DGS MD 001 R1 Vessel Design Basis

7/30/2019 DGS MD 001 R1 Vessel Design Basis

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Abu Dhabi Oil Refining Company

VESSEL DESIGN BASIS DGS-MD-001Rev-1 April 2009

Takreer DGS-MD-001-Rev-1 April-2009 Printed 16-Apr-09 13:58:29 Initials Page 1 of 17

VESSEL DESIGN BASIS

Amendment History

No Date Amendment Description Proposed Approved Incorporated

DGS Histo ry

1 April 2009 DGS-MD-001-Rev-1 Base Reference Project5578

TH/DDC QAM / MAY

0 March 2006 DGS-MD-001-Rev-0 Previous Project / LessonsLearnt Incorporated

TH/DDC ETSDM / EPDM

No Date Description Source Reviewed Approved

DGS-MD-001 Rev-1


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TABLE OF CONTENTS

1.0 GENERAL ........................................................................................................................41.1 INTRODUCTION...................................................................................................41.2 PURPOSE .............................................................................................................41.3 DEFINITIONS ........................................................................................................4

2.0 CODES AND STANDARDS .............................................................................................43.0 REFERENCE DOCUMENTS ...........................................................................................6

3.1 PROJ ECT STANDARD SPECIFICATIONS...........................................................63.2 PROJ ECT STANDARD DRAWINGS.....................................................................7

4.0 DOCUMENT PRECEDENCE...........................................................................................8

5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL ..............................................96.0 QUALITY ASSURANCE/QUALITY CONTROL ................................................................97.0 DOCUMENTATION ..........................................................................................................98.0 SUBCONTRACTORS/SUBVENDORS ............................................................................99.0 HANDLING .......................................................................................................................910.0 DESIGN CRITERIA ..........................................................................................................9

10.1 DESIGN PRESSURE ............................................................................................910.2 DESIGN TEMPERATURE ...................................................................................1010.3 MINIMUM THICKNESS .......................................................................................1010.4 CORROSION ALLOWANCE ...............................................................................1110.5 POSTWELD HEAT TREATMENT........................................................................1110.6 RADIOGRAPHIC WELD INSPECTION...............................................................1210.7 MATERIALS.........................................................................................................12

10.8 EARTHQUAKE LOAD .........................................................................................1310.9 WIND LOAD ........................................................................................................1310.10 HYDROSTATIC TEST .........................................................................................1310.11 INSULATION .......................................................................................................1410.12 VESSEL FIREPROOFING ..................................................................................1410.13 SUPPORTS AND ANCHOR BOLTS....................................................................1410.14 HEADS ................................................................................................................1410.15 MANWAYS AND HANDHOLES...........................................................................1410.16 LADDERS, PLATFORMS AND DAVITS ..............................................................1510.17 NOZZLES ............................................................................................................1510.18 PAINTING............................................................................................................16

ADDENDUMSHEET ...............................................................................................................17


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List of Authorized Signatures/ Initials

DGS Discipline Committee Member, ADRD ------------------------------

DGS Discipline Committee Member, RRD ------------------------------

DGS Discipline Committee Member Leader, E&PD Taha Hussein (TH)

Engineering & Technical Services Manager, E&PD Quazi Abdul Matin (QAM)

Engineering & Projects Division Manager, E&PD Mohamed Al Yabhouni (MAY)


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1.0 GENERAL

1.1 INTRODUCTION

This specification governs the general requirements for the mechanical design of allpressure and vacuum vessels, and spheres. The requirements for the fabrication andinspection of pressure vessels are covered in specifications referenced below.

Specific requirements for any particular vessel will be furnished on the Project vessel DataSheets/drawings.

1.2 PURPOSE

This specification is intended for use in design and construction of pressure vessels.

1.3 DEFINITIONS

For the purposes of this Specification, the following definitions shall apply:

CONCESSION REQUEST A deviation requested by the SUBCONTRACTOR orVENDOR, usually after receiving the contract package or purchase order. Often, it refersto an authorization to use, repair, recondition, reclaim, or release materials, componentsor equipment already in progress or completely manufactured but which does not meet orcomply with COMPANY requirements. A CONCESSION REQUEST is subject toCOMPANY approval.

