Pages From 2. R215-V6 (High Pressure Separator_RevP1

Saudi Aramco 2616-ENG (10/2002)

OP

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SAUDI ARABIAN OIL COMPANY

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DISCIPLINE ENGINEER

DRD DATE JUN-12

PROJECT ENGINEER

________________

DATE ___________

CERTIFIED

RS DATE ___________

CONSTRUCTION AGENCY

________________

DATE ___________

OPERATIONS

________ DATE ___________

ED

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MECHANICAL RERATE REPORT FOR DWG.TYPE PLANT .NO INDEX DRAWING NO. SHT. NO. REV. NO.

HIGH PRESSURE SEPERATOR (R215-V6) DOC Z12 D PP-E05448 52

OF 71

B CLEAN TRANSPORTATION FUELS PROJECT, RIYADH REFINERY

RIYADH, SAUDI ARABIA JO / EWO: BI-10-00741

DOC CLASS: 4 DSN: 2179

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.

APPENDIX 3 – PRELIMINARY SAFETY INSTRUCTION SHEET

psi

I.D. m(ft) Nom. Thick. mm(ins SHAPE

3 mm(in)

EQUIPMENT DATA

3 mm(in)

32-SAMMSS-004

FYC-Z12-32-A039-001-001

ASME VIII DIV 2 1977 Ed, API 510 9TH Ed 2006

; CORROSION ALLOWANCE

SERVICE

SA 266 Cl 2

HGH PRESSURE SEPARATOR

HEADI.D. m(ft.)

ORDER NO.

; CORROSION ALLOWANCE

LENGTH m(ft.)

55BOOT

3.98

0.91

BUTT (SINGLE SIDED GROOVE)SHELL TO HEAD

HEAD FULLBUTT (DOUBLE SIDED GROOVE)

SEAMS TYPE RADIOGRAPHY EFFICIENCY E

225

OC(OF)

7.62

1.67

3.98

: RATING AND FACING

1500# RTJ

1500# RTJ / RF

POSITIONkPa (psi) POSITION

: THICK, MAT'L. AND

LIMITED BY :

LINING

PACKING

TRAYS

BOTH

MDMT:

0.85 / 1.0 POST WELD HEAT TREATMENT

YES (TBC)

AT TOP

SHELL STRESS

232

2904

kPa (psi)

PROTECTED BY SAFETY VALVE ON

TEST PRESSURE, at TOP

103.4EXTERNAL PRESSURE :

S.V. SET AT

MINIMUM THICKNESS

HEADS :

PRESSURE AND TEMPERATURE 47.8

OTHER GOVERNING CONSIDERATION

SHELL SECTION tm mm(ins)

DRAWING NO.

BASED ON :

INDEX

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N N

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NO

. NOTES:1. CORROSION ALLOWANCE HAS BEEN REVISED TO 3MM FROM ORGINAL 4.8MM. NO BENEFIT FROM THIS CHANGE HAS BEEN ASSUMED TO CONTRIBUTE TO MATERIAL PRESSURE THICKNESS, THE EXCESS HAS BEEN ASSUMED TO COVER ANY MATERIAL LOSS FROM OPERATION.2. CALCULATED TEST PRESSURE INDICATED IS AS A RESULT OF THE RERATE TO 232ºC DESIGN TEMPERATURE AND MUST BE CARRIED OUT IN THE FIELD.

BOTH 101.4 INDICATED DESIGN TEMP AND PRESSURE

: THICK AND TYPE

BASED ON INDICATED DESIGN

: NO. MAT'L. AND DRAWING NO.

: SHOP

: SIZE, HEIGHT AND MAT'L.

METHOD OF ATTACHMENT

kPa (psi)FIELD

SHELL

SPECIAL DESIGN CONSIDERATION OR

UNUSUAL CONSTRUCTION FEATURES

kPa (psi)

OPERATING LIMITS

(CHANGES TO OPERATING LIMITS REQUIRE OPERATIONS ENGINEERING APPROVAL)

14514DESIGN PRESSURE, AT TOP OC(OF)

SHELL

INDICATED DESIGN TEMP AND PRESSURE

20030 (Note 2)

TEST PRESSURE, WIND LOAD, OR

DWG. TYPE

: RATING AND FACING

INDICATED DESIGN TEMP AND PRESSURE

SIS

220.2

BOOT

NOTE BELOW ANY SPECIAL HAZARDS, RECOMMENDATIONS, INSPECTIONS, OR TESTS THAT ARE IMPORTANT FOR THIS EQUIPMENT.

