Surface Production Operations: Volume 5: Pressure Vessels, Heat Exchangers, and Aboveground Storage Tanks: Design, Construction, Inspection, and Testing

Surface Production Operations

Pressure Vessels, Heat Exchangers, and Aboveground Storage Tanks: Design, Construction, Inspection, and Testing

First Edition

Maurice Stewart

Table of Contents

Cover image

Title page

Copyright

Dedication

Preface

Acknowledgments

1: Engineering principles

Abstract

1.1: General overview

1.2: Basic principles

1.3: Stress analysis

1.4: Discontinuity stresses

1.5: Fatigue analysis

1.6: Thermal stresses

2: History and organization of codes

Abstract

2.1: Overview and objectives

2.2: Pressure vessels and equipment

2.3: History of pressure vessel codes in the United States

2.4: Organization of the ASME Boiler and Pressure Vessel Code

2.5: Organization of Code Committee

2.6: Updating and interpreting the Code

2.7: ASME Code stamps

2.8: Organization of the ASME B31 Code for pressure piping

2.9: Some other pressure vessel codes and standards in the United States

2.10: Worldwide pressure vessel codes

2.11: ASME Code, Section VIII, Division 1 versus Division 2

2.12: Design criteria, ASME Code, Section VIII, Division 1

2.13: Design criteria, ASME Code, Section VIII, Division 2

2.14: ASME Code, Section IX: Welding

2.15: ASME Code, Section I, Power boilers

2.16: Additional requirements employed by users in critical service

3: Materials of construction

Abstract

3.1: Overview

3.2: Material selection

3.3: Nonferrous alloys

3.4: Ferrous alloys

3.5: Heat treatment of steels

3.6: Brittle factors

3.7: Hydrogen embrittlement

4: Materials selection for pressure vessels

Abstract

4.1: Overview

4.2: Selection of materials for service conditions

4.3: Selection of materials to prevent brittle fracture

4.4: Guidelines for preventing brittle fracture in existing equipment

5: Mechanical design of pressure vessels

Abstract

5.1: Overview and objectives

5.2: General considerations

5.3: Owner’s, user’s, and manufacturer’s responsibilities

5.4: Determining design conditions

5.5: Mechanical design

6: Fabrication, welding, and in-shop inspection

Abstract

6.1: Overview

6.2: Plate materials

6.3: Forming of shell and head components

6.4: Nozzles

6.5: Fabrication welds

6.6: Welding processes and procedures

6.7: In-shop inspection

7: In-service inspection by nondestructive examination (NDE)

Abstract

7.1: Overview

7.2: General considerations

7.3: Design for inspection

7.4: Code and jurisdiction requirements

7.5: Forms of deterioration

7.6: Analysis of in-service inspection data

7.7: Fitness-for-service analysis

7.8: Nondestructive examination techniques

8: Repair, alteration, and re-rating

Abstract

8.1: Overview

8.2: Code and jurisdiction requirements

8.3: Repairs

8.4: Alteration

8.5: Re-rating

9: Heat transfer theory

Abstract

9.1: Overview

9.2: Objectives

9.3: What is a heat exchanger?

9.4: Fouling

9.5: Process specification

9.6: Information needed for specifying work

9.7: Deliverables from the supplier

9.8: Evaluating designs

9.9: Economic pressure drop and velocity

9.10: Basic heat transfer theory

10: Heat exchanger configurations

Abstract

10.1: Overview

10.2: Shell-and-tube exchangers

10.3: Double pipe exchangers

10.4: Plate-fin exchangers

10.5: Plate-and-frame exchangers

10.6: Indirect-fired heaters

10.7: Direct-fired heaters

10.8: Air-cooled exchangers

10.9: Cooling towers

10.10: Other types of heat exchangers

10.11: Heat exchanger selection guidelines

11: Tubular heat exchanger inspection, maintenance, and repair

Abstract

11.1: Overview

11.2: Asian, European, and North American Nondestructive Testing Societies and related organizations

11.3: Evaluating and inspecting heat exchangers

11.4: Tubular exchanger inspections

11.5: Most likely locations of corrosion

11.6: Shop work

11.7: Shop inspection

11.8: Nondestruction examination

11.9: Minor repairs

11.10: Major repairs

11.11: Hydrostatic leak testing

11.12: Hydrostatic leak testing

11.13: Baffles and tube sheets

11.14: Heat exchanger bundle removal

11.15: Bundle removal procedures

11.16: Tube bundle removal

11.17: Shell repair

11.18: Heat treatment

11.19: Double-pipe exchangers

11.20: Inspection and repair of exchanger parts

11.21: Exchanger alteration

11.22: Quality control inspections

12: Heat exchanger materials considerations

Abstract

12.1: Component materials

12.2: Minimum pressurizing temperature

12.3: Sacrificial anodes

12.4: Insulation

13: Above ground storage tanks

Abstract

13.1: Objectives

13.2: Functions of an oil terminal

13.3: Storage tanks

13.4: Other storage facilities

13.5: Measurements of above ground storage tanks

13.6: Samples (Refer to Fig. 13.78)