SHALL Indicates a mandatory requirement.

SHOULD Denotes an action or requirement which is not mandatory but which is stronglyrecommended.

2.0 CODES AND STANDARDS

It shall be the CONTRACTORS responsibility to be, or to become, knowledgeable of therequirements of the referenced Codes and Standards.

The following Codes and Standards, to the extent specified herein, form a part of thisspecification. The latest edition in force shall apply.

Project vessel Data Sheets/drawings shall specify the applicable code, stampingrequirement, design data, specifications, and reference drawings.

The codes and standards listed below shall be used as referenced in this specification oron Project vessel Data Sheets/drawings.

American Society of Mechanical Engineers/American National Standards Ins ti tu te(ASME):


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3.0 REFERENCE DOCUMENTS

The following reference documents, to the extent specified herein, form a part of thisspecification.

3.1 PROJECT STANDARD SPECIFICATIONS

Project Standard specifications listed below shall be used as referenced herein or onProject vessel Data Sheets/drawings:

DGS-CU-002 Structural Engineering Criteria

DGS-MD-002 Pressure Vessels General

DGS-MD-004 Pressure Vessels Supplement for Austenitic, Ferritic and DuplexHigh Alloy Steel, Nickel and Nickel Alloy

DGS-MD-005 Pressure Vessels - Supplement for Alloy Lined Steel

DGS-MD-006 Vessel Trays General

DGS-MD-007 Requirements for Manufacturing Data Report for Pressure Vessels

DGS-MD-008 Ladders and Platforms - Pressure Vessels

DGS-MD-011 Pressure Vessels - Supplement for Low Temperature Services

DGS-MN-001 Insulation

DGS-MU-002 Preservation and Export Packing

DGS-MU-013 Criticality Rating System

DGS-MU-014 Minimum Shop Inspection and Certification Requirements

DGS-MW-001 Welding, NDE and Prevention of Brittle Fracture of Pressure Vesselsand Heat Exchangers

DGS-MW-004 Materials and Fabrication Requirements for Carbon Steel Piping andEquipment in Severe Services

DGS-MW-005 Materials and Fabrication Requirements for Cr-Mo Alloy Steel HighPressure Equipment

DGS-MW-006 Positive Materials Identification of Equipment and Piping

DGS-MX-001 Painting

DGS-MX-002 Galvanizing


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STD-MD-00032 Vessel Tolerances

STD-MD-00033 Flange Bolt Hole Orientation

STD-MD-00034 Tray Support Tolerances

STD-MD-00035 Tray Tolerances

STD-MD-00036 Typical Vessel Ladders and Platform Details, Sheet 2

STD-MD-00037 Typical Vessel Ladders and Platform Details, Sheet 3

STD-MD-00038 Obstruction Lights for Steel Stack

STD-MD-00040 Earthing Clips for Tanks, Vessels and Supporting Structures

STD-MD-00041 Warning Nameplate

STD-MD-00042 Internal Pipe Support Details

STD-MD-00043 Reflux Nozzle Details, Sheet 1



STD-MD-00046 Feed Nozzle Details, Sheet 1



STD-MD-00049 Flash Feed Details

STD-MD-00050 Liquid Drawoff and Vapor Outlet Details

STD-MD-00051 Side Reboiler Draw and Return Details

STD-MD-00052 Tray Support Ring Details

4.0 DOCUMENT PRECEDENCE

The CONTRACTOR shall notify the COMPANY of any apparent conflict between thisspecification, the related Data Sheets, the Codes and Standards and any otherspecifications noted herein. Resolution and/or interpretation precedence shall be obtainedfrom the COMPANY in writing before proceeding with the design/manufacture.

In case of conflict, the order of precedence shall be stated in the AGREEMENT or otherPROJ ECT documents as applicable.


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5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviations to the this Specification and its attachments including, but notlimited to, the Data Sheets and Narrative Specifications shall be sought by theCONTRACTOR only through Concession Request format. Concession requests requireCOMPANY'S review/approval, prior to the proposed technical changes beingimplemented. Technical changes implemented prior to COMPANY approval are subject torejection.

