

PARTS

SAME AS

PRESSURE

PARTS

SA-193GR.B8

SA 194 GR.8

SA 193 GR. B8M

SA 194 GR. 8M

SA479Gr.

304L,316L,

321

ABOVE

538 UPTO

593

SA387GR.22

CL.1/CL.2

SA387GR.21

CL.1/CL.2

SA 335 P22

SA213T22

SA182GR F22

SA 336 GR

F22

SA193GRB5

SA194GR.3

SAME AS

PRESSURE

PARTS

SAME AS

PRESSURE

PARTS

SAME AS

PRESSURE

PARTS

2%Cr.1 Mo

(COMML.

QLTY)

ABOVE

500 UPTO

815

SA240

GR.304H,

316H 321H,

A312/ SA376

TYPE 304H,

316H, 321H

SA213 TYPE

304H,

316H,321H

SA182 GRADES

304H,

316H,321H

SA193GRB8

SA 194 GR.8

(STRAIN

HARDENED

)

SAME AS

PRESSURE

PARTS

SAME AS

PRESSURE

PARTS

SAME AS

PRESSURE

PARTS

SA479Gr.

304H, 316 H,

321 H.

NOTES

1.0 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.

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

of an austenitic stainless steel type which can not be hardened by heat treatment.

JACOBS



DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

3.0 Check for impact testing requirement as per UCS-66 for coincident temperature and part

thickness. 4.0 Selection of stainless steel material shall be based on process recommendation / process

licensor. 5.0 This table is not applicable for atmospheric / low pressure storage tanks. Materials shall be

selected as per API 650 / API 620 as applicable. 6.0 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.

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

consideration as per code. 8.0 All pipes shall be of seamless construction. 9.0 Non-ferrous material and super alloys are not covered above and shall be selected based on

specific recommendation. 10.0 Material for vessel / column skirt shall be the same material as of vessel / column shell for upper

part with a minimum of 500mm. 11.0 All tubes shall be of seamless construction. Materials used for IBR equipment shall meet all

requirements of Indian Boiler Regulations.

12.0 SA 336 shall be used for Heat Exchanger non-standard SS/LAS forgings.

13.0 Internal bolting shall be selected on the basis of shell side material solid or clad as follows:

SHELL MATERIAL STUD NUTS

Carbon steel &up to 1% Cr. ASTM A 193 Gr B-7 0 ASTM A-194 Gr 2H 0

5% Chrome A 193 Gr B5 A 194 Gr 3

13% Chrome A 193 Gr B6X A 194 Gr 6

Stainless Steel A 193 Gr* A 194 Gr*

For low temperatures, min. quality of bolting material shall be as specified for external bolting and shall be improved if shell side materials are better.

* Compatible / same grade of SS. All licensor requirements shall be complied with. However, in case of any contradiction

same to be resolved in consultation with the Owner/Jacobs

JACOBS



DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

SECTION B

TRAYS AND TOWER INTERNALS

JACOBS



DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

1.0 INTENT

1.1 The intent of this specification is to define basis to be followed for Mechanical Design, engineering,. fabrication, inspection/testing, supply and installation (inside the columns at site) of Trays, Packed Column Internals and Tower Packings separately and collectively known as "Internals". For licensed units, in case the requirements specified here are in conflict with licensor's specifications, licensor's requirements shall govern.

1.2 In case of any conflict between various documents, resolution shall be in accordance

with the following order of preference:

• Data Sheets/P&lD's/Design Basis

• Job Specifications

• Standard Specifications/Engineering Standards.

2.0 PROCESS PARAMETERS, DESIGN CONDITIONS & SELECTION OF

INTERNALS

As per Process Datasheets

3.0 USAGE OF EXISTING INTERNALS

For revamp jobs, all "As-Built" drawings of Columns, Tray/Internals as well as Tower Attachments shall be provided by Client, which shall be the basis of revamp to be

JACOBS



DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

carried out by Jacobs. However in case drawings provided by Client are not "As-Built", same shall be treated as base document for proceeding further with engineering. Wherever drawings of existing internals are not available, new internals will be considered including replacement of existing support ring/bolting bars to suit the new configurations.

All existing internals found adequate with/without any modifications will be retained presuming:

(a) All such internals are in good physical conditions and can be retained.

