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Powertech System Integrators Babcock & Wilcox

FFP COMPRESSED AIR SUPPLY SYSTEM: USER COMPONENT

SPECIFICATIONS

Document Number: Z0419-000564-55

Revision Number: 2

0635-302B CI Sheet E533941-2

BABCOCK & WILCOX Confidential

Document No: Z0419-000564-55 Revision: 2 Page i

DOCUMENT TITLE: FFP COMPRESSED AIR SUPPLY SYSTEM: USER COMPONENT SPECIFICATIONS

APPROVAL PAGE

TITLE: FFP COMPRESSED AIR SUPPLY SYSTEM: USER COMPONENT

SPECIFICATIONS

DOCUMENT NUMBER: Z0419-000564-55

REVISION: 2

CLASSIFICATION: Confidential

DATE: 29 March 2016

FILE REFERENCE: Z0419-000564-55(2) FFP COMPRESSED AIR SUPPLY SYSTEM_USER COMPONENT SPECIFICATIONS.docx

AUTHOR(S): Mike Nieuwoudt

APPROVAL: This document is a draft unless approved.

Signature Signature

Name: Mike Nieuwoudt Name: JA Hoogenboezem

Designation: Mechanical Engineer Designation: Project Manager

Date: 2016-03-29 Date: 2016-03-29

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Document No: Z0419-000564-55 Revision: 2 Page ii


AMENDMENT HISTORY

REVISION DATE AMENDMENT DETAILS AUTHOR

A 05 October 2015 Issued for comments Mike Nieuwoudt

1 01 December 2015 Para 5: Vessel layout sketches and vessel minimum wall thickness added Mike Nieuwoudt

2 29 March 2016

Add compressor to dryer air line insulation requirement (6.1.1)

Add cooling line orifice plate specification (6.3.1)

Mike Nieuwoudt

DISTRIBUTION LIST

NAME COMPANY COPY NO.

Mark Petit Babcock & Wilcox

Mike Denk Babcock & Wilcox

David Scott Babcock & Wilcox

Riana Nieuwoudt Eskom

Keagan Naidoo Eskom

JA Hoogenboezem Powertech System Integrators

Grant Westcott Powertech System Integrators

Mike Nieuwoudt Powertech System Integrators

Document Control Powertech System Integrators Master

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Document No: Z0419-000564-55 Revision: 2 Page iii


TABLE OF CONTENTS

1 PURPOSE ............................................................................................................... 6

2 APPLICABLE DOCUMENTS .................................................................................. 6

2.1 Compulsory Codes and Standards ............................................................................................ 6

2.2 Drawings ................................................................................................................................... 7

2.3 Documents ................................................................................................................................ 7

3 SANS 347 CLASSIFICATION ................................................................................. 7

3.1 Instrument and Pulse Jet Air Receiver Vessels ......................................................................... 7

3.2 Pulse Jet Air Pipelines ............................................................................................................... 9

3.3 Instrument Air Pipelines ......................................................................................................... 10

3.4 Closed Circuit Cooling Water Ring Main Piping ...................................................................... 11

3.5 Piping Design Code ................................................................................................................. 12

4 ASME B31.3 FLUID CATEGORIES ...................................................................... 12

4.1 General ................................................................................................................................... 12

4.2 Compressed / Plant Air ........................................................................................................... 12

4.3 Cooling Water (Closed Circuit) ............................................................................................... 12

4.4 Cooling Water (Open Circuit) ................................................................................................. 12

4.5 De-ionised (Demineralised) Water ......................................................................................... 12

4.6 Chemicals for Water Treatment ............................................................................................. 13

4.7 Drains Water ........................................................................................................................... 13

4.8 Classifying Figures ................................................................................................................... 13

5 ASME VIII FORM U-DR-1 USER DESIGN REQUIREMENTS (AIR RECEIVERS) . 17

5.1 Instrument Air Receivers ........................................................................................................ 17

5.2 Pulse Jet Air Receivers ............................................................................................................ 20

