Document No, sexe ong estan ies | MIaNca er RerINeiey Pe} ROCHEMICLS LD. ‘ewomeenmic besiow oasis fart te tm) Design Temperature Unless otherwise specified elsewhere, design temperature shall be as per the following. a) For vessels operating at 0°C and over: Design temperature shall be equal to maximum operating temperature plus 15 °C subject to a minimum of 63 *C, b) For Vessels operating below 0 °C. Design temperature shall be equal to lowest operating temperature, ©) Minimum Metal Design Temperature (MDMT) shall be lower of minimum atmospheric temperature and minimum temperature envisaged during operation. Corrgsion Allowance : # Unless otherwise specified elsewhere, minimum corrosion allowance shall be considered as follows: = Carbon Steel equipment 3.0 mm" = Lowalloy steel equipment ae i + mm for shell & tube exehiangers) = Stainless steel equipment NIL = Clad equipment # NEL (3mm cladding minimum) = Lined equipment 2 3.0 mm (plus = €S Storage Tank bottom most shell ceourse and bottom plate aU = C$ Storage Tank shell (other courses) LSimm = Storage tank Fixed roo!/ Floating Roof : As specified in process data sheet, + CS BurriedVessels (External) LS mm = 8 Spheres LS mm * Except for tubes required on the base metal, The For alloy lined or clad equipment. no corrosion allowanes yess and the same shall ‘cladding of lining material shall be in no case less than 3.0 mm t be considered as corrosion allowance for the purpose of stress analysis. Corrosion allowance for nozzles and manhole neck shall be at least equal to that specified for the equipment. No Corrosion allowance is required for gasket seating face of girth flanges. However, for non standard blind flanges of ehannel covers the corrosion allowance will be appli Format No. NRPL 1641-1924 Rev. 1 TansDOCUMENT No | nege Reg borne IASG MOE REFINERY & PETROCHEMICALS LED, ENGIVEERING DESIGN BASIS eaten eae) 29 2.10.3 (stoves suet Wind Consideration Wind load for equipment including anchor chair shall be calculated on the basis of 1S 875, 2) Drag coefficient for eylindrical vessels shall be 0.7 minimum, b) Drag coefficient for spherical vessel shall be 0.6 minimum considering: K 1.0 (for 50 years fife) = Factor based on category 3 (for units) and factor based on category 2 (for off sites) K, = Factor based on site topography = 1.0 Contingency factor of 1.1 shall be used on wind pressure Eqrthquake Consideration: a Earhquake loads shall be calculated in accordance with site spectra curve using response spectra method with 2% damping. Capacity Tank pacity and stored capaci = Capacity shall be specified as Nomi = Nominal capacity tor fixed! roof tanks shal be volume of eytindrical shett. = Stored capacity for fixed roof tanks shall be equal to nominal capaci board volume (equivalent to 500mm of shell height) = Nominal capacity (also the stored eapaeity) for Toating rooF tanks shall be volume of cylindrical shell minus free board volume (equivalent to 1500mm of shell height) = Nominal eapacity (also the stored capacity) for fixed cum floating roof tanks shall be volume of cylindrical shell minus free board yolume (equivalent to 2500mm to 300mm of shell height for tanks with vent / overflow slot in shell.) Bullets (above ground or under ground) ~ Nominal capacity is the geometric eapacity of Bullet. = Stored capacity shall be 8: Ys of nominal capacity. = Nominal eapacity isthe geometric capacity of Sphere. = Stored eapacity shall be 85% of nominal eapacity. Format No, SIRPL 1681-1924 Rev. 1 ranel sapmagnsnnesters pOCUWENT No, SINCUOREREMINERY€ PETROCHEMICALSLID. —-ENGIVEERING DESION BASIS | Uopisttqean tenon ity ce me <1 Supports Skit supports shall be provided for all tall columns {Refer Cl. 2.2 (c)} and reactors. However, small vertical equipment may be supported on legs (pipe or structural section) or brackels, All horizontal vessels and exchangers shall be supported on tvo saddles. 2.11.2 AllCr-Mo steel reactors shall be supported on skirts. Welding of external clips on C1-Mo stee! Reactors shall be avoided wherever possible. Skirt Thickness G ‘The thickness for the skirts inclusive of corrosion allowance shall be the maximum of following: a) 6mm. b) Thickness required by analysis, 46) 30 mm or 1/3 of the vessel wall thickness whichever is lower. Corrosion allowance of total Imm minimum shall be considered for skirt unless otherwise specified in the projeet specifications to achieve final thickness of skirt shell. 2.11.4 Allcolumns with diameter 1000 mm and more shall be self supporting. All columns with diameter less than 1000 mm shall be supported by superimposed structure ‘around the column covering the entire height. Guy wires are not permitted to be used for supporting any equipment. LTT In specifi eases, columns having diameter fess-than-#000-mm-and total L/D-ratio-not exceeding 10 may be self supported. ure all around for 2.11.7 Fla andl Vent stacks shall be supported structurally by super imposed strn the entire height 2.11.8 Storage spheres shall be supported on pipe legs with tie rod bracing and tun buckles. 2.11.9 Buried vessels shall be suitably anchored to prevent the uplift due to under ground water. Anchor bolts shall have corrosion allowance of 6 mm on diameter. Buried vessels shall be rested on conerete saddles with anchoring bracket at the centerline of the vessel 2.11.10 All skirt supported columns/equipments with height 20 m and above (irrespective of weight) ‘and weight 50 MT and above (irrespective of height) are to be provided with tailing lug. 2.12 Norales and Manhotes : 2A21 Nozzles: ning equipment ( Vessels, Reactors heat 300 #. a) Nozzle rating for all the pressure cont exchangers, Air Coolers ete. ) shall be mi b) Minimum nozzle sizes shall be as below: © Process & Instrument Nozzles on Unelad Vesses! 