(b) All the existing internals are in good physical condition to permit partial

modifications as necessary to make it suitable for revised conditions.

(c) No mechanical design checks of existing internals being retained will be

carried out unless explicitly asked/required by Client based on operating feed

back.

4.0 DESIGN

4.1 Materials

4.1.1 All materials shall conform to those specified in the respective process drawings or data sheets.

No substitution of material will be permitted without the written consent of Owner/Jacobs in required formats as per procedure. In case substitution of material is proposed, vendor shall clearly indicate the reasons for requiring such change and give chemical and physical properties of the proposed alternate material with their standard specification number.

All the material supplied by vendor shall be new and of first quality supported with mill

test certificates.

Unless specified in data sheets, Material shall be as per clause from 4.1.2 to 4.1.7.

4.1.2 13 Cr Stainless Internals.

All sheet and plate material shall be in accordance with SA 240 Type 410S or 410

or 405 having No.1 finish only for thickness more than 4mm. For thickness up to and

including 4 mm, No. 2B/2D finish is also acceptable.

All bolting material shall be SA 193 Gr B6X or B6 for bolts and SA 194 Grade 6 for nuts and lock-nuts.

4.1.3 18 Cr - 8Ni Stainless Internals.

All sheet and plate material shall be in accordance with SA 240 Type 304 having No.

1 finish only for thickness more than 4mm. For thickness up to and including 4 mm, No.

2B/2D finish is also acceptable.

AH bolting material shall be SA 193 Gr B8 for bolts and SA 194 Gr B for nuts and lock-nuts.

4.1.4 Monel Internals

JACOBS



DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

All sheet and plate material shall be in accordance with SB127 in hot rolled, annealed

and pickled condition.

All bolting material shall be Monel, made from rod or bar stock, SB 164.

4.1.5 Carbon Steel Internals

Unless otherwise specified, sheets and plates shall be procured in hot rolled conditions and shall be free of mill scale. Material shall be suitable for bending. The bend test specimens shall stand being bent cold through 180 degree without cracking on outside of the bent portion, to an inside diameter equal to or less than twice the thickness of the specimen or as per relevant material specification, whichever is severe. All sheet, plate material shall conform to SA285, SA283 or better unless specified otherwise on the data sheets/drawings.

All fasteners including clamps, material shall be as per clause 4.1.2 above, unless

specified otherwise.

4.1.6 Gaskets

Trays gasketing material shall be woven tape, fabricated from Asbestos Free Material such as Woven Fiber-glass Tape (Amatex-G36-P752 or equal), Woven Teflon Tape, Woven Expanded Graphite Tape or Ceramic Fiber Tape etc. and shall be suitable for process fluid and column design temperature, unless specified otherwise in the Data Sheets/Purchase Specifications. The thickness of the woven tape shall be 1.5 mm minimum. The use of Woven Asbestos Tape or Wire shall be subject to JACOBS/Owner's prior approval only.

4.1.7 Support Rings/Bolting Bars/Support Cleats

Support rings, downcomer or up comer bars and other parts welded to vessel shall be of same metallurgy as that of vessel. Minimum thickness excludine corrosion allowance of welded parts shall be 6 mm for vessel diameter up to 3000 mm and 10 mm for higher diameter. Corrosion allowance as specified in vessel data sheets shall be added on both sides of Support Ring, Bolting Bar and other welded parts.

4.2 Thickness of Internals

4.2.1. Minimum thickness of lnternals:

Corrosion allowance, wherever specified in the data sheets for Intemals in excess of corrosion allowance as indicated in clause 4.2.2 shall be added to the minimum thickness specified below:

Alloy CS

i) Deck plates, seal pans, draw-off Pans, weirs/seal plates, other removable Components

2.0 3.5*

ii) Welded deck plates, downcomer aprons and other

welded components 3.0 3.5*

JACOBS



DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

iii) Downcomer/Internal pipes 2.0 3.5*

iv) Bubble Caps 1.6 2.0

Risers (fixed) 2.0 3.5*

Risers (removable) 1.6 2.0

v) Valves

1.6 (will not be used)

vi) Structured Packings 0.15 (will not be used)

vii) Support Grid for Structured Packings 5.0 8.0

viii) Locating Grid/Retaining Grid/Bed Limiter 5.0 8.0

ix) Grid Packings

(a)Bottom-most layer 5.0 8.0

(b)Next Five Layers 2.0 (As per vendor’s standard)

