Design Criteria for Mechanical Equipment 4S. 4300 SAI S0003 ISGP G00000

Project: Inspection, Assessment and Rehabilitation of Um Qasr Terminal

Contract No. SIGUP-12-063(a)

Plant: Iraq South Gas Project – Um Qasr Marine Terminal

Job No.: 282402

Client Document Number Contractor Doc. No.

Proj. Orig. Site Plant Unit Dis. Type Seq. 300-PA-E-30002

4300 SAI S003 ISGP G00000 AA 7704 00151 Rev. Sh.

04A 1 of 28

This document is the property of Basrah Gas Comapny who will safeguard its rights according to the civil and penal provisions of the law.

04A Approval for Use (AFU) M.Agja Oommen.K Oommen.K 27/10/13

03A Re-Issued for Approval (IFA) M.Agja Oommen.K S. Kulshrestha 17/09/13

02A Issued for Approval (IFA) MHA/ MRC OKU/ SKU NBM 14/08/1301R Issued for Review (IFR) MHA/ MRC OKU/ SKU LR 11/07/13

Rev Description Prepared Verified Approved Date

DESIGN CRITERIA FOR MECHANICAL EQUIPMENT




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Title: DESIGN CRITERIA FOR MECHANICAL EQUIPMENT

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This document is the property of Basrah Gas Company who will safeguard its rights according to the civil and penal provisions of the law.

REVISION HISTORY Rev. Date Description of Revision Prepared Verified Approved

01R 11/07/13 Issued for Review (IFR) MHA/ MRC OKU/ SKU LR

02A 14/08/13 Issued for Approval (IFA) MHA/ MRC OKU/ SKU NBM

03A 17/09/13 Re-Issued for Approval (IFA) M.Agja Oommen.K S. Kulshrestha

04A 27/10/13 Approval for Use (AFU) M.Agja Oommen.K Oommen.K




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TABLE OF CONTENTS

1 INTRODUCTION.............................................................................................................................................. 5

2 SCOPE ............................................................................................................................................................ 6

3 OBJECTIVE ..................................................................................................................................................... 6

4 DEFINITIONS & ABBREVIATIONS ..................................................................................................................... 6

4.1 ABBREVIATIONS ............................................................................................................................................. 7

5 REFERENCED DOCUMENTS ............................................................................................................................. 7

5.1 PROJECT SPECIFICATIONS ............................................................................................................................... 7

5.2 SHELL DEP ...................................................................................................................................................... 8

5.3 INTERNATIONAL CODES & STANDARDS .......................................................................................................... 8

6 DESIGN PHILOSOPHY / CRITERIA .................................................................................................................... 9

6.1 GENERAL ........................................................................................................................................................ 9

6.1.1 EQUIPMENT SELECTION ................................................................................................................................. 9

6.1.2 MATERIAL SELECTION .................................................................................................................................... 9

6.1.3 ENVIRONMENTAL DATA ................................................................................................................................. 9

6.1.4 WIND DESIGN .............................................................................................................................................. 10

6.1.5 SEISMIC DESIGN ........................................................................................................................................... 10

6.1.6 EQUIPMENT SPECIFICATIONS ....................................................................................................................... 11

6.1.7 PAINTING & COATING .................................................................................................................................. 11

6.1.8 INSULATION ................................................................................................................................................. 11

6.1.9 SPARE PART PHILOSOPHY ........................................................................................................................... 11

6.1.10 CONSUMABLES ............................................................................................................................................ 11

6.1.11 SPECIAL TOOLS ............................................................................................................................................. 11

6.2 DESIGN CRITERIA FOR STATIC EQUIPMENT ................................................................................................... 11

6.2.1 SIZING .......................................................................................................................................................... 11

6.2.2 VESSEL CATEGORIES ..................................................................................................................................... 11

6.2.3 MINIMUM SHELL/HEAD THICKNESS ............................................................................................................. 12

6.2.4 VESSEL END CLOSURES ................................................................................................................................. 12

6.2.5 DESIGN PRESSURE ........................................................................................................................................ 12

6.2.6 DESIGN TEMPERATURE ................................................................................................................................ 13

6.2.7 TEST PRESSURE ............................................................................................................................................ 13

6.2.8 COMBINATION OF LOADS (WEIGHT, WIND, EARTHQUAKE) .......................................................................... 13

6.2.8.1 DESIGN LOADS ............................................................................................................................................. 14

6.2.8.2 LOAD COMBINATIONS ................................................................................................................................. 14

6.2.8.3 FOUNDATION BOLTS .................................................................................................................................... 14




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6.2.9 CORROSION ALLOWANCE ............................................................................................................................ 14

6.2.10 SUPPORTS .................................................................................................................................................... 15

6.2.11 CONNECTIONS ............................................................................................................................................. 15

6.2.12 SPECIFIC DESIGN REQUIREMENTS BASED ON VESSEL CATEGORY .................................................................. 16

6.2.13 DRAIN AND VENT CONNECTION: .................................................................................................................. 16

6.2.14 NOZZLE LOADS: ............................................................................................................................................ 16

6.2.15 GASKETS ...................................................................................................................................................... 16

6.2.16 WELDING ..................................................................................................................................................... 16

6.2.17 NDE ............................................................................................................................................................. 16

6.2.18 IMPORTANT CONSIDERATIONS .................................................................................................................... 17

6.3 DESIGN CRITERIA FOR DIESEL GENERATOR PACKAGE .................................................................................... 18

6.3.1 GENERAL ...................................................................................................................................................... 18

6.3.2 RATING ........................................................................................................................................................ 18

