Points for TBE phase

1.) Check tray weight along with liquid in that.

2.) Wind and seismic data to be checked
3.) Shell where cladding is available, To add undercut of 1mm or 2mm as applicable and
consider the same in corrosion allowance.
4.) Is skirt mean matched or OD matched to be checked and commented
5.) Insulation wherever provided shall(density to be checked). Some time fire proofing density
value is entered in that by negligence. So that should be avoided.
6.) Liquid holdup in packing.
7.) Pressure drop in packing and trays.

Points for Supplier document index

1.) Wherever Multiple equipment is provided, we have to provide separate title with tag
number(ex:- Mechanical design calculation for Tag No ex.-----)

Points for complex calculation where multiple parties are involved

1.) Flowchart/Inspection methodology to be asked from vendor.

Points for Design:-

1. Flanged Covers shall be used for Vessels/Columns of Diameter <= 900mm having internals.(Ref
Jacob - Engineering Design basis for Static Equipments)
2. For vessel with lug support on structure. BCD if under hold the Mechanical departemnet should
give beam size which is considered in calculation which is called as force bearing width.
3. LTCS material has Corrosion allowance-Ref. BD1166A-TEC-17-DS-E-202.
4. A fragile roof is the joint or union between the shell and the roof by a reinforcing angle and this
assembly should preferably fail when there is an overpressure inside the Tank.
5. Wind girder in tank is like a stiffener ring where there is a specific calculation in API which compute
and tell certain value if it is outside limit we have to add stiffener again and check it is a iterative
process.
6. If a column or vessel is having tall and have a body flange, then there is a possibility that the
vessel or column is surrounded with structure because there might be packing inside the column
and that packing needs to be removed during maintenance and for removing that packing vessel
has to be disconnected from body flange so that the section can be kept in structures only and no
need to keep it on ground.

7. API 663 – “Hairpin Type Heat Exchangers”

8. Weight of exchanger can be taken as Pulling force is 1.5 times of Bundle Mass. this can be
considered as Vertical load.
9. The pressure differential used to calculate the pass-partition plates thickness according to
TEMA Standards formula shall be at least two times the allowable pressure drop across each
pass-partition instead of the calculated pressure drop across each pass-partition as specified in
the paragraph 7.4.2 of API Std. 660.
10. API recommended practice 582 “Welding Guideline for the Chemical, Oil and Gas Industries

11. Twisted tapes:-

Advantages of heat transfer with twisted tube

Lower pressure
1 No baffle plate, lower pressure drop in the shell pass
drop
 Higher heat It can increase the turbulent intensity, make the shell flow
2 transfer velocity and the direction change regularly, and enhance the
efficiency mixture in lengthways
3 Less deposit No blind zone in the shell