(c)Balance Layers 1.6 (As per vendor’s standard)

x) Random Packings (As per vendor’s standard)

xi) Loose Beams To suit Load

To suit Load

xii) Lattice Girders

(a) Primary Members 5.0 6.0

(b) Secondary Members 3.0 4.0

(c) Gusset Plates 10.0 10.0

(d) Downcomer bolting bars 5.0 10.0

xiii) Z-Bars 5.0 8.0

(*10 USSG is also acceptable in lieu of 3.5 mm)

All bolting shall be minimum M10 for Internals and M16 for Lattice Girders. All bolt head/nuts shall be hexagonal.

JACOBS



DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

Minimum corroded thickness of the internals for the loading condition as

per Clause 4.3.3. (i) and (ii) below, shall be 3.0 mm.

4.2.2 Corrosion Allowance

The following corrosion allowance shall be added to calculate thickness of Internals

unless otherwise specified on data sheets or bid specification.

i) No corrosion allowance is required for Monel or Stainless steel alloy assemblies.

ii) The corrosion allowance for all surfaces of floor of Carbon Steel assembly shall

be 1.5 mm (total).

4.2.3 Unless specified on the data sheets or bid specifications, corrosion allowance shall be higher of 1.5 mm (total) or one quarter of the vessel corrosion allowance on each surface of trays and its components.

4.2.4 Beams, trusses and other support members shall have total corrosion allowance equal to vessel corrosion allowance for removable type construction and twice the vessel corrosion allowance for non-removable type construction through vessel man-hole.

4.3.0 Design Loadings

4.3.1 Design loads for tray assemblies shall be based on a liquid height of 50 mm liquid above weirs plus self weight of deck plates and beams or live load of 150 kg/m

2

whichever is severe. In case liquid density is less than water, 1000 kg/m3 shall be

considered for purpose of calculating liquid load.

4.3.2 Under-down-flow plates and seal pans shall be designed to withstand a weight of liquid equal to half the normal tray spacing (excluding the locations where tray spacing has been increased to accommodate manholes/feed pipes etc.) or 300 kg/m

2 whichever is

severe plus self weight of udf plates and beams. In case liquid density is less than water, 1000 kg/m

3 shall be considered for purpose of calculating liquid load.

4.3.3 Five trays above/below 2-phase feed inlets and in bottom zone of column wherever process steam or two-phase feed is admitted shall be provided with lock nuts. These trays shall be capable of sustaining a net thrust of

i) 1465 kg/m2 and with shear clips for Vacuum Columns.

ii) 1000 kg/m2 and with shear clips for Crude Column/Main Fractionator Columns.

ii) 450 kg/m2 for all other services

4.3.4 One tray above and below the intermediate vapor/liquid feeds shall also be provided with locknuts.

4.3.5 The packing support plate shall be designed to support the maximum expected load of tower packings, liquid hold-up (min 10 percent). In case of liquid density is less than water. 1000 kg/m

3 shall be considered for purpose of calculating load due to liquid

hold-up.

4.3.6 Bed limiters frame shall be strong enough to take care of surges/uniformly distributed load of 100 kg/m

2 and 135 kg concentrated load at any point.

JACOBS



DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

4.3.7 Hold down plate shall exert sufficient static load on the bed to restrict movement of the packing. The hold down plate shall be designed for exerting a load of 100 kglm

2

minimum on the packed bed.

4.3.8 Liquid distributors/Redistributor shall be designed for self weight plus maximum expected liquid load.

4.3.9 All Internals assemblies except cartridge tray assemblies shall be able to withstand the self-weight plus the following number of 135 kg concentrated loads (maintenance loads) at ambient temperature.

Vessel Diameter Number of 135 kg loads

Up to 1200 mm 1 (at center of diameter)

Up to 3600 mm 2 (at center and 1/4 point of diameter)

Over 3600 mm 3 (at center and 1/4< points of diameter)

4.3.10 Design loads for Chimney/Collector trays shall be based on dead weight plus live load of liquid height equivalent to riser height or 50mm more than weir height. In case liquid density is less than water, 1000 kg/m

3 shall be considered for purpose of

calculating liquid load.