6.0 QUALITY ASSURANCE/QUALITY CONTROL

CONTRACTORS proposed quality system shall fully satisfy all the elements of ISO 9001 -2000 and ISO 9004 2000 with due regard to ISO 19011. The quality system shallprovide for the planned and systematic control of all quality-related activities performedduring design, development, production, installation or servicing (as appropriate to thegiven system). Implementation of the system shall be in accordance with theCONTRACTORS Quality Manual and Project Specific Quality Plan, which shall bothtogether with all related/referenced procedures, be submitted to COMPANY for review,comment and approval as required by purchase/contract documents.

The Criticality Rating (CR) System outlined in Project Specification DGS-MU-013 shall beused by CONTRACTOR or CONTRACTORS designee to develop the design checkinglevels and minimum requirements for shop inspection, testing and material certificationgiven in Project Specification DGS-MU-014.

7.0 DOCUMENTATION

Refer to DGS-MD-002.

8.0 SUBCONTRACTORS/SUBVENDORS


9.0 HANDLING


10.0 DESIGN CRITERIA

10.1 DESIGN PRESSURE

10.1.1 All pressures shown as kg/cm2 are gauge unless specified kg/cm2A.

10.1.2 Unless otherwise specified on Project vessel Data Sheets/drawings, the internal designpressure at top tangent line shall be as follows:

Maximum Operating Pressure (kg/cm2): Design Pressure (kg/cm2):

Full or partial vacuum 1.05 external/3.5 internal


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Maximum Operating Pressure (kg/cm2

): Design Pressure (kg/cm2

):

0 (Gauge) - 0.35 0.5 external/3.5 internal

0.36 - 1.8 3.5

1.81 - 17.2 Operating +1.7

17.3 - 70.00 Operating +10 percent

70.00 - 140.00 Operating +7.00

140.00 Up Operating +5%

10.1.3 Design pressure for vessels subjected to steaming-out shall be 0.5 kg/cm2 external at150C temperature.

10.1.4 Catalyst load (including catalyst suspended liquid) or liquid static heads shall be added tothe design pressure, where applicable.

10.1.5 The maximum allowable working pressure to be stamped on the vessel nameplate, unlesslimited by the flange rating, shall be determined by using the full plate thickness asfabricated less the corrosion allowance of the weakest part of the vessel.

10.1.6 Intermediate heads shall be designed based on maximum possible pressure differentialunder operating conditions. Intermediate heads are not to be used as line of support.

10.2 DESIGN TEMPERATURE

10.2.1 For vessels operating above 0 C, the design temperature shall be the operatingtemperature plus 10C.

10.2.2 The Maximum Allowable Working Temperature to be stamped on the vessel nameplateshall be equal to the maximum allowed by the design stresses without changing the flangerating.

10.2.3 The Minimum Design Metal Temperature of +15C, shall be used unless otherwisespecified on Project Data Sheets/drawings or determined in Project SpecificationDGS-MW-001, Appendix No. 4.

10.2.4 For low temperature services, Project Specifications DGS-MD-011 and DGS-MW-001,Appendix No. 4 rules apply.

10.3 MINIMUM THICKNESS

Minimum thickness for shells, heads and skirts shall be as follows:


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10.3.1 Carbon and low alloy steel vessels - Minimum thickness shall be the greater of 6 mmexcluding corrosion allowance, lining or cladding thickness or .002 x inside diameter plus1.8 mm.

10.3.2 High alloy steel vessels - 6 mm, and shall agree with ASME Section VIII, Division 1.

10.3.3 For cladded or lined vessels - Minimum thickness shall not include the cladding, lining orweld overlay thickness.

10.4 CORROSION ALLOWANCE

10.4.1 Corrosion allowance shall be as specified on Project vessel Data Sheets/drawings with aminimum as follows:

a. Carbon steel and low alloy steel pressure parts - 3.0 mm. In special cases, 1.6 mmmay be specified by the "COMPANY, taking into account the required lifetime ofthe vessel.

b. Alloy Clad or Lined Vessels - cladding or lining thickness as specified.

c. For noncorrosive or very mild corrosive conditions, e.g. in media such as steam, drycompressed air, LPG, LNG and dry natural gas service, a corrosion allowance maybe specified with COMPANY approval.

d. No corrosion allowance is required on the gasket facing of flanges.