6.3.3 STARTING SYSTEM ....................................................................................................................................... 18

6.3.4 NOISE LEVELS ............................................................................................................................................... 19

6.3.5 DIESEL DAY TANK ......................................................................................................................................... 19

6.3.6 PACKAGED UNIT .......................................................................................................................................... 19

6.4 DESIGN CRITERIA FOR NITROGEN BOTTLE RACK ........................................................................................... 19

6.5 DESIGN CRITERIA FOR DIESEL FIRE WATER PUMP ......................................................................................... 20

APPENDIX 1 DESIGN LOADS .......................................................................................................................................... 21

APPENDIX 2 NOZZLE LOADS ......................................................................................................................................... 23

APPENDIX 3 NON DESTRUCTIVE EXAMINATION TABLE ................................................................................................. 25

APPENDIX 4 CRITICALITY RATING TABLE ....................................................................................................................... 27




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1 INTRODUCTION

The NGL/LPG Plant at Khor al Zubair (KAZ) produces Propane, Butane and Natural Gasoline, and the Um Qasr (UQ) Storage Terminal (which comprises Iraq Receiving Terminal (IRT) and Iraq Storage Terminal (IST)) provides facilities for the refrigeration/cooling and storage of these products. The Marine Terminal at UQ was constructed in the 1980s for the export of Propane, Butane and Natural Gasoline supplied from the UQ Storage Terminal. However none of these facilities at UQ were ever commissioned and they have never operated as originally designed. Instead they have been used to import pressurised LPG and Gasoline to supplement domestic production and meet domestic demand. Currently, the Propane and Butane produced at KAZ are being combined in spheres at KAZ and pumped as pressurised LPG to the Propane and Slops storage spheres at UQ Storage Terminal. However, since there currently is insufficient production of LPG to satisfy domestic demand, LPG is currently also being imported via the South Jetty at the UQ Marine Terminal. The combined pressurised LPG is then transferred to the Nassariya pumping station and then on to the Iraqi domestic market via multi-product pipeline. Iraq is also currently not self-sufficient in Gasoline, so Gasoline is imported via the North jetty at the UQ Marine Terminal and is then distributed via a truck loading system situated near the Marine Terminal. The UQ Marine Terminal consists of two main jetties (North jetty – berth 1 and South jetty – berth 2). Located approximately 500m south of the two main jetties is a service jetty which provides berthing space for tugs and other small vessels.




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As part of the Iraq South Gas (ISG) Utilisation Project, it is intended that these facilities at UQ shall be rehabilitated back to their original design capacity by 2016. During the rehabilitation works, import of pressurised LPG and Gasoline must be continued to satisfy the domestic market. It is therefore necessary during the rehabilitation of the North and South jetties at the Marine Terminal to provide alternative means for the import of LPG and of Gasoline in order to continue to satisfy the domestic market. The option to modify the existing Service jetty to allow for safe import of pressurised LPG on a temporary basis has been adopted., with a target milestone of 1 calendar year (365 days) from rehabilitation contract award. When improvements are made to Kor Al Zubair (KAZ) and the upstream facilities and the associated oil fields are further developed, local LPG production is expected to increase gradually. There will therefore be a point at which production will exceed the domestic market requirements; currently anticipated to be Q3 2014, when the pressurised LPG operation will switch from import to export. A plan has therefore been outlined to also modify the service jetty in order to be able to reverse the current mode of operation for importing pressurised LPG so that instead pressurised LPG can be exported as an interim “insurance” mode of operation that can be used if KAZ is capable of producing export volumes of LPG before the rehabilitation of Um Qasr has been completed. Some background information on the original design, current operations, future throughput requirements, and forecast berth utilization rates can be found in report 1000-SGI-U001-GE00-G00000-AA-6480-00001-000 - Design Requirements for the Rehabilitation of Um Qasr and the Marine Terminal. The battery limits of the UQ Marine Terminal scope are at the downstream flanges of the main pipeline isolation valves on the UQ Marine Terminal plot (propane, butane and gasoline export lines) and upstream flanges for the propane and butane vapour return lines.

2 SCOPE

This document is intended to provide basic data, design requirements, applicable code & standards required to perform the detailed / design engineering for the mechanical equipment including static, rotary equipment and packages, but excluding HVAC, to be installed on the Service JETTY.

3 OBJECTIVE

The objective of this document is to describe the minimum general requirements to be followed for design & detail engineering for the equipment. The requirements specified in this document shall be used as the basis for preparation of the detailed equipment specifications and it shall be used as guide line to proceed for designing the equipment.

4 DEFINITIONS & ABBREVIATIONS

COMPANY Basrah Gas Company (BGC)

CONTRACTOR Saipem S.p.A. for Out of Country (OOC) projects Sajer LLC for In Country (IC) projects

SUPPLIER (VENDOR) The party that supplies equipment, technical documents & drawings and services to perform the duties specified by COMPANY and CONTRACTOR

CONTRACT Contract agreement entered between the COMPANY and CONTRACTOR

PROJECT Um Qasr Marine Terminal




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4.1 ABBREVIATIONS

API American Petroleum Institute

ASCE American Society of Civil Engineers

ASME American Society of Mechanical Engineers

BGC Basrah Gas Company

BS British Standard

dB Decibel

dB(A) Decibel with A-weighted scale

DEM Design Engineering Manual

DEP Design Engineering Practice

DG Diesel Generator

ESD Emergency Shutdown

ISG Iraq South Gas

ISO International Organization for Standardization

LPG Liquefied Petroleum Gas

UBC Uniform Building Code

UQ UM QASR

5 REFERENCED DOCUMENTS

Mechanical design shall be based on Project Technical Specification, Shell DEPs (mentioned in this document) and International Codes and Standards.