4.3.11 For Chimney trays, layout shall be made in such a way that there will be adequate space available on the tray for a person to get inside and attend to erection of upper trays. Vendor shall check the constructability of all trays with respect to location of man ways, location of

down comers and space availability. 0

4.4 Allowable Stress and Deflection

4.4.1 Allowable stresses for all Internals shall be as per ASME Sec. II. Part D, latest edition.

4.4.2 The maximum deflection of tray/tower internal assembly shall not exceed 1 mm per meter of column diameter or 7.5 mm, whichever is lower for the design loadings given in clause 4.3.1 and 4.3.2 above. Deflection for distributor assembly shall be limited so that overall liquid maldistribution does not exceed the limit as per clause 4.5.18(v). Deflection for support plate and seal pans shall be limited to U400, where L is the length of individual component.

4.4.3 Deflection as per clause 4.4.2 may be ignored for trays designed based on design loadings as per clause 4.3.3 and 4.3.9.

4.4.4 For large diameter vessels, initial camber may be made in the principal support members of the assemblies so as to limit the deflection as specified in clause 4.4.2 above.

4.5 Arrangement/Details of Internals

4.5.1 All assemblies except one piece cartridge type trays for column ID less than or equal to 750mm shall be of removable type unless otherwise indicated. The general design, number, type and spacing shall be established on the individual vessel drawing/data sheets. Cartridge type trays shall be designed to rest on four support cleats.

4.52 Each removable section shall be so dimensioned / sized to permit passage through vessel manhole and shall be suitable for assembly/ dismantling from upper side in so far as structural contingencies permit. Maximum diagonal dimension of the components shall be restricted to vessel manhole ID - 12mm clearance.

JACOBS



DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

4.5.3 Internals support trusses supporting more than one Internal, as are commonly used in large diameter columns and which cannot be installed through manholes, shall be split into sections for access through manhole and minimizing welding work inside the column.

4.5.4 Internals decks shall have a maximum length of 3000 mm. To achieve this maximum distance between main support beams or girders shall be limited to 3000 mm. However, the main support beams or girders having length more than 3000 mm shall be provided with one butt joint with splice plates of the same thickness as the main member up to 6000 mm length and two butt joints with splice plates of the same thickness as the main member for more than 6000 mm length and so on. The butt joint shall be provided inclined at 45 degrees.

4.5.5 Man ways

i) One man way in single cross flow decks, two man way in double flow decks ' and so on shall be provided. These man way shall be freely removable from top and bottom. Man way shall be in the same vertical line for a set of trays. These shall be at such a location and of a shape and size to permit easy access to every area of the tray. Man way of different set of trays (about 20 trays) shall be staggered to each other. Minimum clear opening on tray shall be 380mm x 450mm. In case same can not be provided due to design conditions, minimum man way size (clear opening) of 360 x 500 or 330 x 550 can be accepted as a special case.

ii) Where man way cannot be provided, decks shall be split (turn-up - turndown) to provide suitable access for Inspection and assembly from top as well as bottom.

4.5.6 Unless specified otherwise, support rings, bolting bars, support bracket/cleats when required, shall be designed for welding to the vessel. All other parts shall be designed for bolting or clamping in place. Clamping shall be used on Tray floor and all downcomer/up-comer shall be through bolted.

Spacing of bolting or clamping shall be close enough to ensure optimum liquid tight construction but shall not exceed 125 mm on deck portion in downcomer area/liquid holding area/downcomer apron bolting etc. and 150 mm in active area. All joints and seams of trays specified to be liquid tight without gasketted joints shall be seal welded at site. Maximum spacing for clamps/bolting for gasketted construction shall be restricted to 100 mm. For revamp jobs, use of Z-Bars shall be maximized to minimize welding/cutting of TSR/BB on the shell, wherever possible.

4.5.7 Drawings and instructions for installation and fabrication of support ring, bolting bar and support bracket/cleats welded to vessel shall be furnished by Internals supplier. They shall show clearly the type, size and extent of welding. All support rings and bolting bars shall be continuously welded on both sides. All support brackets shall be welded all around.