21 %ineh NB © Process & Instrument Nozzles on Cladded Vessels inch NB Fonmat No, RPL 1641-1924 Rev. 1 rightsnye fog tere ES ocuHENT No, SANG ALONE REFINER. ¢ PETROCHEMICALSLID. ENGINEERING DESION BASIS TSE em tenths Manholes: a) Vessels and columns with diameter up to 1000 mm shall be provided with 450 NB manhole, Vessels and columns with diameter greater than 1000 mm and up to 1500 mm shall be provided with $00 NB manhole. However, if required, vessels and columns with diameter 1300 mm and above may be provided with 600 NB manhole. b) High pressure reactor manholes shall be on ILD. basis. Size shall be as per Licensor drawing. ©) Forstorage tanks minimum number of manholes (Size 600mm) shall be as follows : TANK DIAMETER SHELL FLUSH TYPE ROOF MANHOLE CLEAN OUTDOORS MANHOLE (NOTE 1) Diameter. ¢12 m 1 NIL 1 5 12 m< Diameters 45m 2 aoa 2 45 m 61 m 4 2 2 Notes: 1) In the deck of floating roof tank one number additional 30" NB ‘manhole with intemal ladder shall be provided on floating roof as per fabricator’s standard, 2) Tank Manholes including bolting and gaskets shall be as per APL 650. 1d) Clean out doors shall be provided as per MRPL's / process requirements and Size of clean out doors Fittings for tanks shall be 36" (900 mm) x 48" (1200mm). 243 Floating Roof: Urless otherwise specified floating roof shall be of following construction, TANK DIAMETER() TYPE OF FLOATING ROOF (a) (>), External Internal Dei2m Double Deck Type Double Deck 2m60 m Double Deck Type Double Deck 2.14 Minimum Nozzle Size For Vessels And Their Basis: = Minimum Nozzle Size > 40NB = Minimum Nozzle Size for Clad Equipment =: 80 NB* + Safety Valve Nozzle 2 Based on LD. = Self Reinforced Nozzle neck Based on LD. Format No, RPL 1681-1926 Rev. 1 ais| aagetead cr igatecu tes SIaNGaaL ONE REFINERY € PETHOC ron ait tw ‘BOCUMENT Ho. Fue ats Lt, ENGINEERING DESIGN BASIS + Except for MP conection on heat exehanger nozzle where it will be 5O 1D LWN. Flanges: Nozzle flanges up to 600 NB shall be as per ASME/ANSI B16.5 and above 600 NB shall be as per ASME/ANSIB 16.47 (SERIES 'B) except that for high pressure heat exchanger. Non stardard flanges shall be designed as per ASME See. VIII Div. | 2.15.2. Unless otherwise specified, W.N. Flanges shall be used forall classes. 2.15.3 Unkss otherwise specitied, all girth flanges and intermediate body flanges shall be of weld neck type only. 2.154 Flange rating shall be established based on design pressure, design temperature and considering all external loads (moments and axial force). For high pressure (> 60 bar) and high temperature service, flange bolting shall be through the use of torqued or tensioned bolts. No manual bolting is envisaged. 2.16 Internals: Uness otherwise specified removable internals shall be bolted type and material of bolting shall be stainless stee! TP 304, For shell & tube heat exchangers, floating head bolting shall be compatible to shell mater 2.17 Pipe Davit : Bolting SA 193 Gr. B7M/2HM shall be used as a imum. i) Vertical Vesse’Column having safety valve size $0 NB and above and or having internals, shall be provided with pipe davit. ii) Exchanger davits shall be provided for flat channel cover and all types of shell covers. 2.18 Yent/Drain/Ventitation Nozzle Conneetions 1) Vessel shall be provided with one number ventain connection as per following specified in process data sheet: Vessel Vent Drain Ventilation Volume Nozele Nozzle Nozzle (0 (mm v6.0 : 40NB 40NB : 607500mm - 200 NB ae Format No, NRPL 1041-1926 Rev. 1lye enpet gee jpocument Ne. SANG MONE REFINERY PEINOCHEMICALSLID, ENGINEERING DESIGN 8436 tenement (aeves ae rest) Vertical vessel not having any nozzle on the top shall be provided with 50 NB nozzle for conducting hydrotest in vertical conditions. ii) Exchanger shall be provided with yent and drain connection as per P&ID or 40 NB vent / drain nozzle connection with blind flange ete, if not shown in P&ID (Separate Yent and drain will not be provided if vented / drained by other nozzle), For clad ‘exchangers, minimum size of vent and drain nozzle connection shall be SO mm 1D LWN. 2.19 Spares: 2.19.1 Mandatory Spares i) i) Vessels & Columns Gaskets ‘Two sets for each installed gasket, Fasteners + 108% (Minimum two in each size) of installed fasteners other than standard sizes of B72H Sight/Light Glass. +d sets for each installed glass ‘Shell & tube Exchangers: 400% Gaskets 20% Bolting (Min. 4 studs and 8 nuts per Joint) Air Coolers 400% gasket for header cover & nozzles wsith blind flange 200% gaskets for plugs 20% plug 100% belts 100% bearings 10% complete bearing blocks or one rminiraan 20% Bolts & Nuts forall nozzle with BF & Cover plate One set of Diaphragm Actuator with positioner for each type of auto variable pitch fa (Alternatively vendor recommended spares for his type of auto variable pitch fans) 2.19.2 Commissioning Spares: i) Reaetors-and Columns. : Gaskets i 100% (For Manways, Interconneeting Nozzles, and nozzles with blind Flange). Fasteners 5 Format No. NRPL 1641-1928 Rev. 1 iohtsocUMENT Ne, neqetnee cxtgnmeca mee MING ATOM REFINE PE OC ENOMEERING DESIGN BASIS i Ciba hgentetenter Be a fi) Shell tube Exchangers: 200% Gaskets iii) Air Coolers Plug/ Header Gaskets = 30%(Min | no) of Installed quan Plugs > 10% Belts é 100% 2.19.3. Special Tools: i) Air Coolers : Scissor lift platform shall be provided. for each tag number fe, EC-XXXXX A-L (1 