In case of any conflict between this specification and other engineering documents, the order of precedence shall be as follows:

(a) Iraq Statutory Regulations* (b) Project Data Sheets (c) Project Technical Specifications (d) Shell DEPs** (e) International Codes and Standards

* Not available at present time ** Applicable DEM 2 only

5.1 PROJECT SPECIFICATIONS

S. No. Reference Document No. COMPANY Document No. Description

1 000-ZA-E-09025 4300-SAI-S003-ISGP-

G00000-AA-7704-00002 Basis of Design for Service Jetty

2 300-ZA-E-03600 4300-SAI-S003-ISGP-

G00000-PX-5507-00001 Basis of Design for Service Jetty

3 300-RA-E-20003 4300-SAI-S003-ISGP-

G00000-RA-7754-00151 Painting Specification for Service Jetty




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4 300-RA-E-20004 4300-SAI-S003-ISGP-

G00000-MX-7755-00151 Insulation Specification for Service Jetty

5 300-RA-E-20005 4300-SAI-S003-ISGP-

G00000-RA-8241-00151 Material Selection Report for Service Jetty

5.2 SHELL DEP

S. No. Reference Document No. Description

1 DEP 70.10.90.11 SPARE PARTS

2 DEP 30.10.02.31 Metallic materials – Prevention of Brittle Fracture

5.3 INTERNATIONAL CODES & STANDARDS

The following codes and standards in their latest edition including latest addenda shall be followed unless otherwise.

S. No. Reference Code/

Standard Description

1 ASME SEC. II Material Specifications

2 ASME SEC. VIII DIV.1& 2 Rules for Construction of Pressure vessels

3 ASME SEC. V Nondestructive Examination

4 ASME SEC. IX Welding & Brazing Qualifications

5 ASME B 16.5 Pipe Flanges & Flanged Fittings

6 ASME B 16.20 Spiral Wound Gaskets

7 ASME B 16.47 Large Diameter Steel Flanges

8 ISO 3046 (1-7) Reciprocating Internal Combustion Engines - Performance

9 ISO 8528 Reciprocating Internal Combustion Engine Driven Alternating Current Generating Set

10 ISO 10816-1 Mechanical Vibration - Evaluation of Machine vibration by measurements of non-rotating parts

11 ISO 9809-1 Gas cylinders - Refillable seamless steel - Design, construction and testing

12 API 2000 Venting Atmospheric and Low-pressure Storage Tanks

13 API 582 Welding Guidelines for the Chemical, Oil and Gas Industries

14 UBC-1997 Uniform Building Code

15 ASCE 7 American Society of Civil Engineers

16 UL142 Steel Aboveground Tanks for Flammable & Combustible Liquids




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17 WRC Bulletin # 107 Local Stresses in Spherical & Cylindrical Shells Due to External loadings

18

WRC Bulletin # 297 Local Stresses in cylindrical Shells Due to external loadings on nozzles.

6 DESIGN PHILOSOPHY / CRITERIA

Equipment shall be designed in compliance with the latest design code requirements, and applicable standards/Specifications. All design calculations shall be made considering all loads for Erection, Operating and Hydro test conditions.

6.1 GENERAL

6.1.1 EQUIPMENT SELECTION

The principles to be adopted during the selection and specification of Mechanical equipment can be summarized as follows:

(a) Fit for purpose (b) 2 year (min) Design Life (c) Proven and reliable design (d) Suitable for the operating conditions specified in this document and elsewhere in project

documents (e) Accessibility, Operability and Maintainability (f) Availability / Reliability and Robustness (g) Adherence to area classification and environmental conditions

6.1.2 MATERIAL SELECTION

Material selection for each equipment shall generally be based upon nature of service, design and operating conditions. Base material of construction shall be specified in Mechanical Data Sheets of each equipment and shall be in accordance with Material Selection Diagram and Material Selection Report. Detailed information regarding material of construction, i.e. material grade of components, shall be confirmed by equipment vendor.

6.1.3 ENVIRONMENTAL DATA

Surface Air Temperature:

Design Air Temperature 53 °C

Maximum monthly mean July 37.4 °C

1-hour measured minimum -1.1 °C

1-hour measured maximum 51.1 °C

100-year 1-hour minimum -5.5 °C

100-year 1-hour maximum 52.2 °C

Black Bulb Temperature, (Direct exposure to Sunlight) 82 °C




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Relative Humidity:

Barometric Pressure:

6.1.4 WIND DESIGN

Wind design shall be as per ASCE 7 with following Parameters. (a) Design Wind Speed = 44.7 m/s (b) Importance Factor (I) = 1.15 (c) Exposure Category = C

Maximum static deflection The maximum deflection at the top of a vertical item of equipment in the corroded condition as a result of wind loads shall be limited to 1/200 of the total height, unless more restrictive provisions are laid down by the applicable codes. Vibrations due to wind Supplier shall provide a proposal for mitigation against vortex shedding effects for equipment that meet the following conditions:

a) H/D ratio of 15 or greater, and

b) Mass damping parameter (MDP) less than 0.8 under operating conditions, or MDP less than 1.1 when the vessel is under erection or on standby. MDP = mβ Φ.d2 Where m = mass per unit length of the top third of the tower, in the condition considered β = structural damping ratio, 0.004 for empty, unlined steel vessel Φ = density of air d = mean diameter over the top third of the tower D = nominal diameter of tower H = height of tower

A check of the vibrations caused by the “Karman vortex” phenomenon shall be carried out for both erection and operating conditions. Supplier shall propose any solutions to the Employer to avoid problems of instability and fatigue.