4.5.8 Gasketting need not be used in the design or installation of Internals except for bubble cap trays, all liquid holding portions (e.g. seal pans, draw-offs), collector trays, distributors and redistributors. Fabrication shall provide tight metal-to-metal joints. Metal seal plates shall be used to close construction joints where necessary.

JACOBS



DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

4.5.9 All stiffeners and support members shall be located on the underside of the tray floor with the exception of open type trusses supporting two trays. Stiffeners and support members in {\ areas shall not exceed 75 mm in width and shall be designed so as not to impede or channel the liquid flow on the tray. Depth of stiffeners and support members transverse and parallel to the liquid flow shall not exceed 20 and 30 percent respectively of tray spacing.

4.5.10 A minimum of 20 mm overlap shall be provided between tray floor section and support members.

4.5.11 Trays and seal pans not specified to be liquid tight, and of a design which would not easily drain shall be provided with one or more 12mm diameter/square drain holes/slots located in the outlet weir directly above the tray flow. Size and number of drain hole/slot may be reduced depending upon liquid rate. Draw off sumps shall be located flush with the invert inside of draw off nozzles to allow complete draining of sumps.

4.5.12 All the three (3) and four (4) pass trays shall have pressure equalizing pipes (vent tubes) across the downcomers.

4.5.13 Bubble Cap Trays Risers Fixed risers shall be used unless otherwise specified in the data sheets. Riser shall be expanded into upward flanged opening in the deck plates and then stitch welded to

upturned edges of the opening. Always riser shall not be welded to the bubble cap. 0 Bubble Cap

Bubble caps are to be furnished in Full Annealed and scale free bright condition.

4.5.14 Valve Trays

Valve assemblies of proprietary trays shall be provided with following features.

i) A means of preventing the orifice covers from adhering to tray floor.

ii) A means of preventing the orifice covers with integral guide legs and lift stops from popping out of place during operation.

4.5.15 Sieve Trays All perforations shall be punched and made from top side and burr side on tray decks must be downwards when installed, unless specified otherwise. In case of liquid-liquid extractor column trays, punching direction shall depend on the direction of liquid flow of continuous phase.

4.5.16 Burrs shall be removed from all perforated areas and edge of internal sections.

JACOBS



DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

4.5.17 Distributors/Redistributors Distributors of liquid feed to packed beds, unless otherwise specified in data sheets, shall be gravity flow type (e.g. orifice drip trays, tubed drip trays, trough type, orifice header laterals) in accordance with following requirements:

i) Orifice for liquid distributor shall preferably be minimum 8.4 mm diameter and shall

be arranged on an approximate equal spacing throughout the distributor. Distributor supports shall be designed and arranged so as not to interfere with flow from orifices.

In case orifice diameter calculated is less than 8.4 mm, then antifouling covers shall be provided on each orifice. Orifice below 6mm diameter shall be preferably provided at an elevation in drip tube or in side of trough with guide tubes.

ii) Vapor risers shall have a total cross sectional area as per Vendor's design but not less than 15 percent of vessel cross sectional area. Number, size and arrangement of vapour risers shall be such so as not to affect the orifice spacing and liquid distribution to the packings.

iii) Distributor joints shall be gasketted to be liquid tight. Gasket material used shall be

suitable for service and soft enough for leak tight joint.

iv) iDistributor shall be capable of performing satisfactorily for the range of loadings specified to cover entire range of plant operation.

v) Flow variation from orifice to orifice shall not be more than 10 percent at turndown

condition.

vi) Feed pipe shall form part of Distributor supply.

4.5.18 Packing Support Plate Packed bed support plate shall be vapor-injection type, providing separate passage for liquid and vapor flow. The support plate shall have at least 90 percent free area based on cross sectional area of vessel. Slot size shall be so selected to avoid any sneak through of packings from slots.

4.5.19 Bed Limiters/Bed Retainers

Bed Limiters/Bed Retainers shall be located just above top of packings to avoid fluidizing of bed and shall be fixed in position so as not to be moved by the packings and shall be designed so as not to affect distribution from the liquid distributor to the packings. Bed Limiters/Bed Retainers for use with spray nozzle distributor shall be designed with major structural support on the underside of the retainer so as not to affect the spray distribution on the packings. Expanded metal with equal opening area is also acceptable in lieu of wire mesh.