snunnber) ii) Recators/Vessels/Heat + Any Special tools, recommended by the Exchangers/Air Coolers, equipment manufaeturer* : ‘ 2.19.3, Instrumentation - Statie Equipments: Nozzle Requirement & location shall be confirmed with Process & Instrumen {All Instrument Nozzle Locations shall be accessible by’ platforms (Platform Grating ‘hall be located so that tappings/instrument nozzles are 500 to 1000 mm above the top of grating). iii) Instrument Nozzles shall be min 300# (mas being refined by process pressure and temperature conditions). This shall be ensured for low pressure vessels also, 150% Nozzle Flanges/tappings shall not be provided. iv) Minimum stub lengths of 200 mm shall be provided esteral to the vessel for al instruments tapings « vy) Refer Annexure-II for instrument conne 1$ on Statie equipments, Format No. MRL 1681-1928 Rev. 1 Tons_—— ‘pocunent Ne, S1asGc41 ORE REFINERY PETROCTILN {idovesagene ete AD rm ENGINEERING DESIGN 84515, Annexure INSTRUMENT CONNECTIONS ON VESSELS, STANDPIPES AND TANKS = “TPF OF INSTRUMENTS vesset/stanpewre | FIRSTBEOCK T sruuaewe 7 CONNECTION. CONNECTION SRTERNAL BATE PIOATTEVEL a ; : || INSTRUMENT ON VESSEL. rue anes I" S.-W. ASERAE DAL HOATLEVECTRTRININT | —gyimane | rswmon | 1 7 | ETERNAL Ba vswmoe | vswaione | Ms. 3 PNRAL BALL FLOAT STROM | ALA. : TLS. LEVEL GAUGE ON VESSEL FFLab. Frap | 3a scRo 5 [LEVEL GAUGT ON StaNDriPE —aeswneo | SPS warLGo.* | SH SCR © | D.PINSTRUMENT ON VESSEL 112" FLGD. 112" FLGD. 1/2" SCRD. [ir nsTRUNENTON STANDAPE SACLGD.* | SPSAWALGD | 12" SRD, DIATTERCNTSEAL DE. INSTRUMINTON aa 7 + [pace Rub sno | _3*FLaD 9 | EXTENDED D. P, INSTRUMENT ON VESSEL 4° FLGD. +ELGD, (0 [iP TUBE LEVEL INSTRUMENT T2TELGD, 1" SW (BY INST) | 1/2" SCRD. TANRTEVEL NSTRCMENTINECH) ATNc ; TEE RGD TY oy vv | ARLE 1a" re. ts 12" SCRD, > TAN LE VEL NSTRONTENT SERVO AT a FRB) — or rg 12 | pREssuRISED € Fae INST) Sr ELGD. [Tid Pre sstiRe INSTRUMENT ON VESSEL TES FLGD. TAD" FLGD. 12" SCRD. DIAPURAGAT SEAT PRESSCT INSTRUMENT =a i 7 v4] RRA SEA Lua" FLGD, ‘ur ruab, | 12" SCRD. PAPRAGAT SEAL PRESUREINSTRUNTENT = a : El eee Tee, | turnip. | 112" FLD. ia TERWOWEIL Tar : TIB"FLGD. TT STANDAIPE 2 ALG : ; ores M ORANY OTHER INSTRUMENT NOT REFERRED ABOVE, THE CONNECTION DETAILS, SHALL BE AS PER HhowbUAL REQUIREMENT 2. ALL -LANGE/SW RATINGS SHALL BE AS PER PIPING SPECIFICATION. (MIN 3001) 3 IN GASE OF DIRECT MOUNTED FLANGED INSTRUMENTS AND WHERE FLANGED FIRST ISOLATION VALVES ARE PROVIDED, BOLTING 'ANOGASKET SHALL BE IN PIPING SCOPE. “AS PER PIPING SPECIFICATION. Format No, NRL 108-1924 Rev. 1 iseating exits ts ‘DOCUMENT He ASG ALOME REFINERY € PETROCHEMICALS LID, ENGIVEERING DESIGN BASIS (acre Sgenmtenten bs a ers) INSTRUMENT CONNECTIONS ON PIPING ERE eRe] were | mor | nimectas | mmvtciass | mmncctas | cttthet | Imrsemmas. | "rescuns” | rescues seuewen | "a Maser coSMeeHONs | countess | cossteTioNs races | 1emtoce PROCESS | yy hry, | INSTRUMENT INSTRUMENT CONN. VALVE: come | mak CONN. CONN a varsent arse : UzSCRD, 2" sen, | erowsteree | 1#"SeR0 — seb + a a y favewone | seman | teo | vveron- | ue |S | suenane emma 2 | ror rene: (ceo (BY INST _ ‘FLOD. ao - ' aah po ee er ec verse TEST ; i | “i aa ye om ° «| Pressune seseno, | axrseno. swsw | 2 | arsern | 25 | gg | eso ek : weno | weno | iene | ME | AM | rnc eA + | emiowan nnn z viene | AbD ae ho Ta Ao NOTES = TRUMENT NOT REFERRED ABOVE. THE CONNECTION DETAILS SHALL BE AS PER INDIMIDUAL REQUIREMENT. ALL FLANGEISW RATINGS SHALL BE MIN 3008. INCASE OF OIRECT MOUNTED FLANGED INSTRUMENTS AND WHERE FLANGED FIRST ISOLATION VALVES ARE PROVIDED, INSTALLATION OF ALL IN LINE INSTRUMENTS SHALL BE IN PIPING SCOPE, + SEAL WELDING REQUIRED. * CONNECTIONS FOR DP. INSTRUMENT 1/2" SCRO. Format No, WRPL 1641-1924 Rev. 1 “ighteerste BOCUIENT Ne gS MLOME REFINERY & PEIROCHEMUCALSID, ‘enoineeRG O€SiGW BASIS {aon su Sy sean ke nen | INSTRUMENT CONNECTION ON FIRED HEATER VESSELNE | Tee ormermumenrs | SESSEULINE | “rrasretookvatve | WSTRUMENT CONNECTION SLOWELENENT-AVE:PTOT | yo Ta FLANGEDTGY 1 (Geeorree 1112" FLANGED pos ‘v2! NPT (F) Low ELEMENT - VENTURI : ; 2 | TUBE (ON DUCT) 12" SW. 12" SW. V2" NPT (F) 3 [PRESSURE NSTRUMENTION | y-ruanaeo | 1 v2" FLANGED Ve Wr) 7 | BERSSURENISTRORENTION 7 yarrianeD | 1 v2-FLANGED ve wer) GRAFT GAUGE (REFER ; i ® | Oona poten 1172" FLANGED | __1 172" FLANGED ‘V2 NPT (F) TENBERATURE INSTROWENT | + | eMrERATIR 1 FLANGED Te FLANGED TEMPERATURE TISTROVENT | rianceb 1 FIANGED | Se THEROSOURLE PPE 5 [Five GAS AIMLYSER ERLANGED: FLANGED TAANGED wores: 1 PRESSURE RATING OF FLANGE CONNECTION SHALL BE 1504 FOR INSTRUMENTS NOUNTED DIRECTLY Ou nEATER 2, PRESSURE RATING OF FLANGE CONNECTION ON TUBE SIDE SHALL BE MIN 300%. 3. ALL PRESSURE & FLOW INSTRUMENTS SHALL HAVE MECHANICAL ISOLATION VALVES IN ADDITION TO INSTRUMENT ISOLATION & VENT/DRAIN VALVES. Fesmat No. MPL 1641-1926 Rev. 1 Tans‘DOCUHENT He, snytingat or eer hE SIaSG ALONE REFINERS PETROCHEMMCALSLID. eNoINEERIG DESIGN BASIS ‘ten {bate See 2.20 ri ‘seat na MF Conneetion for PG/TI i) ii) ‘Shell & Tube heat exchangers A For Clad Exchangers One no, 30mm ID LWN nozzle with BF on each inlet/outlet nozzle of size 6"NB & 8°NB. For 10" NB and above two nos. shall be provided. Others (Non Clad) One no, 4DNB nozzle with blind on each inlet/outlet ‘Stacked Exchangers Only one MP connection with blind in one of the intermediate nozzles. ‘ Rating shall be same as process nozzle Air Cooler: ‘One on one of the inlet& one on one of the ‘outlets of each header, size AONB nozzle With BF ete. If itis not possible to provide ‘on process nozzle then it shall be provided ‘on header. Rating