The above check is not compulsory when the critical wind speed exceeds 25 m/s.

6.1.5 SEISMIC DESIGN

Seismic Design shall be performed as per UBC 1997 based on following Parameters:

Monthly average minimum, June 17 %

Monthly average maximum, January 61 %

Design Barometric Pressure 1024 hPa

1-hour maximum 1033 hPa

1-hour minimum 989 hPa




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Seismic Zone - 2B Zone Factor - 0.20 Importance Factor - 1.25 Soil Profile Type - SD

6.1.6 EQUIPMENT SPECIFICATIONS

Technical specifications for each type of equipment like Pressure Vessels, Diesel Generator set and Nitrogen Bottles shall be prepared which shall contain detailed requirements pertaining to design, procurement, fabrication, inspection, testing, operation & maintenance and safety.

6.1.7 PAINTING & COATING

Equipment shall be painted in accordance with Project specifications 300-RA-E-20003. The exception to the painting could be packaged equipment or Vendor standard, where, equipment vendor shall make their recommendation of appropriate painting system. However, it shall be ensured that the painting system recommended by the vendor is suitable for the application and have a proven record for the similar installation and operating conditions.

6.1.8 INSULATION

Insulation shall be provided as per Project specification 300-RA-E-20004.

6.1.9 SPARE PART PHILOSOPHY

Equipment / Package vendor shall submit a detailed itemized price list, with delivery items, of recommended spare parts for commissioning, start-up and 2 years operational spares.

6.1.10 CONSUMABLES

First fill of lubricants and consumables shall be supplied by vendors.

6.1.11 SPECIAL TOOLS

Special tools, if applicable, shall be supplied by the Vendor as indicated in respective material requisition.

6.2 DESIGN CRITERIA FOR STATIC EQUIPMENT

6.2.1 SIZING

Static Equipment sizing basis shall be based on internal diameter.

6.2.2 VESSEL CATEGORIES

Pressure vessels shall be segregated into 3 different vessel categories based on criteria given in APPENDIX 4. This categorization is on the basis of equipment criticality, which includes:

a) Operational Risk- Loss of production and loss of containment including environmental and people risks.

b) Design Complexity – High operating temperatures and pressures, potentially high corrosion rates, hydrogen service

c) Fabrication Complexity – Complex materials of fabrication, heavy wall, complex internals, PWHT requirements,




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The vessel categories will be: Category 1 Highest category, associated with potentially high operational, design or fabrication

risk. Warrants the most stringent design and fabrication requirements.

Category 2 Medium category, associated with potentially moderate operational, design or fabrication risk. Warrants some special design and fabrication requirements.

Category 3 Lowest category, associated with reduced operational, design or fabrication risk. Standard design and fabrication requirements are sufficient.

6.2.3 MINIMUM SHELL/HEAD THICKNESS

The various components of equipment shall have minimum thicknesses not less than that required by the applicable codes and standards. Moreover the shell and head thickness in mm, shall not be less than:

3 mm for high-alloy steel vessels;

For carbon and low alloy steels tmin (including the corrosion allowance) for carbon and low-alloy steel vessels transported as one unit or in cylindrical parts. tmin shall be derived from the following equation, with a minimum of 6 mm:

t min = D + 1.8 ( mm) 650

Where: D = mean vessel diameter in mm

For vertical equipment supported by a skirt, the skirt minimum thickness is given according to the thickness T of the item to which it is connected. Skirt minimum thickness = T for T ≤10 mm Skirt minimum thickness = 10 mm for T >10 mm

6.2.4 VESSEL END CLOSURES

2: 1 semi Ellipsoidal Dished End shall be used for pressure vessels unless for high design pressure condition where hemispherical type heads may be used. Whenever possible, heads shall consist of a single piece or the smallest possible number of pieces. If heads do not consist of a single piece, welded joints shall be positioned in such a way as to intersect a concentric circle having a diameter equal to 0.8 times the head diameter. Otherwise they shall all be situated within the circle. These limitations do not apply to hemispherical heads Pipe Caps may be used for vessels diameter 600mm having no internals. Flat heads may be used for atmospheric Vessel. Flanged Covers shall be used for Vessels/Columns of Diameter 900 mm having internals.

6.2.5 DESIGN PRESSURE

Design pressure shall be considered as specified in process datasheet. VACUUM conditions must be considered wherever applicable.




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The design pressure at any lower point is to be determined by adding the maximum operating liquid head and any pressure gradient within the vessel. Vessels shall be designed for steam out conditions if specified in process data sheet. Minimum design pressure for pressure vessel shall be 7.5 bar g, unless otherwise stated in process datasheet.

6.2.6 DESIGN TEMPERATURE

Design Temperature shall be considered as specified on process datasheet. Minimum Metal Design Temperature (MDMT) shall be lower of minimum atmospheric temperature OR minimum temperature envisaged during operation.

6.2.7 TEST PRESSURE

Pressure Vessels shall be hydrostatically tested in the fabricator's shop as per design code.

In the case of vertical vessels the hydrostatic test pressure shall be that measured at the top of the equipment when positioned vertically. Unless agreed otherwise, a vertical position check shall always be carried out. Hydrostatic test for vertical vessels in horizontal condition is not acceptable without prior COMPANY approval. In hydrostatic test conditions, the maximum stress on the pressure parts shall not exceed 90% of the material yield stress, unless otherwise indicated in the applicable codes. In addition, all vertical vessels, columns, and horizontal vessels shall be designed so as to permit site testing of the equipment with water at the test pressure on the top of the equipment considering 25% wind load. The design shall be based on fully corroded condition. All equipment foundation shall be designed and constructed for water full condition when equipment is new with 25% wind load. Vessels open to atmosphere shall be tested by filling with water to the top.