5.3 Air Receiver Minimum Wall Thickness ................................................................................... 23

5.4 Air Receiver Coating and Marking .......................................................................................... 23

6 PIPELINE SPECIFICATIONS ................................................................................ 24

6.1 Pulse Jet Air Pipelines ............................................................................................................. 24

6.1.1 Air Pipelines: Compressor to Dryer and Post Filter ................................................................ 24

6.2 Instrument Air Pipelines ......................................................................................................... 24

6.3 Closed Circuit Cooling Water Pipelines .................................................................................. 24

6.3.1 Closed Circuit Cooling Water Pipeline Restriction Orifices .................................................... 24

6.4 Open Circuit Cooling Water Pipelines .................................................................................... 24

6.5 De-ionised (DI, Demin) Water Pipelines ................................................................................. 24

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6.6 Coolant Chemical Dosing Pipelines ........................................................................................ 24

6.7 Drain Water Pipelines ............................................................................................................. 24

6.8 Pipeline Protective Coatings ................................................................................................... 24

6.9 Pipeline Marking ..................................................................................................................... 25

6.10 Pipe Hangers and Supports .................................................................................................... 25

7 MAIN COMMERCIAL COMPONENT SPECIFICATIONS ...................................... 26

7.1 Compressor Specifications ..................................................................................................... 26

7.1.1 Conditions ............................................................................................................................... 26

7.1.2 Requirements ......................................................................................................................... 26

7.2 Dryer and Post-Filter Specifications ....................................................................................... 26

7.2.1 Conditions ............................................................................................................................... 26

7.2.2 Requirements ......................................................................................................................... 26

7.3 Coolant Pump Specification .................................................................................................... 27

7.3.1 Conditions ............................................................................................................................... 27

7.3.2 Requirements ......................................................................................................................... 27

7.4 Coolant Cooler Specification .................................................................................................. 27

7.4.1 Conditions ............................................................................................................................... 27

7.4.2 Requirements ......................................................................................................................... 27

7.5 Make-up Tank Specification ................................................................................................... 28

7.5.1 Conditions ............................................................................................................................... 28

7.5.2 Requirements ......................................................................................................................... 28

7.6 Chemical Dosing (CC) Unit Specification ................................................................................ 28

7.6.1 Conditions ............................................................................................................................... 28

7.6.2 Requirements ......................................................................................................................... 29

7.7 Chemical Dosing (OC) Unit Specification ................................................................................ 29

7.7.1 Conditions ............................................................................................................................... 29

7.7.2 Requirements ......................................................................................................................... 29

8 APPENDIX 1: FLUID SERVICE SHEETS .............................................................. 30

8.1 Fluid Service Sheet FS001: Air (Compressed / Plant) ............................................................. 31

8.2 Fluid Service Sheet FS002: Water (DI) .................................................................................... 33

8.3 Fluid Service Sheet FS003: Water (Cooling) ........................................................................... 35

8.4 Fluid Service Sheet FS004: Water (Treatment Chemicals) ..................................................... 37

8.5 Fluid Service Sheet FS005: Water (Drains) ............................................................................. 39

9 APPENDIX 2: PIPING SPECIFICATIONS ............................................................. 41

9.1 Piping Specification PS001*: Carbon Steel (Normal Fluid Service) ........................................ 42

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9.2 Piping Specification PS002*: Stainless Steel 304L (Normal Fluid Service) ............................. 45

9.3 Piping Specification PS003*: PVC (Normal Fluid Service) ....................................................... 48

10 APPENDIX 3: FULL FACE RESTRICTION ORIFICES FOR COOLANT LINE ...... 50

11 APPENDIX 4: PIPE ROUTING PLAN VIEW (INFORMATIVE ONLY) ................... 51

12 APPENDIX 5: INSTRUMENT AIR AND PULSE JET AIR RECEIVER MINIMUM WALL THICKNESS ............................................................................................... 52

12.1 BOTH RECEIVERS..................................................................................................................... 52

12.2 IA RECEIVER VESSEL ................................................................................................................ 52