shall be same as process nozzle. Tinportant Considerations, Vessels and columns shall be designed considering masimum operating liquid head in addition to design pressure. ‘All columns and vessels shall be capable of withstanding water full condition during system testing. Inaddliton, all vertical vessels, columns and Horizontal vessels shall be designed so as to permit site testing of the equipment with water atthe test pressure on the top of the equipment considering 33% of design wind load. The design shall be based on fully corroded condition, All equipment founclation shall be designed and constructed for water full condition ivhen equipment is new with 33% of design wind load. Vessels and columns shall be tested at shop hyrostatcally at pressure caleulated as per applicable code in new and cold condition Seismic design shall be carried out based on site spectra. Design of components not covered in IBR (Indian Boiler Regulations) shall be in accordance with ASME SEC VIII DIV 1. All stress analysis. local load analysis ete. shall be earried out For eritical equipments ony. Feat No. NRL 1641-1924 Rev. || ange trp sgn ts | Greve eocuMent No. (OMPREFINERY € PEINOCHEMICALSLID. ENGINEERING CESION BASIS fete et ere ‘ All nozzle necks, all nozzle flanges and blind flanges shall be of weld deposit construction for clad equipments. Loose liners are not permitted. All vertical ent shall be provided with to lifting lugs. Lifting lugs shall be designed with impact factor of two, Mechanical design of self supporting Tall Columns ‘Tower shall be carried out for various load combinations as per Clause 3.2 Material of various parts of equipment shall be selected a per Table given in ‘Annexure-I unless otherwise stated on process data sheet. Stress analysis shall be carried out for nozzle to shell junetion using masimum shear sires theory for vessels and columns. Allowable stress intensity shall be as per ASME. SEC Vill Div 2. 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 casey skirt shell join is of butt welded construction, the same shall be 100 % radiographed. Projection of vacuum stiffening rings, on insulated vessel shall be less than insulation thickness wherever possible. Alternatively, the stiffening rings shall be covered with station & cladding.Annular space shall be provided between the insulation support tings and shell and shall be designed to avoid CUI. Heat Exchangers: L Tube Sheet type for floating Non extended for floating head. head and Utube heat Extended for Stab in bundles only of BY type: exchanger stationary head of U tube exchangers Testing accessories for shell 1 Testing rings shall be provided on all Noating 'S! and tube Heat Exchanger & 'T' head type exchangers. 2 Dummy shell shall be provided for fixing test ring for exchangers such as Kettle type or floating head without shell covers (TEMA 'AHT’ or "AKT) of sinb in bundle where shell design pressure is higher than tube side pressure ‘Test flanges shall be provided i 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, 4 Minimum number of test rings’ test flanges! dummy shells shall be at least one per set of three bundles. $ For shell side interconnected and stacked exchangers the minimum number of test 1 shall be equal to the number of exchangers in one stack, 6 — For ‘U" tube & removable bundle exchanger, rhumber of test flanges shall be equal to number ‘of exchangers in one stack. erat No, MPL 1641-10926 Rev. 1 ‘ighameter rato AS ‘DOCUMENT He, ANC MLDuE REFINERY & PEFHOCHEAMCSLSILED ENGINEERING OESIGN BASIS TAME Seta steaten me a ees 3. Cathodie Proteetion ‘Anoxles and painting shall be provided wherever ‘specified in thermal data sheets. 4. Maximum Tube-bundle ‘As per thermal design basis. Weight S Gaskets Spiral Wound or Cam Profile only 6. Cleardistance between 300 mm edge of foundation and back of girth flange. 223 Coolers 1, Noise level ‘The noise level shall be limited to 85 dB(A) max. measured at a distance of one meter fom the bundle at the header access platform ‘walkways and one meter from the bay limit on ‘motor maintenance platform, The noise level 3 ‘within the air cooler bay shall be 90. dB(A} maximum, at locations defined as per API. 2. Type of Belts + Toothed timing belts, Oil resistant in accordance with BS 903 part A16, as well as fire resistant and anti static "PRAS" conforming to BS 3790, 3, Access Platform forcooler = ~—- Shall be provided on all the four sides at header box elevation, (width - 900. mm) with stairs on one side and ladder on other side. 4, Maintenance Platform for——:—_Refer 2.19.3 (i. tans and motors 5. Protective Covering (for + By heavy duty wire mesh. finned tubes) on bundle top 6. Hotdip galvanizing of air: AS per structural design basis. ‘cooler structutals 7, Final Painting of header box: All header boxes shall be finally painted at vendor's shop. 8. Vibration Measurement + Accelerometer of 100 mV/G shall be mounted fon the fan bearing housing and eabled to a junetion box at a accessible location and provided with MIL-C-3015, 2 pin conneetor/BNC. 3.0 DESIGN CRITERIA / REQUIREMENTS - SPECIFIC APPLICATIONS 3.1 LPG Storage Spheres/Mounded Bullets = The design pressure shall be established based on the composition and vapour pressure ‘of stored product at design temperature, but in no case it shall be less than 14.50 Kg./em’g atthe top of the sphere for LPG Sphere/Mounded Bullets. = Selection of material of construction for various LPG Storage applications shall be as per following = Format Wo, URPL. 1641-1928 Rev. 1 iiscocuneNT He. sneetongt other hes Mas atone REFINE & PEIROCHEMICALSLED, ENGINEERING DESION BASIS: {none igen seats Ss ee me a) For marketing and similar application: SA-316 Gr 70(IT) [SA 337 (where HyS is not present) CL.MITYEQV. bb) For refinery and gas processing plants: SA-316 Gr 60 (ITYEQV. {ovhere HaS presenee cannot be ruled out) = AILLPG spheres/LPG Bullets shall be post weld heat treated irrespective of storage application and adopted shell thickness. 