Water containing not more than 50 ppm (mg/kg) chlorides shall be used for the hydrostatic testing of stainless steel, stainless steel clad or lined equipment (whether austenitic or not).After the hydrostatic test the vessel shall be immediately and carefully drained and all parts where water could collect shall be dried. Suitable measures shall be taken in respect of the water temperature during the hydrostatic test to avoid brittle fracture. This shall be done by taking into account the thickness and type of steel involved. The gaskets used for pressure tests at the workshop shall be of the same type as those required for operation and shall not be re-used.

6.2.8 COMBINATION OF LOADS (Weight, wind, earthquake)

For all items of equipment, in addition to checking the strength for the internal and external design pressure and hydrostatic test conditions, it is necessary to meet the strength requirements for the equipment in a combination of design loads for the erection, hydrostatic test and operating conditions. The method of combining the loads of the various conditions is described in the following paragraphs, unless otherwise required by the law, codes or other applicable documents.




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6.2.8.1 Design loads

Design loads are classified as per APPENDIX 1.

6.2.8.2 Load Combinations

Vessels and their supports shall be designed to meet the most severe of the load combinations mentioned in below table:

Load Combination Description

L1 + L6 Erected condition with full wind load

L1+L2+L4+L6+L8 ( Note 2) Operating condition, no pressure, with full wind load

L1+L2+L31 +L4+L6+L8 ( Note 2) Operating condition with full pressure and full wind loads

L1+L2+L4+L7+L8 (Note 2) Operating condition, no pressure, with full seismic loads

L1+L2+L31 +L4 +L7+L8 ( Note 2) Operating condition with full pressure and full seismic loads

L1+(F)L32 +L5+(0.25) L6 ( Note 1) Initial hydrostatic test condition when specified by the COMPANY

L1+(F)L31 +L5+(0.25) L6 ( Note 1) Future hydrostatic test condition when specified by the COMPANY

NOTE 1: (F) is the hydrostatic test factor from the code of construction. 2: Actual resonant sloshing forces parallel to the longitudinal axis of the vessel.

6.2.8.3 Foundation bolts

Load on Bolts:

Foundation bolts shall be sized considering the two following cases: (a) Maximum load due to wind with exposed surfaces in operating conditions with empty weight.

(b) Earthquake load during operation with the weight in operating conditions.

Sizing shall be made on the basis of more severe of the two conditions (a) and (b).

6.2.9 CORROSION ALLOWANCE

Pressure Parts:

The corrosion allowance will be indicated on the individual item specification for the equipment or on the datasheets/drawings. The corrosion allowance for nozzles, flanges, heads and other parts under pressure will be considered equal to that of the shell or the heads to which they are welded. No Corrosion allowance is required for flange faces. The minimum corrosion allowance for Carbon Steel and Low Temperature Carbon Steel shall be 1.6mm.




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Internals:

The corrosion allowance for the carbon steel or low alloy steel internals will be assumed as follows:

a) Internal parts welded to the shell or which are non-removable: corrosion allowance equal to that of the shell, applied on all the exposed surfaces including welds. b) Internal parts that can be removed (excluding trays, support or retention grids): half of the shell corrosion allowance applied to all the exposed surfaces including welds. c) No corrosion allowance will be assumed for stainless steel and for non-ferrous materials internals.

Supports and Anchor Bolts

No Corrosion allowance is required for Equipment Supports and anchor bolts.

6.2.10 SUPPORTS

The support design shall conform to Appendix G of ASME, Section VIII, Div. 1 and to the following provisions.

Skirt

Continuously welded Skirt supports shall be provided for all vertical vessels. However, small vertical vessels (vessel diameter <1500mm) may be supported on legs (pipe or structural section) or brackets, Use of bracket is not permitted for vessel in cryogenic service and is allowed subjected to COMPANY approval. Vertical equipment supported by brackets shall have the stress values checked at the brackets using the method illustrated in WRC Bulletin no. 107 and 297 or other international methods.

Saddle

Horizontal equipment shall be supported by only two saddles, the stress values shall be checked at the saddles. This check shall be made following the methods described in PD 5500 or the L.P. Zick method (published by ASME in “Pressure Vessels and Piping Design”). Equipment Supports to be provided with min 2 earthing lugs. Material of construction for the supports, for min design temperature of -30°C or less, shall be same as of the pressure part on which it is welded.

6.2.11 CONNECTIONS

Nozzle connections shall be set-in type with full penetration weld. For nominal diameters up to and including NPS 10 inches, nozzles shall be fabricated from seamless pipe. For nominal diameters over NPS 10 inches, nozzles may be fabricated from plate with one longitudinal seam Each "welding-neck" type flange shall have a neck of the same thickness as the nozzle pipe to which it is welded. For nozzles size up to NPS 2 inch min SCH 80 pipe shall be used. Min Nozzle size shall be NPS 1½ inch unless equipment is in nontoxic ( air/water) service where NPS ¾ inch size is acceptable. Socket welds or threaded connections are not acceptable unless service is non-toxic & approved by COMPANY.




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Flanges with a NPS over 24 inches shall be in accordance with ASME B 16.47 - series A and checked according to ASME, Section VIII, Div. 1, Appendix 2 and Appendix S. Flanged connections are not allowed inside skirts

6.2.12 SPECIFIC DESIGN REQUIREMENTS BASED ON VESSEL CATEGORY

Based on the vessel Category following table indicates the minimum design and fabrication requirements for each of the vessel categories. The table outlines only the areas where there are different requirements based on the Vessel Category.