12. Low-alloy steels are the ones which have up to 8% alloying elements whereas high-alloy steels
have more than 8% alloying elements..
13. Clear opening is required for Instrument nozzle where temperature element is inserted or for
Diaphragm type (diaphragm type can be seen in P&ID).
14. Why there is a subtraction of Static head in UGG99(c ) condition. Because UG-99(c) hydrotest
pressure is the calculated test pressure in new and cold condition of the vessel. It is derived based
on the actual thickness used and in new condition (un-corroded) . Maximum allowable pressure
(MAP) is reverse calculated for all pressure parts. This pressure is multiplied by 1.3 and the liquid
head acting on that part is deducted to obtain the calculated test pressure for each part. Test
position is important consideration. Minimum of this calculated pressure is considered as UG-99(c)
test pressure. In any case this calculated pressure shall not be less than that in UG-99(b).(ref:-
https://www.eng-tips.com/viewthread.cfm?qid=434704)
15. Terminology in Insulation:-
16. HC- Heat Conservation
17. PS-Process stabilization
18. PP-Personnel Protection
19. FPI- Fire Protection
20. FH- Full heat Conservation
21. DH-Dual Heat Conservation
22. For Stainless-steel in High Temperature Service, SS 321H grade shall have a carbon content
equal to C min. = 0,04 % and SS 321H grade shall conform to an average grain size in the
range No. 4~No. 7 as measured by Test Methods ASTM E112. In order to minimize Sigma
phase in welds, the ferrite content shall have an allowable range in the weld metal of less than 3
FN to 10 FN content.(Ref 12 – OCC REACTOR/12-R-201 A/B MATERIAL REQUISITION) Design
temp 620 Deg C. and Operating Temp 590 Deg C
23. 10/13th rule for Heat Exchanger:-
Pressure on lower side shall be greater than or equal to 10/13 of higher side. So that In case
of tube rupture the pressure from higher side will flow to lower side which may cause the
failure of lower side as It Is no designed for high pressure.
Look at example below
Higher side pressure(shell side) - 20 kg/cm2
Lower side pressure (Tube side) - 10 Kg/cm2
Not acceptable as per 10/13 rule
So we have to Increase tube side pressure from 20 x 10/13 = 15.38Kg/cm2
15.38 will be pressure on the tube side as If In case of tube rupture. The 20 Kg Pressure will
flow from shell side to tube side and If 10/13 Is applied then 15.38 x 1.3 = 20 Kg/cm2, Hence
there will no chance of failure. during design operation also If there Is a failure during
hydrotest still we can take a benefit of 90% of yield which will not go beyond 20x1.3=26kg
and this can be considered for a very small period of time. so Its manageable to overcome this
Issue so Its manageable to overcome this Issue we have to place rupture disc on Tube side
outlet.
24. Tube type In exchanger are of 2 Type:-
Plain and Finned type
25. In case of silos in aluminum, Content of magnesium shall be less than or equal to
3% (Mg < .03) & the surface finish of plates shall be Ra<7 µm. This is applicable for
pallet storage silos, (Content is LDPE (Low density poly ethylene) & EVA (Ethylene
vinyl acetate)
26. Seal Pan to be asked in MR Column vendor scope of supply.
27.) In heat exchanger where there is a name plate, We have to refer UHX-19, where for
radiography we can specify with hyphen like Stamping for individual chambers: RT1-T / HT-
T / RT3-S
28.) On vessel with design temperature over 400°C a "hot box" shall be provided under the
insulation on the inside of the skirt-to-shell attachment to reduce the temperature gradient of
the junction weld (refer to Vessel engineering drawing(s) and to Figure 4.15.8 of ASME VIII
div 2).
29.) Fabricated flange, tube sheet and cover made of solid austenitic stainless steel shall be
designed considering the allowable stress of the “low stress” material to avoid possible
leakage due to deformation. The use of high allowable stress forging material as per ASME
VIII part IID ”Notes G5” is not allowed.

Points during Kick off meeting(KOM)

1.) If hemispherical head is provided and is mean matched,, then there is a chance of weld to weld gap between
Head to shell and skirt to head joint, which needs to check and ask vendor to correct or else ask design
engineer to correct it. We should avoid less weld to weld gap.
2.) For temperature above operating 400 Deg C Hot box is applicable and FEA is a mandatory requirement for
that hot box to be done as per ASME Sec VIII Div-2 Fig 4.15.8. and FEA calculation to be submitted
3.) If transportation calculation is to be provided, It has to be either provided with Mechanical design
Calculation, or a separate design calculation to be submitted which has to be mentioned in SDI, (Supplier
document index)
4.) If there are some licensor specification attached along with MR or PR, the same has to checked for other
relevance document connected to it example Nozzle load refernce is given in MR also in Licensor document
which is a conflict so a written agreement to be taken for considering which document.
5.) In SDI(Supplier document index) if there is any sub vendor associated with the company, then please clarify
who will check the ITP(Inspection Test Protocol), PMI, WPS, welding repair procedure and weld
consumables handling, welding map, heads forming procedure , is it the responsibility of EPC or
vendor will check the sub vendor quality document and will merge and submit together or they will provide
separate, If they provide separate then SDI to be updated.
6.) Nozzle pipe fabricated from plate to be 100% RT if not specified in MR then still vendor to comly the same.

BD1166A-DS-004479 FOR LAS HEAT TREATMENT AS PER ASME SEC VIII DIV-2

Haldor topsoe Requirement – SP340-EN- Material for vessel in Hydrogen service at elevated
temperature shall be chosen on the basis of Nelson Curve and other Data Contained in API Code 941
latest Edition as specified in Topsoe Standard No – SP-287-EN.

ASME PCC-2-2018 – For clad or overlaid with austenitic stainless steel chloride content of less than
50PPM.

Flash Point – It is a temperature where liquid generate enough vapours concentration that if ignition
source comes in contact it will catch fire.

Oil grease & Lubrication first fill is asked for optional quotation as there is problem in transportation
of oil, So Vendor generally provide detail description of oil and grease and it is purchased from local
market.