2 Tall Columns Vertical vessel with Height (TL to TL) / Diameter ratio greater than 5 shall be considered as tall column. Mechanical design of self supporting tall column and its anchorage block shall be earried out considering combination of various loads, Loadings ‘The londings to be considered in design (i) Internal and or external design pressure specified on process data sheets, trays, welded and removable attachments, insulation and operating liquid ‘weight of attachments to be considered shall be as per Table-! enclosed, Gi) Other toadtings as" specified in UG-2 of ASME Code See, VHT Divts applicable. iv) Seismic forees and moments shall be computed in accordance with IS 1893 (latest in project specification. Unless otherwise portance factor and damping coefficient shall be considered as 2 and 2% respectively. Soil /foundation factor shall be considered based on soil/foundation of edition) unless otherwise specified specified (v) Basic wind pressure and wind velocity (including that due to winds of short duration analysis respectively shall be in accordance with IS 875 (atest edition), Additional wind loading on column due to extemal attachments like platforms, ladders, piping and asin squalls) for the computation of torcesimoments and dynamic attached equipment should be given due consideration (vi) Loadings resulting in localised and gross stresses due to attachment or moun refluxireboiler, condenser, etc. Loading Condition Analysis shall be carried out for following conditions : (i) Erection Condition Column (uncorroded) erected on foundation. without insulation, Fall wind platforms, trays ete, but with welded attachments plus fon column. ‘ wg a self Supporting tall columnitower shall inelude: Self weight of column inclusive of piping, platforms, ladders, manholes. nozzles. ete. The ‘wherever Format No. MIRPL 1641-1924 Rev. 1 ng ofOCUMENT No, expen caine es SANG WOME REFINERY € PETROCHENUCALS 1D, ENGIVEERING DESION BASIS | CAN SiSqemnatenten tie st nee) Column (in corroded condition) under design pressure, including welded items, ays, removable internals, piping, platforms, ladder, reboiler mounted on column, insulation and operating liquid ‘ete, plus full wind on insulated column with all other projections open to wind, or earthquake forces. (Gi) Operating Con Test Condition Column (in corroded condition) under test pressure, filled with water plus 33% of specified wind load on uninswlated column including all attachments shall be considered. (iv) Earthquake And Wind Shall Be Considered Not Acting Concurrently. 3.2.3. Deflection of Column Maximum allowable deflection at top of column shall be equal to height of the column dlivded by 200 up to a maximum of 300 mn. i) Wthe deflection of column exceeds the above allowable limit, the thickness of skirt shall be inereased as fist trial upto a maximum value equal to the column thickness nd this exereise shall be stopped if the deflection falls within allowable limit, ii) LF 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 oF half angle of cone reaches maximum limit of 9. (iii) 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 ‘horton course above skirt and proceeding upwards till the deflection falls within allowable limits. 3.24 ‘Stross Limits loads shall be combined using maximum L, ‘Thicknesses are accordingly chosen to The stresses due to pressure, weight, windisei principal stress theory for ASME Section VIII keep the stresses within limits as per Table-2. Skirt Support Base Base supporting including base plate, anchor chairs. compression ring, foundation bolting ete. shail be designed based on over-turning moment (greater of seismic or wind). A minimum umber of 8 foundation bolts shall be provided. Nos. of foundation bolts shall be in multiple of four. Format No. NIRPL 1641-1024 Rev. 1 rightsDOCUMENT He, eqetemgd ex ihere ier NANG ATONE REFINERY & PETROCHEMICALS BD, ‘ENGINEERING DESIGN BASIS en hee Misimum Hydrotest Pressure Minimum Hydrotest Pressure (in Horizontal position) shall be equal to Q x design pressure s temperature correetion factor, as specified in ASME Code Section VIII Div.1 /Div.2, at top of column unless specified otherwise, where Q is a factor depending on code of construction. Dynamic Analysis of Columa/Tower Dynamic analysis of each column shall be carried out for stability under transverse wind indaced vibrations as per standard design practice. ‘Storage Tanks ‘Allstorage tanks shall be designed as per code considering liquid height upto top eurb-angle of shell. “Tauks shell thickness ealeulation shall be carvied out by the one (1) ~ Foot method as per API 630 for tank diameters less than and equal to 60m (200 feet). Maximum height of unstiffened shell shall be calculated based on the corroded thicknesses of shell courses. Section modulus of wind girders shall also based on corroded thickness of shell courses, Seismic design as pet API 650 (Appendix-E) is mandatory for storage tanks. Annular bottom plates shall be provided for all storage tanks 12 metre diameter and above. “Anchor bolts shall be provided bused on design considering wind/scismie loads. uplift due to Nernal pressure etc. However, tanks