4.5.20 Hold Down Plates

Hold down plates shall be provided on the top of ceramic or carbon tower packings. The hold-down plate shall directly rest on the bed without any support cleats. Hold-down plate shall exert sufficient static pressure on the bed to restrict movement

JACOBS



DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

of the bed. Care shall be taken not to use hold-down grid with metallic or plastic tower packings.

4.5.21 Flash Feed Distributor

Flash feed distributor for flashing or mixed phase, vapour and liquid feeds to packed bed shall be designed to separate the two phases and distribute the liquid phase on distributor/redistributor. If flashing feed gallery is used, riser area shall be 50% of vessel cross sectional area.

4.5.22 Tower Packing

If type of packings is not specified in the process data sheets, following shall be taken as guidelines:

i) For wash zone of vacuum column, Grid Packings shall be used. ii) For all other applications preferably Pall Rings shall be used. If pall rings are

not expected to perform to desired performance, proprietary random Packings like Intalox saddle of Norton/Koch-Glitsch or similar.

iii) If structured packing has been specified, it shall preferably be from the identified source

4.5.24 The maximum allowable pressure drop for a packed bed shall include packed

bed support, bed limiter and distributor.

5.0 FABRICATION AND SUPPLY

Tolerances

All sections shall be truly flat within 2 mm and shall be tree from burrs and welds spatters.

Tolerances wherever unspecified shall be taken as ±1 mm and not to be accumulative, except on thickness and assembly diameter. Tolerances on thickness shall be as per applicable specification and tolerances on assembly diameter shall be as below:

5.2.0 Welding

5.2.1 All welding shall be done by metal arc welding. For welding on thinner gauge sheets TIG welding is preferred.

5.2.2 Gas or Carbon arc welding shall not be used.

JACOBS



DOC.NO. 44LK5100-00-V.02-0001-A4 Rev. 0

5.2.3 Welding electrodes of composition similar to Internals material shall be used except austenitic electrodes of higher chromium and nickel content such as AWS A5.4, ASME SFA 5.4 class E309 and E310 may be used for 12Cr stainless steel. For dissimilar material welding, electrode composition shall be similar to nobler material being welded. Following electrodes shall be used unless specified otherwise:

E 7018 for all CS materials

E308 for all SS 304 to SS 304

E 308L for all SS 304L to SS 304L

E 309MoL for SS 410S to SS 410S, SS to CS, SS 410S to SS 304, 304L,316, 3l6L

E316 for all SS316

E316L for an SS316L

E Ni Cu7 for Monel to Monel and Monel to CS/SS

5.2.4 Welding wherever specified, is to be done by qualified and approved welders using the suitable fillers and fluxes recommended for the materials in the fabrication drawings. For welding the stud on tray decks and support beams, use of stud welding gun with suitable flux is acceptable. In manually welding the studs, care should be taken to minimize the weld spatter and the outside diameter of the weld so that it should not foul with tray deck or washer. For stud welding, proper welding procedure shall be established. Torque required for welding failure shall be higher than the torque required for failure of the stud.

5.2.5 A proposed Welding Procedure Specification (WPS) shall be submitted to AlA for his approval. On approval, a Procedure Qualification Test (PQT) shall be conducted which shall be witnessed by AlA. On acceptance of all tests as per ASME Section IX, a final WPS along with Procedure Qualification Record (PQR) shall be submitted. Production welding shall start only after approval of final WPS/PQR and qualification of welders as per ASME Section IX. AlA may accept previously qualified WPSIPQR at his sole discretion.

5.3 Miscellaneous

5.3.1 All parts fabricated shall be smooth, true, clean and free from burrs, grease and dents. Openings for passage of workman must have exposed edges rounded.

5.3.2 All support rings, bolting bars, beams support brackets and other components which are integral and therefore welded to the column shell inside, shall be supplied and installed by column fabricator.

5.3.3 Total draw-off trays shall be designed for zero leakage construction and may be seal welded (if required) at site to attain zero leakage.

5.3.4 Seal welds shall have a throat thickness at least equal to the specified corrosion allowance.

5.3.5 All stainless steel tray assemblies/internals and their components (e.g. Bubble caps, valves etc.) shall be pickled and passivated. Pickling and Passivation shall be as per ASTM 380.