Material - 10-R-301

Code of Construction ASME Sec VIII Div-2

Shell – SA-533 Gr.B Cl 2

Forging – SA-508 Gr.3 Cl-2

Flange – SA-182 F11

Bolting – SA-193

Titanium Cladded Material

Shell Ti Cladded sheet– SB-265 Gr.1 , Fe – 0.05% H2 – 60PPM

FRP – Fiber Reinforced Plastic Code of Construction is ASME Sec X

In Heat Exchanger, We have to consider only straight tube length for net heat transfer surface area.
U side tube need not be considered. Because fluid is not in full contact in U side. So we should
consider U side while calculating heat transfer area.

Minimum Distance between 2 Bullet / EUMA / 190 . Also given distance between 2 Equipment OISD.

API-582- Welding Guideline for the chemical, Oil & Gas Industries.

Full radiography for P No 4 CS MOC is from 16 mm thickness as a mandatory requirement as

per ASME.
Full radiography for P No 5 .MOC is from 0 mm thickness as a mandatory requirement as per
ASME.
Generally P No 4 & 5 comes under Low alloy CS.

Bullets:-
Stiffening ring on Bullet to be designed on basis of EEMUA -190-2000 Appendix A & C.

For MR review of unknown file

Silencer

1.) material certification required.

2.) Performance guarantee
3.) Reference standard for flange
4.) Codes for design
5.) Guarantee clause
6.) Sizing
7.) And if sizing to be done then performance guarantee to be given by vendor
8.) Signed and stamped copy of MR with data sheet (if applicable).

In PTA unit External corrosion allowance was provided in all equipment.

While considering External corrosion allowance recheck flange because there are maximum chance of failure of
flanges when external loads are applied and has to be checked. The lesson learnt point from PTA Paradeep project.

In Bukhara project Licensor said that External corrosion allowance is provided because the working fluid is highly
corrosive in nature, if it gets leaked from any place the working fluid will mix in the atmosphere and will make
atmosphere corrosive and if it went inside the insulation it can make external shell corrosive also, so for this reason
external corrosion is considered.
For Cladded vessel.

For pipes there is a possibility that OD of pipe may not match with ASME 36.10 because of cladding and neck
thickness to be increased due to WRC or Thickness requirement as per UG-45. But at the end of the pipe ID for
cladded pipe hasa to be matched with companion pipe.

Material classification for all material:

Ferrous – having iron greater than 50%

Non ferrous – having iron less than 50%

SS is not used at elevated temperature because of IGC(Inter Granular corrosion).

For elevated temperature we use Coarse structure for example (SA-515 & SA-387)

If not otherwise specified, Vessel is in Hydrogen Service when the hydrogen partial pressure of 100
psia (6.9 bar a) and greater or service containing 90% hydrogen or higher at any pressure level.

Wind laod and seismic load cannot be considered at same time and the same is not specified in load
combinations in PVE, because as per IS 456, Both wind and seismic cannot be applied at same time.

As per IS 9595 single V butt weld is done from 5mm onwards but Double V can be used over 12mm
only, but in case of AWS Double V can be considered only after 16mm .

Length of Stud and Bolt will be a little higher in case of Cladded vessel, so always discuss with piping
department and give a separate material requisition for companion flange stud and not. As cladding
can effect the over all length of stud length

ASME Sec II Part-D, Table-U for tensile stress calculation.

For checking SS vessel, always check that low strength in flange is considered, because there may be a chance of
failure in primary membrane stress in WRC calculation as that low allowable strss is governing in WRC condition.

Always check the reference of slope in slopped vessel and also the slope in GA as it may be missed.

For vessel with PSV, Always check if multiple PSV is connected to 1 branch of nozzles, if yes always ask Process
department if 2 branch are required or not for maintenance purpose

If a vessel(U-stamp) is attached to a reboiler(exchanger) example vertical boiler with side mounting exchanger always
ask to the vendor that how they will provide U Stamp, ie they will provide 1 name plate for both vessel and
exchanger or they will provide separate name plate for both, in MTO vendor agreed to provide 1 U-stamp name plate
and 2 different manufacturer name plate separate for column and exchanger. Because the design pressure &
Temperature for shell side of exchanger and column was same. Also the procedure for hydrotest to be asked that
hydrotest will be done separately or together and how they will maintain the pressure if pressure is different.

Reinforcing pad is made with one plate in DFCR unless practically acceptable. However Wood Exchanger standard
specify that the reinforcing pad is made in 2 halves, then a vent hole shall be provided on both the halves reinforcing
pad made of more than 2 pieces are not acceptable.