12.2.1 Minimum wall thickness for internal pressure to ASME VIII Div 1 ......................................... 52

12.2.2 External Pressure allowed at selected 16mm plate thickness ............................................... 52

12.2.3 External Pressure allowed at reduced plate thickness of 12.7mm (1/2”) if available ........... 53

12.3 PJ AIR RECEIVER VESSEL ......................................................................................................... 53

12.3.1 Minimum wall thickness for internal pressure to ASME VIII Div 1 ......................................... 53

12.3.2 External Pressure allowed at selected 12mm plate thickness ............................................... 54

ABBREVIATIONS

CC Closed Circuit (Cooling)

CH Compressor House

DI De-ionised (water, also demineralised of “demin”water)

FF Flat Face

FFP Fabric Filter Plant

HDG Hot Dip Galvanised

HH Heavy hex

IA Instrument Air

OC Open Circuit (Cooling)

PJ Pulse Jet

PJFF Pulse Jet Fabric Filter (Unit or Casing of a Unit)

P-Spec Piping Specification (Appendix 2)

TBC To be confirmed

TBD To be determined

TBS To be specified

TBV To be verified

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Document No: Z0419-000564-55 Revision: 2 Page 6


1 PURPOSE

This document collates the user (in this case also the owner, Eskom) specifications for the components of the compressed air supply system for the Tutuka Power Station Fabric Filter Plant (FFP).

The components addressed here are:

a) Instrument Air Receivers b) Pulse Jet Air Receivers c) All Compressed and Plant Air Pipelines (PJ and IA) d) All Coolant Water Pipelines (CC, OC and treatment chemicals) e) Drain Water Pipelines f) Pipeline Hangers and Supports g) Air Compressors h) Air Dryers and After-Filters i) Coolant Pumps j) Coolant Cooling Units k) Coolant Make-up Tank l) Coolant Water Chemical Treatment Units (CC and OC)

The document further provides the user identified mandatory code and standard requirements for these components, and provide justification for the relevant vessel and pipeline classifications to meet the regulatory requirements.

2 APPLICABLE DOCUMENTS

2.1 Compulsory Codes and Standards

[1] OHS Act 85 of 1993; Republic of South Africa [2] SANS 347: 2012; Categorization and conformity assessment criteria for all pressure equipment [3] ASME B31.3; Process Piping; Latest Applicable [4] ANSI/MSS SP-58-2009; Pipe Hangers and Supports -Materials, Design, Manufacture, Selection,

Application, and Installation [5] ASME B&PVC; Section VIII Division 1 - RULES FOR CONSTRUCTION OF PRESSURE VESSELS; Latest

Applicable [6] ISO 5389:2005; Turbocompressors -- Performance test code [7] ISO 8573-1:2010; Compressed air —Part 1: Contaminants and purity classes [8] ISO 7183:2007; Compressed-air dryers – Specifications and testing [9] SANS 121:2000 (ISO 1461:1999); Hot dip galvanized coatings on fabricated iron and steel

articles — Specifications and test methods

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2.2 Drawings

[10] Eskom Drw. No. 0.61/97041 Rev 1 Sheet 1 – 4; Tutuka Power Station; P&ID Unit 1 – 6; Fabric Filter Plant Pulse Air System

[11] Eskom Drw. No. 0.61/97042 Rev 1; Tutuka Power Station; P&ID Unit 1 – 6; Fabric Filter Plant Pulse Air Distribution Manifold

[12] Eskom Drw. No. 0.61/97043 Rev 1; Tutuka Power Station; P&ID Unit 1 – 6; Fabric Filter Plant Instrument Air Distribution

[13] Eskom Drw. No. 0.61/97044 Rev 1; Tutuka Power Station; P&ID Unit 1 – 6; Fabric Filter Plant Pulse Air and Instrument Air Cooling System

[14] Eskom Drw. No. 0.61/97045 Rev 1; Tutuka Power Station; P&ID Unit 1 – 6; Fabric Filter Plant Compressor and Dryer Instrument Air