10.4.2 Nozzles and manhole necks shall have the same corrosion allowance as specified for theshell or heads.

10.4.3 Clad vessels do not require a corrosion allowance on the carbon steel backing.

10.5 POSTWELD HEAT TREATMENT

10.5.1 Postweld heat treatment shall be implemented when required by process requirements,the ASME Code Section VIII, and/or additional requirements of DGS-MW-001.

10.5.2 When Postweld heat treatment is required, the entire vessel shall be heat treated in anenclosed furnace whenever it is feasible. When heat treating the entire vessel in anenclosed furnace is not feasible, the procedure and requirement shall be approved by theCONTRACTOR/COMPANY .

Where postweld heat treatment is required to be performed in the field, the procedure andrequirement shall be subject to review by the CONTRACTOR/COMPANY.

10.5.3 See Specification DGS-MW-004 for vessels containing caustic, amine or chlorinesolutions.

10.5.4 Chrome-moly material shall be postweld heat treated in all thicknesses unless otherwisespecified.


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10.5.5 No welding is permitted after postweld heat treatment. Add this note on vessel fabricationdrawings, and CONTRACTOR drawings and/or Data Sheets. The vessel shall be clearlymarked "POSTWELD HEAT TREATED. DO NOT BURN, WELD OR HAMMER."

10.6 RADIOGRAPHIC WELD INSPECTION

As a minimum, all vessels shall be spot examined by radiography. Minimum of 10% ofeach process and each operator shall be taken to examine the welds. Additionalradiography may be required by code or to reduce material costs. Requirements shall beshown on Project vessel Data Sheets/drawings as a minimum requirement only.

10.7 MATERIALS

10.7.1 In general, materials for carbon steel vessels shall be in accordance with the followingASME material specifications, unless specified otherwise:

Shell and Heads SA-516 Gr 55 to 65

Supports SA-285 Gr C for temperatures of 343C or below. Sameas shell over 343C for at least 700 mm at top of skirt.

Internals Same as shell and head materials.

Same alloy as lining for alloy clad or alloy lined vessels.

Trays and Tray Fasteners As specified in Vessel Trays - General Specification DGS-MD-006.

Tray Support Rings andOtherTray Supports welded toVessel

Carbon steel for carbon steel vessels. Same lining foralloy clad or alloy lined vessels.

Flanges SA-105

Internal Bolts and Nuts For uncladded vessels or vessel sections: carbon steelunless otherwise noted.

External Bolts SA-193 Gr B7 (except as noted in para. 10.7.5)

External Nuts SA-194 Gr 2H (except as noted in para. 10.7.5)

Nozzle Necks SA-106 Gr B or same as shell or head.

Gaskets See Technical Specification for Piping SystemsDGS-PU-003.


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10.7.2 Carbon content of carbon and carbon-manganese steels shall not exceed 0.23%, exceptfor forgings and castings, where this may be relaxed to 0.25%. For pressure containingcomponents, the carbon equivalents (CE) shall not exceed 0.43, as given by:

15

Ni+Cu+

5

V+Mo+Cr+

6

Mn+C=CE

10.7.3 In accordance with Project Specification DGS-MW-001, Appendix 4, all pressure parts inlow temperature (MDMT


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10.10.2 Shop Hydrostatic Test: Integrally clad vessels shall be tested to a calculated test pressurebased on the full metal thickness (base metal plus cladding). Nonclad or lined vesselsshall be tested to a calculated test pressure based on the full metal thickness (includingcorrosion allowance). Allowable stresses shall be based on new and cold condition.

10.11 INSULATION

Vessels shall be insulated in accordance with the Insulation Specification DGS-MN-001when required by the Project vessel Data Sheets/drawings.

10.12 VESSEL FIREPROOFING

Saddles supporting horizontal vessels shall not be fireproofed.

When specified on the vessel drawing or data sheet, the skirts of vertical vessels shall befireproofed as follows:

Vessel Diameter Internal Protection External Protection

1220 mm and less None 50 mm concrete

Over 1220 mm and larger 50 mm concrete 50 mm concrete

10.13 SUPPORTS AND ANCHOR BOLTS

10.13.1 The outside diameter of vertical vessel skirts shall equal the outside diameter of the vesselshell with shell thickness up to 38 mm. The mean diameters of the skirt and shell shall

align for shell thickness over 38 mm.