Cladded Vessel PWHT is required or not:- PWHT is required in cladded vessel as per UCL-34 it says that PWHT is
required - Vessels or parts of vessels constructed of base material with corrosion resistant integral or weld metal
overlay cladding or applied corrosion resistant lining material
shall be postweld heat treated when the base material is required to be postweld heat treated.
(b) Vessels or parts of vessels constructed of chromium stainless steel integral or weld metal overlay cladding and
those lined with chromium stainless steel applied linings
shall be postweld heat treated in all thicknesses, except vessels that are integrally clad or lined with Type 405 or Type
410S and welded with an austenitic electrode or non‐air‐hardening nickel–chromium–iron electrode need not be
postweld heat treated unless required by (a) above.
Chromium stainless steel is SA-240 410 (Ferritic or Martensitic (Chromium)

Austenitic (Chromium-Nickel) (Chromium-Manganese-Nickel) – SA-240 304, 304L, 316, 316L.

For pressure vessel having deign pressure of more than 20 MPa and code of construction is ASME Sec VIII Div-1. If
it is beyond 20MPa still designed as per ASME Sec VIII Div-1 then Code case – 2695

Joint efficiency of Head(Knuckle portion) to skirt joint is considered as 0.55 as the same is not given in ASME it is
specified in Bednar in chapter Design of tall column self supporting Process columns CL-4.3

P11 & P22 difference between

For P11- Chromium content is 1-1.50% Composition

For P22 - Chromium content is 2-2.50% Composition

If duplex material then any special requirement -

1.) Then it comes in Solution annealed form.

2.) Ferrite Level determination
3.) Corrosion testing

For SA-516 Plates above 40mm thickness shall be normalized.

Lesson learnt –

1.) Carbon steel(CS) to be epoxy lined internally in case of working fluid is instrument air, Since fluid is
instrument air, carbon steel with epoxy lining has been specified in order to guarantee purity/cleanliness to
avoid any possible damage/plugging of instrument due to any possible rust particle that could form in the
drum, as alternative also galvanized carbon steel can be used.
2.) Reinforcement pad shall be of 1 piece or made of 2 Piece but with full RT or if not made full RT then 0.75
of Area A5 to be considered

When there is PWHT requirement between 2 different material of LAS(SA-387 Gr11) & CS (SA-516 Gr.70)

SA-387 has PWHT Temperature of range 660 Deg C to 680 Deg C

SA-516 has PWHT Temperature of range 595 Deg C to 650 Deg C

So for that we have to separately do the PWHT for CS & LAS part and then final portion where LAS has to be
combined with CS there LAS portion has to be done with buttering with some intermediate CS alloy and the CS
welding has to be done.

The reason for not providing LAS buttering & welding because after welding because after PWHT has been done for
final portion and if LAS welding has been done then PWHT temperature will be around 660 Deg C to 680 Deg C
which is not acceptable for CS MOC

Tank:-

As per API 650 Appendix-T

-Vacuum Box test is required for testing leakage in Base plate.

- There is no helium test done for API tank

- For corner joint between base plate to shell also Vacuum box test can be done.

- For large tank Pneumatic test is preferred also one Hydropneumatic test is preferred where Water is filled
upto HLL level of tank and above space will be pressurized by air with 1.25 times design pressure.

Vapor distributor and chimney tray are same thing as per Sulzer

For Stainless Stell (SS) plates Full RT is required above 38mm as per UW-2.

SA-537 CL-1 plates to be normalized.

SSA-537 CL-2 & 3 to be quenched & tempered

Tempering temperature for CL-2 is 595 Deg C

Tempering temperature for CL-2 is 620 Deg C

SA-387 Gr 11- Cr content % - 1.25 Moly – 0.5%

SA-387 Gr 12- Cr content % - 1.00 Moly – 0.5%

SA-387 Gr 22- Cr content % - 2.25 Moly – 1.0%

Except 91 Grade all plate shall be thermally trated either by annealing, normalizing & tempering or when permitted
by purchaser, accelerated cooling from the austenitizing temperature by air blaster or liquid quenching followed by
tempering, Minimum tempering temperature shall be as follows:-

Gr 2, 12, 11 – 620 Deg C

Gr 22, 21, 9 – 675 Deg C

Gr 5 – 705 Deg C

Austenitic Grain Size—Grade 2 material shall have a coarse austenitic grain size.

Code case – 2694(high temperature material)

ASME Sec VIII Div-1 Appendix-46

Fiber elongation as per Division-2

Neutral axis shift method as per PV elite

Anchor bolt & Base plate for vertical vessel is always designed for Hydrotest case also as operating case is governing
for calculation PV Elite take operating Load & Operating Moment with seismic as governing