[15] Eskom Drw. No. 0.61/97046 Rev 1; Tutuka Power Station; P&ID Unit 1 – 6; Fabric Filter Plant Pulse Air Cooling Water Chemical Dosing

[16] Eskom Drw. No. 0.61/97039 Rev 3 Sheet 1-2; Tutuka Power Station; Unit 1 – 6; Fabric Filter Plant Pulse Air System PFD

[17] Eskom Drw. No. 0.61/97049 Rev 3; Tutuka Power Station; Unit 1 – 6; Fabric Filter Plant Instrument Air Distribution Manifold PFD

[18] Eskom Drw. No. 0.61/97050 Rev 3; Tutuka Power Station; P&ID; Unit 1 – 6; Fabric Filter Plant Pulse Air and Instrument Air Cooling System PFD

[19] Eskom Drw. No. 0.61/97172 Rev 00 Sheet 1-3; Tutuka Power Station ; Fabric Filter Plant; Pulse Air & Dust Handling Plant; Compressor House - PLAN LVL. 0,00, PLAN LVL +2,755 & +4,355 and SECTIONS & ROOF PLAN

[20] Pipe Routing Drawings (Drawing to be Generated) [21] Instrument Air Receiver Nozzle Layout Drawing (Drawing to be Generated) [22] Pulse Jet Air Receiver Nozzle Layout Drawing (Drawing to be Generated)

2.3 Documents

[23] Eskom Specification ESKSCAAC6 Rev 0; Specification for the Identification of the Contents of Pipelines and Vessels

[24] PTSI Doc. No. Z0419-000157-45 Rev 1; FFP ICD:PTSI SEGMENT MECHANICAL AND PROCESS INTERFACES

[25] Eskom; Thermal Insulation Standard; Unique Identifier 240-56247004 Rev1 [26] Eskom Specification for painting of vessels (To be obtained)

3 SANS 347 CLASSIFICATION

3.1 Instrument and Pulse Jet Air Receiver Vessels

Both the Instrument Air Receiver (Design Pressure 800 kPa, Volume 33m3) and the Pulse Jet Air Receiver (Design Pressure 800 kPa, Volume 15m3) are Category IV vessels to SANS 347:2012. This is shown in the following figure for SANS 347:2012 categorization.

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Figure 1 - Air Receiver Classification

The pressure vessels shall be designed and constructed to the requirements of ASME VIII Division 1. In addition to the requirements of ASME B&PVC Section VIII Division 1, the requirements for Category IV vessels to SANS 347: 2012 shall also be met.

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3.2 Pulse Jet Air Pipelines

The largest pulse jet air pipeline (Design Pressure 800 kPa, Nominal Diameter DN200) is a Category I pipeline to SANS 347:2012. This is shown in the following figure for SANS 347:2012 categorization. All pulse jet air pipelines of this system shall thus meet at least these category requirements.

Figure 2 - Pulse Jet Air Pipeline Classification

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3.3 Instrument Air Pipelines

The largest instrument air pipeline (Design Pressure 800 kPa, Nominal Diameter DN100) is a Category SEP (sound engineering practice) pipeline to SANS 347:2012. This is shown in the following figure for SANS 347:2012 categorization. All instrument air pipelines of this system shall thus meet at least these category requirements.

Figure 3 - Instrument Air Pipeline Classification

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3.4 Closed Circuit Cooling Water Ring Main Piping

The largest closed circuit cooling water pipeline (Design Pressure 800 kPa, Nominal Diameter DN200) is a Category SEP (sound engineering practice) pipeline to SANS 347:2012. This is shown in the following figure for SANS 347:2012 categorization. All closed circuit cooling water pipelines of this system shall thus meet at least this category requirements.

Figure 4 - Closed Circuit Cooling Water Pipelines Classification

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3.5 Piping Design Code

Irrespective of the minimum requirements for their SANS 347 Classification, all pipelines shall be designed, constructed and supported to the requirements of ASME B31.3 (Process Piping).