having diameter S 10 meter shall be provided with anchor bolts and shall be spaced at approximately 1.8M of circumference. ‘Tanks having design temperature more than 100 °C shall have thermal isolation bartier (Guitable fice bricks) between tank bottom and foundation, Mounded Bullet Mechanical design of mounded bullet shall be carried out considering combination of various loa. Loading Because of critical relationship between the foundation and vessel design, construction of sard-bed / foundation and settlement shall be strietly monitored during various stages of construction, vessel hydrotest ete. Following loading shall be considered for design: a) Operating Condition: Self weight of vessel (but corroded thickness), mound load, Foundation’ sand-bed reaction, liquid weight, earthquake loading, differential settlement, desiyn pressure. longitudinal fretional load due to thermal and pressure expansion, explosion pressure on mound (if specified). Fermat No, WRPL 1641-1024 Rev. 1 ans| mgtongt ceteris OCUNENT Ne, USS atone RFI PEEROCHEMICLST. ENGIEERING DESIGN BASIS Une ge tedten BRD reve me 343 3a 3aS 346 b) Hydro Test Condition Self weight of vessel, mound load (in case of health check-up), foundation / sand-bed reaction, water weight, differential settlement, test pressure, longitudinal frictional load due to thermal and pressure expansion. Stress Analysis Detail stress analysis shall be carried out by using finite Element Method, Stiffness matrix method or any other relevant structural mechanics approach. Used software must be properly ‘vl dated giving references of similar installations for which the package has been used, Cathodic Protection Impressed current cathodic protection system shall be designed and installed as per the CONSULTANT Specification, Exiernal Coating Applied protection shall be fully tested for absence of holidays using high voltage spark tester. Internal Coating, Bostom 90 degtee of internal surface of vessel shall be coated with a suitable for stored product, -cortosion coating Location / Spacing of Vessels Minimum spacing of vessels and other safety tegulation shall be as per OISD ~STD- 150. ‘Mound Load ated for saturated mound and specific gravity of mound for this purpose, Load of mound on a vessel shall be 8) Weight of mound shall be eal shall be taken not fess than 2 calculated with arching effect. b) Mound depth above top of the vessel shall not be less than I metre, Format No, WRPL 1641-1924 Rev. 1 “asmagresmanrmesibe: ocUMENT He. SIASGATORE REFINERY € PEEMOCHEMUICALSL®, ENGIEERING DESIGN BASIS, Uinonee agro seat hes ne 34.8 Load due to Uneven Settlement a) To make allowance in the design for effect of tolerances in alignment of shell section, sesmuanengi unevenness in sand-bed, ete. a maximum/minimum reaetion may be assumed as given below. b) Based on soil investigation along with vessel axis, sub grade modules of soil / bed shall be calculated. Value of Pmax/Pmin may be reduced to 1.30 provided Foundation js constructed and_differential_settlement_isensured by the contractor and demonstrated during hydrotest. = ©) Sand-bed should be properly prepared and compacted 10 obtain effective angle of Support at least 120° and differential settlement should not be more than 40 mm between mid-point of vessel and end-point of vessel. During initial hydrotest condition sand bed contact angle may be taken as 6Odex without mound over vessel if such condition arise during construction and hydrotesting of vessel. 35 Reactors a) The design shall be done based on Process Licensor’ Specifications, b) Material selection shall be strietly be as per Licensor’ Specification. ©) Minimum thickness as per Licensor’s Specification shall be adhered to. ) — MDR & UDS as per ASME Code shall be obtained by the Fabricator for Reactors designed and stamped as per ASME SEC. VIII Div. I ) FEM Analysis shall be done for all Process nozales, shell to head junction ¥ shaped skirt, welded/wveld overlayed support rings and any other stressed point as defined in Licensor's specification. Format No, MRPL 1641-1824 Rev. 1 iocuMENT Ne, eget ea ite es 3.6 31 38 UW REFINERY PET ROCHTESICALSLD, ENGWEERING DESION Basis inter ssa wes internals shall have minimum thickness as given in Process Licensor's mand shall be designed for loads defined in Livensor's drawings. 2) Thermal analysis for HOT box shall be conducted. hy Reactors as well internals shall be fabricated by Process Licensor's approved Vendors. i) Lifting arrangement shall be as defined by Process Licensor’s drawings |) Floating type insulation supports shall generally be provided wherever feasible. Heat Exehangers Mechanical design of heat exchangers shall preferably be done by softivare developed by CONSULTANT. It complies with TEMA & ASME Sec. Vill Division | and also has certain praotiges builtin over and above these codes based on CONSULTANY's experience. Further CONSULTANT specifications shall supplement various Code's requirements to assure better ‘quality. For Vendor des sofiware complyi yned equipment, mechanical design shall be done by internationally wetted ng with the code requirement. (One exchanger from each type and each manufscturer shall be hydrotested in-situ at site. In addition, in ease, time wap between last hydro test is more than 6 months. then also exchangers are to be rehydrotested. After hydrotest, water draining and thorough drying shall beensured. Air Coolers Mechanical design of air coolers shall preferably be done by a software developed by CONSULTANT. It complies with ASME See. VIII Division 1 and also has