ENGINEERING AND DESIGN DEVELOPME Case history: Replacement of existing pressure vessel Installing new equipment involves more processes to ensure safety and to meet new codes D. FEARN and J. MCKAY, Fluor Canada Ltd, St. lah, New Brunswick, Canada he replacement of presie vesicle common function inan operating telinery, prialstlythow units that have been in operation free fll dag ie ofthe vse Fom the ints perspective a wate may have operated succes fe many yes beyond te oihaldevgn ie wth no ue lt replacement shouldbe eal accomplished given the lative sce ofthe original desig. In the eal world the replacement ofexiing refinery ves in a Brownfield environment se dom replacement a Kad Some minor, yet npn activites shouldbe addresed wo ensure projec suse Tn the presented exsmple, work proceses used oceplace hydrogen slid (5) abeorber as pact ofa refinery ce unit that wa ongally iene as replacement kind wl be dis ‘se. In adion ro working to = documented work proces, there are many areas where the varios design engine ast ‘hink ouside ofthe exablshed work pace to ensure dhe ‘mel fe and eet imseallation of ew velo Ths eile snot meant to replace exirng work process twill entfy tncearares that ext when pling esuipment Inst exng operating une The project. This unplelmhestheplcement fan HS sete toes Thi over common od ney cee {Isparta hema of hs don by {elves egal el cong rena ffs psid won ‘The puro the owes removeH,S,anitinecery ‘0 minimize slur diode (S0,) cmsions fom an nocene soaps nce where he ed ffs burned. hte {imesh Frac nd sda renege clon ope {trey lm pre eros do hough eH seer ‘ns be mil od ese fc on tao Sed dum HS removal. To doshese thee avis, the esl separated Int hee ajc component, The bottom drum enti il ‘abons, HS sluion and detyolamine (DEA). The dram Femoes he ydroeaboas rom he Ht he DEA asi wih this proces. The sd HS ream isen fom the Bose dea Lup itoan Hy absorber exon tha led with andom pace Ing. Treated ofgas isn ino the top drum where he unened DEA issenrback othe abrobersectn aid the us forwarded ‘othe adjacent furnace Ashe vee operates in an HS ad ich-DEA environment ‘he tefnery performs regu aspecions a par of ik based Inspection (HB) program as ound by indy standard prc ‘ice sefnry pei pracces and guideline erliched by the ‘AmeianPevoleum Insite Followingan atonal ulesonic testing (AUT) and mancal lez eing (MUTT Inspection ‘fhe bottom dum, sea found at ee oreted prog, induced cracking (SOHTC), rang in top me cracking and [ste ormason was present inthe drum with concentons Aighes inthe lower drum elon (Fig 1). Ref ervie ea. ‘ulations resale i the recommendation co replace the ese thus prevecinga pont unplanned production inctupin, I. The orignal veel was bale in 1974 co ASME Section VIL, Divison 1, 1971 Ed. The wet was spc fed wih oie efcency of 0.85 (Spoe RT) andthe meta ‘construction was SA-285 Grade C. Alhough vend mateENGINEERING AND DESIGN DEVELOPMENTS rocpost wed hea reated (POH) weld hades ws inited 9 200 HB. Theborom drum 4 Rin diameter and 0 fein hgh (including the Mf i). The op dru and packed section 70 long nd 2 in damete. “The Hs absnber intemal consid of our ali-down plas sand 120 fof random packing, To ditbute solution vo the HS aloe, angel nomi! were wed on he inl nome “her the ston woud calle onder hearth hen [rai fed down trough the packing. To imi et contact {and subsecueneroxion) of DEA and HS on cubon ste the tangential rome ected fow eoward a 304 sails sel SS) lad pt a as welded tthe vse nena diameter, ‘Theoretical design considerations and scope. In tly the pj eqtemen was the replacement in ind of he ‘ene other equipment cre azached or adhcent tthe ee “would so ned tobe examined. For example, he piping sem thacalo process rich DEA and HS was potency a for sociated neallugcal damage mechanisms. The foundation ‘ad conesponing anchor bol needed tobe revewed to deter “nine they were aecepiable for conned service forthe ext- ‘ated desig fe ofthe replacement vest Elec an onal [tens wee lo reviewed to determine exiting ses te ‘Sod complane and adhere to cree refinery practices, While ‘othe dips face challenges imaro the vel designe, his sve wil focus sly onthe veel nplacinent. However noted Irems are considered Iner-ipline elated, For the vesel designer the cope to replace a vex inl, far more than she placement in kind ofan exiting a and ‘rtng tat che new ner wl eee nt code. The degnet, ‘urtengage operation ro ensre th many ee and ost, Tadder and patio acu, packing ssn, ear secepbl to the caren and frre nerds Some teed may nob Wesied ‘une ehe piping, lee and connols designers als de thee respecvedsign actives. "Ate requ rom the cen watt replace the vel in kind, the eiting veel we ode nea vb simulation mel 'edeerminefevsions 0 ASME Seion VII benween 1971 and 2008 would elim an overall design change to the new vee Forshirvetl paral arenson was paid the intel head design forthe bocomitop drum asenblis, wea the ns tion (48 nto 24m) beeween the bottom deum and rzdam packing scan. Where dhe new vsel wast be contracted of SAS16-70N, the greater allwablesues compare othe orginal SH283 ose any cade changes chr would otberwie incense ‘he over hicknes and potently mpac the tol dimensions “Animporant acy