4 ASME B31.3 FLUID CATEGORIES

4.1 General

The following ASME B31.3 fluid category definitions may be applicable to this system

For compressed plant and instrument air and demineralised (DI) water:

(a) Category D Fluid Service: a fluid service in which all the following apply:

(1) the fluid handled is non-flammable, nontoxic, and not damaging to human tissues as defined in para. 300.2

(2) the design gage pressure does not exceed 1035 kPa (150 psi)

(3) the design temperature is from −29°C (−20°F) through 186°C (366°F)

For all cooling water, drains water, and water treatment chemicals, due to mild toxicity of the treatment chemicals:

(e) Normal Fluid Service: a fluid service pertaining to most piping covered by this Code, i.e., not subject to the rules for Category D, Category M, elevated temperature, or High Pressure Fluid Service.

However, the owner (in this case Eskom) has not designated the compressed air and demineralised water lines for Category D Fluid Service, resulting in all lines for this system being designed to the rules for Normal Fluid Service.

The fluid service categories for the fluids of this system are shown in the following figures based on Figure M300 of ASME B31.3. The fluids are:

4.2 Compressed / Plant Air

All the compressed plant air piping shall be designed to the code rules for normal fluid service. The classifying is shown in Figure 5.

4.3 Cooling Water (Closed Circuit)

All the closed circuit cooling water piping shall be designed to the code rules for normal fluid service. The classifying is shown in Figure 6.

4.4 Cooling Water (Open Circuit)

All the open circuit cooling water piping shall be designed to the code rules for normal fluid service. The classifying is shown in Figure 7.

4.5 De-ionised (Demineralised) Water

All the de-ionised water piping shall be designed to the code rules for normal fluid service. The classifying is shown in Figure 8.

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4.6 Chemicals for Water Treatment

All the cooling water treatment chemical piping shall be designed to the code rules for normal fluid service. The classifying is shown in Figure 9.

4.7 Drains Water

All the drains piping shall be designed to the code rules for normal fluid service. The classifying is shown in Figure 10.

4.8 Classifying Figures

Figure 5 - Compressed/Plant Air Fluid Service Classifying

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Figure 6 – Closed Circuit Cooling Water Fluid Service Classifying

Figure 7 – Open Circuit Cooling Water Fluid Service Classifying

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Figure 8 – Demineralised (DI) Water Fluid Service Classifying

Figure 9 – Cooling Water Treatment Chemicals Fluid Service Classifying

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Figure 10 – Drains Water Fluid Service Classifying

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5 ASME VIII FORM U-DR-1 USER DESIGN REQUIREMENTS (AIR RECEIVERS)

5.1 Instrument Air Receivers

The ASME VIII Div 1 U-DR-1 user design requirement for the instrument air receiver vessels is shown in the following two pages. The form is available as a secured .pdf file.

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5.2 Pulse Jet Air Receivers

The ASME VIII Div 1 U-DR-1 user design requirement for the pulse jet air receiver vessels is shown in the following two pages. The form is available as a secured .pdf file.

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0635-302B CI Sheet E533941-2




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5.3 Air Receiver Minimum Wall Thickness

The basic wall thickness determination of the IA and PJ Air Receivers to ASME VIII Div 1 for internal and external design pressure is shown in Appendix 5. The minimum wall thicknesses are

• IA Receiver 12.4mm, but due to standard stock sizes in RSA 16mm plate should be used. • PJ Air Receiver 10.7mm, but due to standard stock sizes in RSA 12mm plate should be used.

5.4 Air Receiver Coating and Marking

All air receivers shall be coated inside and outside with a corrosion resistant non-metallic coating to Eskom specification (TBS).

The coating colour and vessel markings shall be to Eskom specification ESKSCAAC6 Rev 0. The pulse jet air receivers shall be coloured as service/plant air but marked as Pulse Jet Filter Air (TBC), and the instrument air receivers shall be coloured and marked as instrument/control air, to Annex A of ESKSCAAC6.