eertain practices built in over and above this code based on CONSULTANT's experience. Further CONSULTANT specifications shall supplement various codes requirements to assure better quality. For Vendor designed equipment, mechanical design shall be done by internationally wetted sofware complying with the code requirement, of pressure vessels presents unique materials considerations in the design, fabrication, and testing of these vessels. FRP can be used for handling different types of liquid including acids. ‘The General requirements for equipment’s fabricated using FRP are given below. i, Materials: fa) The entire material requirement with respect to the FRP shall be followed as per requirement of PART RM of ASME sec X, The composite material will offen have directional properties which shall be considered in design. General specifications for Format No. RPL 1681-1924 Rev. 1‘BOCUNENT Ne, ENGIIEERING ESIGN BASIS ¢ materials (fiber reinforcement and resin) shall be mentioned for ination of elastic properties for the composite material (laminate) produced. ‘materials, when used in conjunction with reinforced fiber laminates, are required to meet ASME Boiler and Pressure Vessel Code specifications, Section VIII, Division 1. That Section must be used for the design, fabrication, quality control, and inspection of such metallic parts. However, for hydrostatic leakage testing, these metallic materials that complete the vessel are required to meet Section X requirements. ii. Design: a) Adequacy of specitie designs shall be qualified by one of two basic methods (these two methods shall not be intermixed): % Class { Design — qualification of a vessel design through the pressure testing of + a prototype; * > Class II Design — mandatory design rules and acceptance testing by nondestructive methods. b) Chass 1 designs based on the qualification of a prototype vessel require that the minimum qualification pressure of the prototype be at least imes the design pressure, The maximum design presstre shall be limited to 150 psi (1 MPa) for bag- molded, centrifugally cast, and contact-molded vessels; 1500 psi (10 MPa) for filament-wound vessels; and 3000 psi (20 MPa) for filament-wound vessels with polar boss openings. ©) Chass Il designs based on mandatory design rules and geceplance testing must comply with Article RD-I1 and Article RT-6 of ASME See X, The maximum design pressure allowed under this procedure shall be as specified in RD-1120. 4) Spherical heads or elliptical heads having an ellipse ratio greater than 2:1 shall not be used, Sphetical heads can be used when the material has isotropic properties. Elliptical heads are preferred when the material has anisotropic properties. e) The maximum design, operating, and test temperatures of Class | vessels shall be as follows: > 150°F (65°C) for design temperatures less than or equal to 150°F (65°C) > 250°F (120°C) or to within 35°F (19°C) of the glass transition temperature (whichever is lower) for design temperatures in excess of 150°F (65°C). 1) The maximum design, operating, and test temperatures of Class II vessels shall be lirtited to an inside wall temperature of 250°F (120°C) or to within 35°F (19°C) of the glass transition temperature of the resin (whichever is lower). The minimum, design temperature of both Class | and Class II vessels shall be -65°F (-54°C). iii, Fabrication: Class I vessels shall be limited to four processes, namely, filament winding, bag molding, contac! molding, and centrifugal casting. Class II vessels shall be limited to two processes, namely, filament winding and contact molding, iv, Inspeetion: Format No. MRPL 1041-1924 Rev. 1 anesrachonpt reine hs Aeeaabr MRACAIDNE REFINERY PETROCHEMICALSLTD, ENGINEERING CESION BASIS (iioscn igen sexton ts ere =) ‘The general philosophy of Section VIII. Division 1, regard fabrication shall be followed for FRP equipment’s also. Familiarity with the laminate production processes and the nature of vessel imperfections is required for the Inspector. v. Line Liners may be used in FRP vessels as a barrier between the laminate and the vessel contents. Such liners shall not be considered part of the structural component of the vessel. 3.9 Usage of Existing Equipment 3.9.1 Shall & Tube And Air Cooled Heat Exchangers the revised process/ design a) Adequacy checking of the existing exchangers w. conditions, shall be carried out based on the following: & i) Dimensions available in the As-Built drawirtes, if As-Built drawings are available, Dimensions available in the thermal design data sheets, if As-Built drawings are not available, IF both As-Built drawings and thermal design data sheets are not available & mechanical design pressure and / or temperature, die to revised process condition, exceeds the original design parameters, then new exchangers shall be provided to replace the existing exchangers. by MRPL shall furnish As-Built drawings for existing exchangers (which are tobe checked for adequacy) and As-Built isometries of thermosyphon re-boilers. ©) Health check of the existing exchangers shall be carried out by MRPL. Mechanieal adequacy checking shall be done on the basis of avaitable thickiiess of components. In absence of Health check report, adequacy checking shall be carried out based on thickness of components indicated in the As-Built drawings, considering no reduction in thickness of components over the years during operation, 4) MRPL shall indicate if any of the existing exchangers have already undergone any ‘modification from the As-Built drawings. Otherwise, adequacy checking shall be carried out based on As-Built drawings, considering no modification over the years during operation, ©) MRPL. shall check and inform plugging of tubes & damages to the existing exchangers, ifany. 