13.7: Common tank problems and possible solutions

14: Selection of tank materials

Abstract

14.1: Overview

14.2: Selection of materials for service conditions

14.3: Typical tank materials considerations

15: Tank design

Abstract

15.1: Objectives

15.2: General design considerations

15.3: Basic data

15.4: Tank sizing

15.5: Safe oil height (SOH) and LPO determination

15.6: Bottom design

15.7: Shell design

15.8: Seismic and wind design

15.9: Roof design

16: Foundations

Abstract

16.1: Objectives

16.2: Soil considerations

16.3: Foundation design and secondary containment

17: Fabrication and construction

Abstract

17.1: General considerations

17.2: Foundation

17.3: Site construction

17.4: Erection considerations

17.5: Bottom construction

17.6: Shell construction

17.7: Roof considerations

17.8: Site construction

17.9: Erection sequence

17.10: General considerations

18: Inspection and testing

Abstract

18.1: Inspection philosophy

18.2: Inspection frequency

18.3: Inspection and testing techniques

18.4: Records

18.5: Tank inspection checklists

19: Fire protection

Abstract

19.1: General considerations

19.2: Common causes of fires

19.3: Design considerations for fire fighting

19.4: Location and spacing

19.5: Drainage and impounding

19.6: Fire suppression systems

19.7: Design requirements

20: Maintenance and repairs

Abstract

20.1: General considerations

20.2: Out-of-service replacement or repairs

20.3: In-service repairs

20.4: Specific considerations

Appendix A: Design calculations for an aboveground welded steel storage tank

A.1: Aboveground welded steel storage tank design

Appendix B: Design of a concrete ringwall foundation

B.1: Concrete ringwall foundation design example

Appendix C: Design of a crushed stone (gravel) ringwall foundation

C.1: Crushed stone ringwall foundation design

Appendix D: Design of a pile supported concrete slab foundation

D.1: Pile-supported concrete slab design

Index

Copyright

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Notices

Knowledge and best practice in this field are constantly changing. As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary.

Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility.

To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein.

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ISBN: 978-0-12-803722-5

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Dedication

This book is dedicated to my wife, Eli, and son, Chad, for their enduring support, patience, and tolerance throughout the preparation of this book; and in memory of my parents Maurice and Bessie Stewart.

Maurice I. Stewart Jr., PE, PhD

Preface

Maurice I. Stewart, Jr., PE, PhD

I wrote this book with the intention of providing facility engineers, process engineers, petroleum engineers, senior field operations personnel, and managers with a starting point for addressing pressure vessel, heat exchanger, and aboveground storage tank selection, design, construction, testing, troubleshooting, and repair tasks.

Engineering curricula for mechanical and chemical engineers provide students with a basic understanding of the thermodynamics, thermal design, fluid mechanics, and stress analysis of surface production equipment. However, for the most part, the curricula doesn’t deal with the day-to-day needs of the practicing professional. This book is an attempt to bridge the knowledge gap by providing the necessary information for the day-to-day needs of the practicing engineer. This book begins by covering fundamental principles and then proceeds to address more advanced principles, such as the effects of wind and seismic loads in susceptible areas.

Practicing engineers responsible for selecting/designing surface production equipment frequently have information scattered among numerous books, periodicals, journals, and old notes. Then, when faced with a particular problem, they spend hours researching its solution only to discover the execution may have been rather simple. This book is an attempt to eliminate those hours of research by providing guidance as to the problems most frequently encountered in the selection, design, troubleshooting, testing and repair of pressure vessels, heat exchangers, and aboveground storage tanks.

This book makes no claim to originality other than that of the format. The material is organized in the most concise and functionally useful manner. Whenever possible, credit has been given to the original sources. Although every effort has been made to obtain the most accurate data and solutions, it is the nature of engineering that certain simplifying assumptions be made. Example problems should be viewed in this light, and where judgments are required, they should be made with due consideration.

Many experienced facility engineers will have already performed many of the calculations outlined in this book but will find the approach herein slightly different. All procedures have been developed and proven, using actual design problems. The procedures are easily repeatable to ensure consistency of execution. They also can be modified to incorporate changes in Codes, Standards, Recommended Practices, and requirements of the Authorities having Jurisdiction. Everything required for the solution of an individual problem is contained in the procedure.

This book may be used directly to solve problems, as a guideline, as a logical approach to problems, or as a check to alternative design methods. If more detailed solutions are required, the approach shown can be amplified where required. The user of this book should be advised that any code formulas or references should always be checked against the latest editions of Codes, that is, ASME Section VIII, Division 1 and Division 2, API 510, API 650, API 653, API 620, and API 2000. These codes are continually updated and revised to incorporate the latest available data.

1 am indebted to my many friends and colleagues for their help and advice to make this book possible and invite any suggestions readers may make concerning corrections or additions.

Acknowledgments

Maurice I. Stewart, Jr., PE, PhD, Stewart Training and Consulting (STC), LLC

This book is essentially a summary of the knowledge accumulated by the author with more than 45 years as a facility engineer practicing in the upstream and midstream oil and gas industry. I would like to take this opportunity to express my appreciation and gratitude to my many friends, colleagues, and mentors for providing invaluable learning opportunities.

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