Category 1 Category 2 Category3

Nozzle reinforcement

Integral reinforcement Reinforcing Pad or

IntegralReinforcing Pad or

Integral Nozzle

Attachment Set In Set In Set In

Flange tightening Controlled Bolting Controlled Bolting Controlled Bolting for class 300 or higher

Nozzle Loads As per APPENDIX 2 As per APPENDIX 2 As per APPENDIX 2

6.2.13 DRAIN AND VENT CONNECTION:

Size for the drain connection shall not be less than NPS 2 inch. Size for the vent connection shall not be less than NPS 1½ inch.

6.2.14 NOZZLE LOADS:

Allowable Nozzle loads shall be considered as per APPENDIX 2.

6.2.15 GASKETS

Gaskets used for hydro testing of equipment shall be of same specification as that of services gaskets. Gaskets containing asbestos shall not be allowed.

6.2.16 WELDING

The requirements for welding shall be in accordance with API RP 582 and applicable construction codes. WPS’s/PQR’s shall be qualified in accordance with latest edition of ASME Section IX.

6.2.17 NDE

a) Radiographic examination

The radiographic examination of welds shall be carried out in accordance with the codes and provisions indicated in Equipment Inspection datasheet. Radiographic films shall be fine-grained and high contrast type.

All radiographic plates shall show quality indicators (penetrameters) in accordance with ASME. The sensitivity shall not be less than 2% of the thickness or 1.5% if the MDMT is below 0°C.

In the case of spot radiographic examination, weld intersections shall be radiographed. Welds between shell and head and welds of heads consisting of more than one part shall always be totally radiographed.




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With the exception of equipment having a MDMT < 0°C for which no interference is permitted, if a reinforcing plate or another structure to be welded to the plate surface interferes with a vessel joint, the Supplier shall grind that part of the weld causing the interference so that it is flush and he shall radiograph a section equal to twice the length of the weld to be covered. The reinforcing plate or whatever interferes shall then be welded to the shell with a continuous bead.

In addition to that required by the applicable codes and documents, longitudinal and circumferential welds shall be totally radiographed in the case of:

- Equipment in lethal fluid service;

- Equipment in ferritic steel (clad and not lined) hydrogen service.

In these cases, welds that cannot be radiographed (e.g. nozzle-shell connections) shall undergo ultrasonic examination

b) Magnetic Particle Inspection

Magnetic particle inspection shall be performed taking adequate precautions to ensure that the steel is not damaged and it shall be performed in accordance with ASME, Section VIII, Div. 1, Appendix 6.

c) Liquid penetrant Inspection

Liquid penetrant inspection shall be performed in accordance with ASME, Section VIII, Div. 1, Appendix 8 and ASME Section V - Article 6.

In the case of vessels with a design temperature or a MDMT ≤ - 45°C, a liquid penetrant inspection of all the welds and weld overlays both on the internal and the external surface of components under pressure, after the hydrostatic test.

d) Ultrasonic Examination of Welds

When a partial radiographic examination is required, ultrasonic examination shall be performed on at least 10% of the pressure resistant welds that cannot be radiographed and at least one nozzle selected by the Inspector shall be fully examined. Should any defects be found, the examination shall be extended to 100% of the welds that cannot be radiographed.

These tests shall be carried out in accordance with ASME, Section VIII, Div. 1, Appendix 12 and reports shall be drawn up in accordance with paragraph 12-4 of Appendix 12. Refer APPENDIX 3.

6.2.18 IMPORTANT CONSIDERATIONS

Vessels shall be designed considering maximum operating liquid head in addition to design pressure. All vertical vessels shall be provided with two lifting lugs. Lifting lugs shall be designed with impact factor of two (2). 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 examination shall be carried out for shell to nozzle junction as per ASME SEC VIII DIV 2. Analysis shall be done by using the method illustrated in WRC Bulletin no. 107 and 297 as applicable. Flanges inside the vessel that are not subjected to differential pressure can be cut from plate and machined. Wherever multiple components are used the minimum distance between longitudinal weld seam shall be min of 200 mm and 5 x thickness.




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When two allowable stresses are given in the reference codes, the more stringent stress value shall be used in the calculation of flanged joints and of components in which even a small deformation can cause leakage or malfunctioning.

6.3 DESIGN CRITERIA FOR DIESEL GENERATOR PACKAGE

6.3.1 GENERAL

The DG set and other items within the package shall be designed in accordance with latest edition of international codes & standards and Project Documents.

The DG shall be suitable for unattended operation and automatic starting unless initiated by manually.

The starting system shall be automated electric designed. Manual facility shall also be provided for local starting capability.

The DG Sets shall be complete, skid mounted, radiator cooled and self-contained packaged units. Single Starting Battery Rack for each DG skid shall be provided. Batteries shall be rated for twelve (12) sequential starts. The Governor shall be of an electronic type for close speed control. The data sheet shall contain conditions at the battery limits under which the DG set shall operate. The DG shall be the standard product of a Vendor regularly engaged in the production of such sets. It shall be of modern design and with proven performance. Design and construction of the generator set shall provide accessibility for all components requiring routine operational attention and maintenance. The DG Set shall be designed and configured to optimize inspection/maintenance and overhaul activities. Components with weight / mass greater than 25 kgs shall be provided with lifting lugs. Generators shall have jacking bolts or facilities to lift the generator with the aid of a mechanical jacking device to facilitate alignment of the generator with the prime mover.