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5.3.6 All parts shall be fabricated in accordance with good shop practice and in uniformity so that all corresponding parts will be inter-changeable.

5.4 Spares

Following spares shall be included as part of the supply:

5.4.1 Constructional Spares

The supply shall include the following as constructional spares:

Bolts/Nuts 10% of total for each size

(Minimum 10 nos. of each size)

Clamp assemblies 10% of total for each type and size

(Minimum 10 nos. of each size)

Valves for trays 5% of each type

Bubble caps 5% of each type and size

Gasketing or tapes 100% of each type and size

Sealing foils for 200% of each size

cartridge trays

V-clamps 10% of each type and size or 10 nos. whichever is

minimum

Tower Packings 10% for Metallic and Plastic Packings

(Only random packings) 15% for Carbon and Ceramic Packings

Spray Nozzles Up to 25 Nos. (of each type)- 100%

More than 25 (or each type) - 25%

(subject to minimum of 25 Nos.)

5.4.2 Vendor shall submit list of spares recommended for two years of satisfactory operation.

However, following operational spares as a minimum shall be supplied as Mandatory

Spares:

i. Valves for Trays - 10% of each type ii. Bolts/Nuts - 10% of total for each type/size

(minimum 10 nos. of each size) iii. Clamp Assemblies - - do - iv. Gaskets or Tapes - 100% of each type and size v. Sealing foils for Cartridge Trays - 200% of each size vi. Spray Nozzles - 25% subject to minimum 5 Nos. of

each type and size. vii. Tower Packings - 5% of each type and size. (Only

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Random Packings)

If desired by owner, item wise price for above spares shall be furnished after award of the job.

6.0 INSPECTION AND TESTING

6.1 General

6.1.1 The materials, fabrication, testing and trial assemblies are subject to inspection by Owner/JACOBS, at shop floor before shipment and during installation.

6.1.2 Any rejection made by Inspector shall be final. Approval/Inspection by Jacobs/Owner and/or their designated representative shall in no way relieve the Vendor of his responsibility to meet all the requirements of the Purchase Order.

6.1.3 Owner/Jacobs authorized Inspector shall have free entry to the Vendor's shop at all times where and while the work is being performed. The Vendor shall offer the inspectors all reasonable facilities to satisfy them that the materials are being furnished in accord3nce in accordance with the specifications.

6.1.4 Vendor shall notify the Owner/JACOBS sufficiently in advance of any fabricating operations to permit the Inspector to arrive at the Vendor's shop.

6.2 Stage Inspection during Fabrication

6.2.1 Dimensions

The inspector will check that the thickness and the dimensions of all parts for the Decks, Weirs, Seal and Draw off pans, Down comers, Draw off pipes, Supports, Beams, Valves, Bubble caps, Clamps, Studs, Bolts, Nuts, Risers, Washers and Gaskets etc. are as per the approved drawings.

6.2.2 Fabrication

The inspector shall check each individual part of the equipment fabricated as per approved drawings and specifications. For instance, for the Bubble cap dimensions, height, width and number of slots, heights, O.D. and I.D. or riser and cap, shroud ring height, exit and inlet weirs height etc. shall be measured. The inspector will check that all identical parts shall be interchangeable.

Inspector shall check that the sharp edges on the internal components; man way covers, weirs, downcomers etc. are properly removed. Also that all burrs from punched holes and loose weld slags and materials are removed from all components. Stage-wise inspection during fabrication will be thoroughly carried out.

Before starting welding, welders' qualification test will be carried out, if required, as per ASME Sec. IX. Where numbers of similar items are to be made, inspector shall give the clearance for the fabrication of the lot only after checking and approving the first sample piece.

6.3 Trial Assembly

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Trial assembly of one tray of each type and size with its accessories shall be carried out inside the fabricators' shop as floor mock-up. The components for such an assembly will be taken at random from each lot of identical items.

The assembled tray will be carefully checked for its dimensions, tolerances, number and arrangement of perforation, the working of the valves in case of valve trays, V-notch or Blocked Weir, adjustability of weir, vent tube details, downcomer clearance, weir heights, downcomer length and width, number of clamps, gaps and potential leakage points etc.

The assembly shall also be checked for each type and size of packed tower internals.