1 OF 1

PLANT NO.

A

SHT.NO. REV.NOSIS FOR

SAFETY PRECAUTIONS

CALCULATED TEST PRESSURE OC(OF)kPa(g) (psi) @

TESTS NEW

AMB

APPLICABLE CODE AND EDITION

N/A

HEMISPERICAL

19123 HORIZ

kPa (psi)

MANWAY

NOZZLE

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R.

SPEC'N NO.

HORIZONTAL

1977

RU822M0008

CONCRETE LINED BOTTOM HALF OF VESSEL AND BOOT, BOTTOM NOZZLES MONEL LINED

KOBE STEEL LTD

SHELL

ASSEMBLY DRAWING

110

N/A

INSULATION

AZ12

1.0

1.0

HYDROCRACKER UNIT (Z12)

HIGH PRESSURE SEPARATOR

Nom. Thick. mm(ins)


SAUDI ARABIARIYADH,

EKRD/2694-1110.XLS

R215-V6NO.

POSITION

DESIGN SHEET NO.

HEADS

R215-V6

MANUFACTURER

SHELL SECTION


DATA AND OPERATING LIMITS SHEET - PRESSURE VESSELS

Z12-D-PP-E01204

MANUFACTURER'S SERIAL NO.

EQUIPMENT NO.

MATERIAL SPECIFICATION SA 516 Gr 70

YEAR BUILT

MATERIAL SPECIFICATION

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34

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SPOT FULL

PARTIAL FULL YES NO


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DISCIPLINE ENGINEER

DRD DATE JUN-12

PROJECT ENGINEER

________________

DATE ___________

CERTIFIED

RS DATE ___________

CONSTRUCTION AGENCY

________________

DATE ___________

OPERATIONS

________ DATE ___________

ED

SD

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APPENDIX 4 – EXTRACTS FROM ASME II D – MATERIAL PROPERTIES


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PM

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DE

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(F

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JUN

-12

RE

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DISCIPLINE ENGINEER

DRD DATE JUN-12

PROJECT ENGINEER

________________

DATE ___________

CERTIFIED

RS DATE ___________

CONSTRUCTION AGENCY

________________

DATE ___________

OPERATIONS

________ DATE ___________

ED

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.

APPENDIX 5 – FWS STANDARD MINIMUM NOZZLE LOADS

Extract from FWS Standard Nozzle Loads for 1500# Process Nozzles

Fx Fy Fz Mx My Mz

Nozzle Size (inch), D = 4 4.0 4.0 5.6 1.9 1.9 2.610 10.8 10.8 15.2 11.3 11.3 15.912 13.5 13.5 19.2 16.4 16.4 23.316 19.4 19.4 27.6 29.4 29.4 41.4

Direct Loads (kN) Moment Loads (kNm)


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JUN

-12

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A

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DISCIPLINE ENGINEER

DRD DATE JUN-12

PROJECT ENGINEER

________________

DATE ___________

CERTIFIED

RS DATE ___________

CONSTRUCTION AGENCY

________________

DATE ___________

OPERATIONS

________ DATE ___________

ED

SD

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OF 71




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.

APPENDIX 6 – INSPECTION REPORTS

••RIYADH REFINERY DEPARTMENT

ENGINEERING DIVISIONINSPECTION UNIT

2009, TRS INSPECTION FINAL REPORT

2009Field Insp. Supervisor:M. Banammahl M.RALAL

4.8mm

177 .C

03/23/2009Plant No.:2-12

Date prepared:Locationl Area:G-H drocracker

Date Inspected:110/2009Unit Supervisor:Yahya, Kh Ii

Corrosion Allowance

Design Press.

Design Temp.

Claddingl Lining

E ui ment data:Material

Report No.: INSP G/021/09Equipment No. & Service:215-V-6 Se arator

Reason for Inspection:TRS, March/Februa

P&E Inspector:Greg Jolley API #5184

Thick.