10.13.2 The design of skirts shall be such that the temperature of any supporting concrete will notexceed 100C. For vessels with operating temperatures below ambient, this temperatureshall be such that no condensation will occur under normal operating conditions.

10.13.3 Anchor bolts shall be 19 mm diameter minimum size. Anchor bolts shall be designedusing allowable stresses in accordance with Specification DGS-CU-002. Do not apply acorrosion allowance.

10.14 HEADS

10.14.1 Two to one ratio ASME semi-ellipsoidal heads are preferred. Hemispherical heads are

acceptable under certain conditions; i.e., large diameter, high pressure and temperaturevessels.

10.14.2 Conical heads or transitions shall have a 9.0 percent knuckle radius when the design

pressure exceeds 10.61 kg/cm2 and/or design temperature exceeds 232C.

10.15 MANWAYS AND HANDHOLES


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10.15.1 A minimum of two 610 mm (24") nominal manways, one above the tray section and onebelow the tray section, shall be provided on columns with trays. Additional manways shallbe provided between trays, the recommended number of trays between manways will be10. Additional manways shall be provided as required for service conditions andmaintenance.

10.15.2 A minimum of one 610 mm (24") nominal manway shall be provided for other vessels.Manway size for small diameter vessels shall be analyzed on a case by case basis.

10.15.3 Top and side entry manways shall be provided with a davit.

10.15.4 Bottom entry manways shall be provided with hinges.

10.15.5 The minimum diameter for inspection openings (handholes) is 150 mm nominal.Handhole covers shall be provided with hand grips.

10.15.6 Manway and handhole covers shall be flat type of rolled or forged plate.

10.16 LADDERS, PLATFORMS AND DAVITS

Ladders, platforms and column davits shall be provided in accordance with SpecificationDGS-MD-008.

10.17 NOZZLES

10.17.1 All nozzles on pressure vessels shall be flanged. Welding neck type flanges with raised-face shall be used. Slip-on and lap joint flanges are not permitted unless otherwiseapproved by COMPANY. The minimum nozzle size shall be 2 inches.

Flanged connections inside skirts of vertical vessels are not permitted unless otherwiseapproved by CONTRACTOR/COMPANY.

10.17.2 Stubbed, socket welded, pad type or built-up type and screwed connections are notpermitted.

10.17.3 All 2 inch connections shall be a minimum of Class 300 and shall be braced with twogusset plates at 90 orientation apart.

10.17.4 All connections on which relief valves are mounted shall be Class 300 minimum.

10.17.5 Flange Face Finish

a. Rating and facing of flanged nozzles shall conform to ASME B16.5 and to theapplicable Piping Specification.

For spiral wound and flexible graphite based gaskets, the gasket contact surfaces shallhave concentric or spiral grooves, resulting in a roughness height within the range of

3.2-6.3m Ra (smooth finish) in accordance with ASME B46.1.


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b. For jacketed type gaskets, the gasket contact surfaces shall be 0.8-1.6 m Ra.

c. For solid metallic type gaskets, the gasket contact surfaces shall be 0.8 - 1.6 m Ra.

10.17.6 8" and smaller pipe size nozzle necks shall be a minimum of schedule 80 seamless pipe.Larger nozzles shall be a minimum of 12 mm wall.

10.17.7 Nozzle Reinforcement

a. Shell and head mounted nozzles and manways with integral reinforcement shall beused when the design temperature of the vessel shell/head or nozzle wall is above399 C. They shall also be required on refractory lined vessels operating over399 C.

b. Reinforcing pads shall not be used in hydrogen service above 230C.

c. When Minimum Design Metal Temperature (MDMT) is equal to or lower than -29C,integrally reinforcing forged neck shall be used.

10.18 PAINTING

All designated vessel surfaces shall be prepared and painted in accordance with PaintingSpecification DGS-MX-001.


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ADDENDUMSHEET

All revisions to this DGS subsequent to the issue of Rev Zero shall be recorded in thisaddendum sheet and shall be incorporated into the DGS in the next revision.

Date Proposed Revision Remarks

Documents

DGS MD 001 R1 Vessel Design Basis