Inspector will also check the flatness and deflection of the trays, internals, beams, tray edges and beam ends clearance.

Leak Testing

Bubble cap, Collector trays, Liquid holding portion of other trays such as Seal pans, Recessed 'seal pans, Draw off pans, Distributors/Redistributors shall be subjected to leakage test at shop floor (by internals vendor) and in the field (by installation contractor) by filling water up to weir level or up to normal liquid level as the case may be.

However, in case site installation of these is also included in internals vendor's scope of work, leak testing at shop floor for items in single piece construction is not required. Appropriate ring fixture or a portion of column shell with supports for seal pan/recessed seal pans/draw off box etc. shall be made by Internals Vendor to facilitate leak testing in the shop.

Leak testing shall be carried out with service gaskets and drain holes temporarily plugged.

All distributors/redistributors shall be leak tested with all holes temporarily

plugged. It shall be ensured that leakage is uniform and not from few concentrated

places/corners. All plugs shall be removed after leak testing is over.

Leakage rate shall not exceed 0.5 percent of design liquid flow rate unless

otherwise specified.

6.5 Distributor Testing -

6.5.1 Vendor's Proprietary Liquid distributors/redistributors shall be water tested in the vendor's shop only by the following procedure at 50%, 100% and 110% of the design liquid volumetric flow rate. The vendor shall certify to the purchaser at the time of bidding that they believe their equipment can meet the testing requirements listed below:

(i) If the distributor contains a pre-distributor, it shall be tested first to ensure that it has a CV of 5 or less at the design flow rate. Each orifice in the pre-distributor shall be tested. The CV is defined as the ratio of the standard deviation to the sample mean, expressed as a percent.

(ii) The distributor/re-distributor itself shall be tested and the CV determined. To determine the CV, at least 30 pour points or at least 10% of the pour points

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(whichever is higher) shall be randomly selected and tested. If the CV specified below cannot be met, the vendor will correct the problem at its expense.

(a) For orifice pans, tubed drip pans and other similar devices, a CV of 10 or less must be achieved at the design liquid volumetric flow rate.

(b) Four orifice parts, tubed drip pans or trough distributors that employ a modular (sectional) design, (wherein many pieces are geometrically identical) all pieces of the same geometry shall be treated as one group or strata. One piece from each strata shall then be tested by the procedure outlined above.

(c) The average flow rate per pour point for any grouping of 10 of the tested pour points from a single area should differ by no more than 5% from the average for the group or strata being tested.

(d) The test results shall be furnished to Jacobs/Owner in a written report. This report shall also contain a drawing of the distributor in plan view. This drawing shall be broken down into 3 radial zones of equal area and the location of pour points sampled in each zone.

In case vendor can demonstrate procedure establishing above quality requirements, performance testing of distributors can be waived off.

6.5.2 SPRAY NOZZLE DISTRIBUTORS

Spray nozzle distributors shall not be tested in the vendor's shop but must be tested in

the tower prior to start-up to ensure that all nozzles are operable and develop the

desired spray pattern. This test shall be carried out as close to design rates as possible.

SPRAY NOZZLES

Apart from the usual material quality tests (chemical analysis and mechanical properties) and manufacturing quality control tests, vendor shall include for & carry out the

testing of the spray nozzles with respect to the flow rates for specific ∆P, spray angle, spray coverage and distribution for the tip distance given in the data sheet. The testing medium shall be water. These results shall be, submitted to Owner/JACOBS for review. Tests and acceptance criteria is as below:

Flow rates - ±5% for specific ∆P Spray angle - ±50 Flow variation - As per vendor's Standard. (Data to be reported for

Information) No. of nozzle to be tested - 10% of each size and type. (Min. 2nos. of each

type & size)

7.0 SITE INSTALLATION AND SUPERVISION

For revamp jobs, cutting & removal of existing attachments, welding of new attachments inside the existing columns and installation of new internals shall preferably be done by column internals supplier. Alternatively, all these activities can be included in the scope of Mechanical Contractor (covered in separate mechanical tender) to have single point responsibility for complete Site Work. In such a case all

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such modifications, installation shall be carried out under the supervision of Internals supplier so as to ensure guarantee of performance of column internals by supplier.

For new columns, installation of internals shall be done by column internals supplier only.

hindustan petroleum corporation ltd....

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