1) Mechanical adequacy checking of existing equipment shall be carried out as per latest ASME codes. 3.9.2 Cohimns and Vessels a) Adequacy checking of the existing columns & vessels wart. the revised process/ design conditions, shall be earvied out based on the dimensions available in the As- Built drawings. if As-Built drawings are available, Format No. MPL 141-1924 Rev. 1 aneocumENT Ne. se Rep cs ioe MANGALONEREFINERY 4 PETROCHEMICALSLLTD. ENGINEERING DESIOW BASIS ‘yeaternine Tors gee ‘ae ») ° 2 3.10 IF As-Built drawings are not available & mechanical design pressure and / oF temperature, due to revised process condition, exceeds the original design parameters, then new columns & vessels shall be provided to replace the existing columns & vessels. MRPL shall fumish As-Built drawings for existing columns & vessels (which are t0 be checked for adequacy). Health check of the existing columns & vessels shall be carried out by MRPL. Mechanical adequacy checking shall be done on the basis of available thickness of components. In absence of Health check report, adequacy checking shall be carried out based on ness of components indicated in the As-Built drawings, considering no reduction in thickness of components over the years during operation, MRPL shall indicate iFany of the existing columns ft vessels have already undergone ‘any modification from the As-Built drawings. Otherwise, adequacy checking shall be carried out based on As-Built drawings, considering no modification over the years ‘during operation. Mechanical adequacy checking of existing equipment shall be carried out as per latest ASME codes. ‘Transportation (Columns and Vessels) Columns and Vessels shall be transported in single piece. For large vessel/ column which ‘anaot be transported in single piece from the shop. following methodology shall be-adopted ‘The vessel (column shall be fully fabricated with additional length and fully hydro tested at shop. ‘The vessel/ column shall be cut into number pieces as approved with exact dimensions ( Max 2 site welds) ‘Transported to site, fit up, fabrication welding carried out, 100% ra weld joints taken apart from other QC aetivity. Limpet coil hydro te Limpet coil shall be cut and removed later on, ‘Additional cleats to be welded on the equipment for erecting temporary platforms Format No RPL 1641-1924 Rev. 1 ane—— ecu | MaNG Aton REFINrIE PETROCHEMICALS ENOIEERING DESION Basis | bees steer eee rABLI JLS AND WEIGHT OF COLUMN ATT: T 1. Shave factor for shell 07 (for wind force ealeulation) 2. Weight of ways (with liquid) to be 2 120Kg/m*, considered. 3. Weight of plain Ladder : IS Kgdin 4. Weight of caged ladder 5 ST Kg/m 5. Equivalent projection to be considered for: 300mm wind load on caged ladder 6. Disiance of platform below each manhole: Approx, 1000 mm 7. Masimum distance between consecutive: 5000mm plaiforms - 8. Prejection of Platform 900 mm upto | meter dia. column and 1200 mm for column dia, >1 meter, from ‘column insulation surface, 9, i) Equivalent height of platform (for: 1000 mm wind load computation) ii) Shape Factor for platform so 10, Weight of platforms : 1T0Kg/m2, LL. PlatZorm shall be considered all around for top & bottom platforms. All intermediate platforms shall be taken as half. Fonmot No, MRPL 1641-1624 Rev. 1 “ighgeting oven te Sealer, MANE MORE REFINERY & FETROC ENGMEERING DESIGN BASIC dans ier ees EY TABLI ALLOWABLE STRESSES FOR COMBINED LOADING) VESSEL CONDITION/TEMP. TYPE CONDITIONS OF STRESSES ERECTION | OPERATING TEST NEW OR CORRODED NEW CORRODED | CORRODED’ TEMPERATURE ‘AMBIENT DESIGN ‘AMBIENT LONGITUDINAL KXSXE KXSeE O90 PXE LONGITUDINAL COMPRESSIVE 1B xB B STRESS. Where s Basie allowable Tensile Stress as per Clause UG 23(a) of ASME Code See. VIII B= Biv cleats por Case UG-25 E = Weld joint efficiency of circumferential weld, depending on extent of radiography. K = _ Factor for increasing basie allowable value when wind or seisiie load is present, - Note : Allowable stresses in skirt to shell joint shall be as per fallow a) 0.495. ifjointis shear type. b) 0.705, ifjoint is compression type. Format No. MRPL 1641-1824 Rev. 1 ‘aisiat emihile eocuMeNT Ho. SANG ALOMF REFINE PE ROCHENMICATS LTD, [ENGINEERING CeSION BASIS | Citas Seaton he om ANNEXURE -1 MATERIAL SELECTION “The following table gives general guidelines for materia seleetion for various Pressure Parts/Non Pressure Parts of the equipment based on design temperature wherever material of construction is not specified by the process liensor, 1 eae ome ee Tusk reese, 7 TE RODS a Bore pe ae a oe Bite [BSE | Bien REE [OME [HGR ime wwe [a sores eee age» [smo [ay soe use lemme [ome Joo faa, amg, [omae [amas [svimam [semis Bei aay sain owner [ages [mem [ama [eats gga. [seer [ema [man [oom wow laws awe eae fan | peer fowear [wiwan | oomusn Bie age stucat | vrs | agar [pe | nee [ge | smn | onan | mato TAPER IA TE TEMPERATURE amor, [await [sve fom Pages Yuta |i, | ee ie Tea foowme | gosar [pore [acmoen | gsmuate | eteews | Agate | seinem | aa, Bee | moe |e aemge fey fam [RR [RBLEERT / BBRMkeraus | ARR | em | ee spmore | au. Pana | at wae arcs, | sumone | sage ea | A | EIR | BRitherae | Rae [SM | Ss me Re 5 Ee ua ED TEMPERATURE aa Bh, | Weve | ABB | mae | ase ST Bila, | MiBlenon | paBte | oman | guna snore uae [mains [esr [ose [come ER EE eae ? cam | soe [anus [eae | Som ae Fonmat No. NRPL 1641-1924 Rev. 1