6.3.2 RATING

The DG Set rating shall be the total net output rating at the generator terminals. The component (e.g. engine, generator, coolers, etc.) with the lowest individual rating shall provide the limit for defining the net output of the generator set. The rating of any significant electrical auxiliaries, such as electric cooling fans, shall be deducted from the output rating. The Generator shall have a continuous rating and overload rating based on the maximum site ambient temperature. The generator set shall have a continuous power rating as stated on the specification & data sheets, at a power factor of 0.8 lagging.

6.3.3 STARTING SYSTEM

Total Starting Time (Ready to Accept Load) is 10 sec. Starting control shall be integrated with the DG Set control system. Starting system shall be electric and shall include:

(a) Batteries

(b) Battery chargers

(c) Motor

(d) Starter control




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(e) Starter contactor

(f) Starter over speed limiting switch

6.3.4 NOISE LEVELS

It shall be ensured that the overall noise level generated by the DG Set shall not exceed 85 dB(A). If noise levels exceed 85 dB(A) at one meter, mandatory measures to reduce equipment noise below this limit shall be included in the equipment. The noise exposure limit of 85dB (A) has been specified over a weighted 8 hour day, VENDORS are to ensure that this noise limit is not breached at a 1m. VENDOR is also to supply Sound Power levels at source. Where an operator will breach the 85dB(A) over a weighted 8 hour period then they are to list recommendations to ensure no damage to operators can occur. The VENDOR shall provide noise emission details of their equipment (octave bands) including any narrow band emitted that is noticeable to the ear.

6.3.5 DIESEL DAY TANK

Day tank shall be sized for 4 days storage. The tank shall be provided within the DG enclosure as a part of DG skid and shall be manufactured as per Vendor’s standard.

6.3.6 PACKAGED UNIT

With the intention to minimize the site work, the equipment shall be pre-fabricated, shop tested and pre-commissioned prior to site installation. The DG package shall be fabricated and assembled in accordance with applicable codes and standards, technical specifications, material requisition and data sheet.

The vendor shall supply the package with complete standard electrical, instrumentation & piping facilities in compliance with detailed technical specification, data sheets and relevant Project documents attached with requisition.

The package shall be designed to minimize lift and installed weight. It shall be designed to suit open, outdoor installation in a hot, humid and dusty environment on JETTY. Ingress Protection rating shall be IP55 for the Generator. All the piping battery limits shall be flanged up to the skid edge. Electrical and Instrumentation battery limits shall be up to Junction boxes mounted on the skid edge.

6.4 DESIGN CRITERIA FOR NITROGEN BOTTLE RACK

The Nitrogen Bottle Racks package shall include cylinders, Pressure reducing station, Pressure relief valve, interconnecting Piping, Pressure indicator and valves. Nitrogen Bottles shall be manufactured and certified in accordance with the latest edition of ISO 9809-1. Nitrogen bottles within the rack shall be arranged in vertical orientation. Nitrogen Bottle racks inside package skid shall be provided with the required isolation valves to allow the changing over and swapping the bottle racks. Each nitrogen bottle shall have individual isolation valve. A separate isolation valve will be provided near the common header outlet to isolate complete rack.




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6.5 DESIGN CRITERIA FOR DIESEL FIRE WATER PUMP

The Diesel fire water pump package should be designed in accordance with the international code & standards or equivalent vendor standard. The package shall include a day tank facility for at least 8 hours operation.




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APPENDIX 1

DESIGN LOADS




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a) Dead Load (L1) is the weight of the vessel including internals, platforms, insulation, fireproofing, refractory, piping, and other permanent attachments.

b) Operating Load (L2) is the weight of the liquid at the maximum operating level or catalyst content. The maximum operating level shall include upset conditions including the liquid full case if this is a credible scenario. When applicable, loadings resulting from topsides acceleration shall be included.

c) Pressure Load (L31) is the pressure, internal or external, hot and corroded condition, to which the vessel is certified considering the pressure variations through the vessel, if any. This is typically the stamped MAWP or MAEWP.

d) Pressure Load (L32) is the pressure in the new and cold condition. This is considered the maximum allowable pressure, and is designated as MAP. It may be higher than MAWP.

e) Thermal Load (L4) is the load caused by the restraint of thermal expansion /interaction of the vessel and its supports.

f) Test Load (L5) is the load under hydrostatic test conditions including the weight of the test fluid, usually water.

g) Wind load (L6) The specific loads for unit areas exposed to wind are given by the applicable codes and documents. A description is given below of how to calculate the additional surfaces exposed to wind during erection, hydrostatic test and operation.

Vapour-line

For columns one vapour line running down from the top head nozzle to the lower tangent line shall be considered, with an increased diameter to include the insulation.

Other lines

For the other connection lines, a projected surface area corresponding to 15% of the equipment exposed area shall be assumed.

Platforms

A platform with a projected surface area of 2 m2 shall to be considered at each manhole.

Ladders

Ladders shall be considered to have a length corresponding to the total length of the equipment and a projected surface area of 0.6 m2/m.

Insulation

The diameter of exposed equipment shall include external insulation for operating conditions, but insulation shall not be considered for hydrostatic test conditions (if the thickness is not indicated it shall be assumed to be 80 mm).

h) Seismic Load (L7) Earthquake loads shall be calculated according to the applicable standards and documents, considering the weight during operation.

i) Piping and Superimposed Equipment Loads (L8) are loads caused by piping other than Dead Load (L1) and superimposed equipment. Such loads shall be considered as applicable. When applicable, loadings resulting from wave action and/or sloshing shall be considered.