ofthe eel desgners to aly and place ands on every tem of deve and co check ac ‘acy guns the oignal desig ravings Thi ints adisonl ‘este penertons platform lads or squlprent chat wa cr pat ‘the ginal design, Depending an the level of docursnetion ontrl within he exiting faci ts posble ha che orginal Armvings donot ex or aro ich poe qualita new Inge mir be dae, ‘Wheres constuction snot ply engaged ul farce in ‘he abveaon proces, bowabelcevlopment should elude dig consideons recommended by te construc eam sdf contactor ems added iad the tng of nae ‘rveallaon, adding i ls o eloetng platform clip locone {fact italian whee space ined ‘The ovpuc fom this proces sould incade a defined and Inver dtipline reviewed datthet and gener artangemenc raving (bul or ew) cae willbe sud the vesel abc {oe This allows all disciplines otevew poten interFemnces eowee nee clips, guides sper ih ange, et ‘Actual design conditions and scope development. ‘The orginal projet rope bars wa fora replacement In kind vessel However, daring project developmen, many changes vere made. To deny the changes eguled for ths ese, ach ‘Becpline apt vas cdi spantey Mechacical rated changes Ginn the presence of HS and SOHIC; the bse materilewere upgraded 0 SA SI67ON -HIC rent carbon sel and incled fx PWHT in accordance wich ‘he recommendations of NACE MROI7S. The radiographic tt. Ing (RT) wa need fll 100% RT while maining the 2100 HB barns Li, "To ptrent ation entrant Knee the ogi ine shale aver Al eld ety om po SO. Min ‘um weld vey thicker wasp oem degue thicke ‘eat for Ingen proecon. Addonl NDE we sec For ‘he ove, suchas LP, UT (or disbndment and ete testing “Thieves lie he ae dames and, without sp plementary support i eules nina mera on tbe base ing Eechorbolsand inh Manges resting tothe wind se ‘mic oneraning moment The opal veel degn includedENGINEERING AND DESIGN DEVELOPMENTS ues, as shown in ig. 2a ure upper lvaton whereby the $Mjacent column povided suppor. The incon ofthe ues enied the esulbutn of wind lad (oneruing moment on ‘he vesel base) andthe aczepeans ofthe eating chor bl ae esl ike Per tequltemens bythe client and construction tem hand hoes were installed ro fear lspeeon removal and tal tin ofthe random packing Lif unions were ao asta on the bat ofthe pak seton to fae iveliatin, Seve new pipe guides and suppor wera inalled on the veel 0 ‘emove load fom plato Following view ofthe loas placed om the aes and plat forms in adi w oecupaonal health and afer hangs sce ginal eonsretion,theladers nd platforms wore esi “lee related changes Ashe finery specitons have ‘hanged ove the er the equiemen we made ince for tablet clipson the vse lie eel cable istalion td predeing peor oi Vessel fabrication. Fo thi prt pes, he ves fb ‘eso was provided wth the orginal a bul reselling and revised dates The abvicuoe was required wo peodace new ravings incorporating allo the changes For the ee designe, thiseqiesatecion f deal wenatchee dimer ‘Sosa consent wth be egal desig changes are bes Incoeporaed int the new desig, “To ep fact quai concerns beween che fbricaor and let thed-pary nec vas cated throghowt the bcs sion proces. The scope a he hil party nspector wa enc the agreed co inspection and ext plan war being adhered toys vee bea client epresemne or any ld pins dung ae viii rial assembly and expres. ‘As new platloms were specified forthe replacement vse ie ‘was decided that shop il ret shouldbe done Ths erred ‘hac he plafors would fie during ssallation and prevented ‘ony rework onsite that might, othe, have ro be psfrmed ‘win therumrouind window Demolition and installation of vessel. Depending on ‘Sete aval spc condertons ad eure wali the conse em may chon ral many eed ‘lated component pose ote constuction cs and { poet ding wock wna oprng unt Th tyne predrsingSreprooing prose ppe he tang aaron, ares, platorn, ints intruenation ad cable ye ‘Wher thi vead asbingemonedand edn an oper cvronnen se procera illowed * Lift contac reviewed salable sce and determined smuimimalinabe acy ig *,Contrcion dened he tended exe of re deasng Nechnilepoeing declan he tl weigh nd cer fg ve Compa wt al re sed con oven Depending he snout omnis feta Stoo ead feugiat si oe ‘rs ineported io tol mesa i ni. A co ‘oe 30% not uncommon nde for eon wing fication wires Ths weg ones ey ipo Spuelabiymay ii he ce ype and pacar ‘eg einai connor ay ei inte sal or ‘oobi ofc sg I || eg PASS ase + The ft contactor verified the weigh prior othe demal- ‘iowosallaion eo confirm that cane eaaciy would not be peer Elevations, offzets and grouting of baseplate. Dur ing the design and eonseraction proces, he eevaton of the foundaion and underside ofthe veel bs ing was rvs ‘Thisensed chat he veal wold ec at simar elevation to the original ae, ‘With he rg vesel emove the Foundation as pupae to acre the ew vesel and anocted gout One the ee ws installa suvey vascomplaed arte underside of the base nat ‘heshimlocasnsas wel eal gh anger on the vee. Th sere ‘sa check ere here warn "wolcin the veel ection, ‘Once the veel ha achieved proper alignment ese ws outed othe foundation with de renaining componcas (a ‘is, ners) isle ha could not be p-desed. MP Sprnneeclcorrmpesavouwaocmrtngre i et an Poo es gn ot a wracamouocsn MUAY |