Inspection summary:

A full internal and external visual inspection was performed per API-510 and Aramcoguidelines, during the February 2009 plant wide T&1. A scaffold was erected for fullaccess. The bottom half is concrete lined. Civil required minimal repairs. The top halfwas grit blasted for WFMP on the welds with no relevant indications. A new demisterwas installed. The top unlined portion of the vessel has mild corrosion .030" (.nOmm)shell and .060" (1.54mm) nozzles. Corrosion in the manway RTJ "0" ring will requirerepairs next scheduled T&1.

Observations:

There was 3" of product sludge found in the bottom prior to cleaning. The vertical walldemister was removed and replaced with like kind 316ss, double wired down andvisually accepted. The support ring was securely attached by to the shell with no visiblecracking or corrosion noted. This demister was moderately fouled with scale andproduct. Previous process changes eliminated the use of the outlet gas demister. A fullscaffold was erected for access. The bottom half is concrete lined with minor repairs.The boot section was also lined. Minor repairs were required (see civil for iining issues).The top half had a scattered thin hard scale. Corrosion in the top half is generally .030"(.770mm) with isolated pitting in the middle top section to .040" (.1OOmm). The welds arein the same condition as the adjacent base metal with no visual defects. Nozzles wereclear and free of obstruction. General corrosion in the nozzles 10 was .040" (.700mm)and isolated pitting in the top nozzles to .060" (.150mm). The inlet distributor was clearwith no corrosion. The slots were full thickness. There were 2 of the 3 hold downbolts/nuts missing. These were replaced with like kind and accepted. The liquid outletstand pipe was intact and secure with no corrosion or erosion. The bottom outlet nozzlewas flushed free of any loose hardware and debris. The top gas outlet nozzle (12") andmanway RTJ "0" rings and seats were PT tested and had no corrosion. The top manwayand cover has moderate corrosion on the RTJ "0" ring seating surface and is

738

user

Cloud

user

Cloud

user

Text Box

Only head material SA 516 Gr. 70. Shell, boot, nozzles SA 266 Cl2

user

Arrow

user

Text Box

148 kg/cm2

•recommended to weld build up and machine next scheduled T&1. The top half of theshell welds were grit blasted for WFMP with no relevant indications reported. This vesselis fit for continued service until the next T&1.

Refractory lining:

The bottom half is concrete lined with minor repairs. The boot section was also lined.Minor repairs were done and accepted by civil inspector.

RepairsIT ests:

1. Minor concrete lining repairs were made per the civil recommendations.2. UT scanning the bottom external performed on the shell with no issues reported.3. UT thickness was performed with no measureable wall loss noted.4. WFMP was performed on the top welds after grit blasting with no indications

noted.5. A new vertical wall demister was installed.6. The top gas outlet was lifted and the RTJ "0" ring and seats PT tested with no

indications or corrosion

Future Recommendations:

1. Open, clean and Inspect during the next scheduled T&I,March 20132. Flush with firewater to remove sludge3. Build full scaffold for access to the top head4. Grit blast the top section welds for WFMP(grit blasting was performed this T&I

because wire brushing would not remove the hard scale)5. Flush outlet piping after all work is completed, break outside flange and gap

minimum 30mm to flush loose nuts and bolts6. Weld build up the manway gasket surfaces and machine (both head and cover)

due to corrosion on the seats.7. Install new demister pads8. Remove support rings on gas outlet nozzle for inspection and NOT.9. Open water boot and offer for inspection.10. Remove bottom insulation for UT11. Straight beam scan to check thickness under cement lining.12. Provide 110/220 power cable for WFMPI

cc:Area (G) foremenT&I SupervisorEquipment File

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JUN

-12

RE

V.

NO

.

A

B

DISCIPLINE ENGINEER

DRD DATE JUN-12

PROJECT ENGINEER

________________

DATE ___________

CERTIFIED

RS DATE ___________

CONSTRUCTION AGENCY

________________

DATE ___________

OPERATIONS

________ DATE ___________

ED

SD

V

ER

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AT

ION

CO

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OF 71




TH

IS D

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ON

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OF

IT

S O

WN

ER

.

APPENDIX 7 – PVELITE OUTPUT (FOR VALIDATION ONLY)

Documents

Pages From 2. R215-V6 (High Pressure Separator_RevP1