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APPENDIX 2

NOZZLE LOADS




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FLANGE CLASS

150 300 600 900 1500 2500

NPS M

( kN-m)

F (kN)

M ( kN-m)

F (kN)

M ( kN-m)

F (kN)

M ( kN-m)

F (kN)

M ( kN-m)

F (kN)

M ( kN-m)

F (kN)

2 0.38 1.04 0.40 1.37 0.44 1.91 0.48 2.46 0.56 3.55 0.69 5.41

3 1.15 1.83 1.23 2.40 1.37 3.36 1.51 4.32 1.78 6.25 2.25 9.51

4 1.79 2.39 1.94 3.14 2.19 4.40 2.44 5.65 2.94 8.16 3.80 12.43

6 3.75 3.88 4.2 5.11 4.95 7.15 5.70 9.19 7.20 13.28 9.75 20.23

8 6.18 5.48 7.16 7.21 8.79 10.10 10.42 12.98 13.69 18.76 19.24 58.57

10 9.05 7.17 10.84 9.43 13.82 13.20 16.80 16.97 22.76 24.51 32.90 37.34

12 12.35 8.92 15.28 11.73 20.16 16.43 25.04 21.12 34.79 30.51 51.38 46.47

14 16.10 10.73 20.54 14.12 27.93 19.77 35.33 25.41 50.12 36.71 - -

16 20.30 12.59 26.66 16.57 37.27 23.20 47.88 29.83 69.09 43.07 - -

18 24.96 14.51 33.71 19.09 48.29 26.72 62.87 34.36 92.02 49.63 - -

20 30.11 16.46 41.73 21.66 61.11 30.33 80.48 38.99119.23

56.32 - -

24 41.89 20.49 54.00 26.96 92.61 37.74124.30

48.52187.70

70.09 - -




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APPENDIX 3

NON DESTRUCTIVE EXAMINATION TABLE




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Joint Type NDE method Category 1 Category 2 Category 3

All welds Visual 100% 100% 100%

Longitudinal and circumferential butt joints

RT or UT1

MT or PT

100%

100% 3,4

100%

100% 3,4

10%2

10% 3,4

Nozzle attachment weld inspection

RT or UT1

MT or PT

100%

100%

100%

100%

20%

20%

Lifting lugs and Supports MT or PT 100% 100% 100%

Non-Pressure attachments

MT or PT 100% 100% 10%

Weld Inspection Prior to PWHT

Yes Yes Optional

Notes:

1. UT (Utilizing continuously data recording) in lieu of RT is preferred for ferretic materials optional < 38mm (1.5 inch), mandatory 38mm (1.5 inch) and thicker. For Austenitic Stainless Steels, this requirement shall only apply when specified or approved by COMPANY.

2. If more economic, substitute 100% to increase joint efficiency factors.

3. Also inspect 100% after working if worked >5%.

4. 100% wet fluorescent MT is mandatory for carbon steel pressure containment and attachment welds exposed to process in wet H2S service or Hydrofluoric service.




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APPENDIX 4

CRITICALITY RATING TABLE




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The Criticality of each Pressure vessel SHALL [PS] be determined in accordance with Tables A, B & C as described below:

Table A : Operational Risk

Operational Risk

Category Explosive / fire potential Toxicity Stored energy

Potential for rapid corrosion or cracking

1 Release > 10 tonnes (11 tons) of flammable fluid >1000 MJ (737 MM ft-lb)

2 Release > 2 tonnes (2.2 tons) of flammable fluid Very toxic <1000 MJ (737 MM ft-lb)

Potential

3 Release < 2 tonnes (2.2 tons) of flammable fluid or release of non-flammable fluid

Not very toxic <300 MJ (221 MM ft-lb)

None

Table B : Design Complexity

Design Complexity Category

Design Pressure based on flange

class

Design Temperature

Lower Design

Temperature

Cyclic service

Design methodology

Specialty design

Heat Exchanger Specifics

1 Class 1500 and higher

>510oC (950oF)

Severe cyclic service

Prototype design

Proprietary closures and TEMA Type ‘D’ front channel

2 Class 600 and 900

>440oC (824oF) or when creep analysis is required

<-50oC (-58oF)

Yes Stress analysis

Proprietary design component

Supplemental or alternate design analysis

3 Class 150 and 300 <440oC (824oF)

>-50oC (-58oF)

No Vessel design software / design by rule

No specialty design elements

Exchangers of standard TEMA types

Table C : Fabrication Complexity

Fabrication Complexity Category

Wall Thickness

Vessel Outside

Diameter (m)

Base Material

Overlay/Cladding internal coating

PWHT Internals Heat Exchanger

Specifics

1 >100 mm (4 in)

>7 m (23 feet)

Difficult materials requiring specialized fabrication procedures

Other overlay materials

Stainless steel or Nickel alloys with PWHT

Refractory, external jacketed or internal bundle shrouds

2 >50 mm (2 in)

>5 m (16.4 feet)

The balance of fabrication materials

Austenitic stainless steel, internal coatings

Local PWHT Complex internals

Non-standard fabrication processes

3 <50 mm (2 in)

<5 m (16.4 feet)

CS<510 mPa (74ksi) 304/304L or 316/316L SS

No overlay. No coating or non-critical coating

No PWHT or complete PWHT

Simple trays, packing, distributors

Standard fabrication processes

NOTES: 1. For Tables A, B & C, a blank cell in a column means there is no driver for that column criterion to specify the increased vessel

category. For each column choose a non-blank cell. 2. The highest category from each of the columns becomes the category for that table. See Table A. 3. The heat exchanges specifies in the Table B & C are intended to be in addition to, not in-lieu of, the other columns in the table.