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6 PIPELINE SPECIFICATIONS

6.1 Pulse Jet Air Pipelines

All pulse jet air pipelines shall be constructed to the fluid service sheet requirements of Appendix 1 paragraph 8.1 (Fluid Service Sheet FS001: Air (Compressed / Plant))

6.1.1 Air Pipelines: Compressor to Dryer and Post Filter

The temperature of this line is expected to reach 185°C (see Compressor Specification). These lines shall be insulated and lagged for personnel protection to a maximum cold face temperature of 50°C. Insulation and lagging design and installation shall be to the requirements of the Eskom Thermal Insulation Standard [25].

6.2 Instrument Air Pipelines

All instrument air pipelines shall be constructed to the fluid service sheet requirements of Appendix 1 paragraph 8.1 (Fluid Service Sheet FS001: Air (Compressed / Plant))

6.3 Closed Circuit Cooling Water Pipelines

All closed circuit cooling water pipelines shall be constructed to the fluid service sheet requirements of Appendix 1 paragraph 8.3 (Fluid Service Sheet FS003: Water (Cooling))

6.3.1 Closed Circuit Cooling Water Pipeline Restriction Orifices

Restriction orifices are required for flow limitation in each of the closed circuit coolant DN80 lines to the compressed air dryer and post filter. The orifices shall have an area of 10% of the nominal DN80 Sch 40 pipe flow area, resulting in a nominal orifice size of 24.6mm diameter. The detail of the full face restriction orifices is shown in Appendix 3.

6.4 Open Circuit Cooling Water Pipelines

All open circuit cooling water pipelines shall be constructed to the fluid service sheet requirements of Appendix 1 paragraph 8.3 (Fluid Service Sheet FS003: Water (Cooling))

6.5 De-ionised (DI, Demin) Water Pipelines

All di-ionised water pipelines shall be constructed to the fluid service sheet requirements of Appendix 1 paragraph 8.2 (Fluid Service Sheet FS002: Water (DI)

6.6 Coolant Chemical Dosing Pipelines

All coolant chemical dosing pipelines shall be constructed to the fluid service sheet requirements of Appendix 1 paragraph 8.4 (Fluid Service Sheet FS004: Water (Treatment Chemicals))

6.7 Drain Water Pipelines

All drain water pipelines shall be constructed to the fluid service sheet requirements of Appendix 1 paragraph 8.5 (Fluid Service Sheet FS005: Water (Drains))

6.8 Pipeline Protective Coatings

All carbon steel pipe components shall receive a hot dip galvanised coating on all surfaces (internal and external) after final fabrication. Although required to meet ASTM A123 / A153, these procedure standards may be substituted by SANS 121:2000.

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Special care shall be taken to ensure flange faces are restored to the required surface finish after galvanising.

Note that this coating application may require the piping to be disassembled from site, transported to and from the galvanising works, and re-assembled. This have to be provided for in design and construction.

6.9 Pipeline Marking

All pipelines shall bear markings in accordance with Eskom Specification ESKSCAAC6 Rev 0. Take note of the exceptions for stainless steel and galvanised piping (paragraph 4.2.7) and plastic piping (paragraph 4.2.8).

6.10 Pipe Hangers and Supports

To meet the requirements of ASME B31.3 (Process Piping) all pipeline hangers, supports, and anchors shall meet the requirements of ANSI/MSS SP-58-2009.

The following points from SP-58 are particularly relevant to this system:

a) All the pipelines in this system meet the requirements for ambient piping systems in SP-58 section 5.1(b).

b) Hanger and support type selections from SP-58 Table A1 and Figure A1 shall be done to the requirements for an ambient piping system.

c) The design load ratings for hangers and supports shall meet the requirements of SP-58 Table 1 as a minimum for all pipelines.

d) Pipe hanger and support horizontal spacing shall not exceed the values as shown in SP-58 Table 4 for all pipelines

e) All carbon steel hanger and support components shall receive a hot dip galvanised coating after fabrication to the requirements of SP-58 section 10.3.4, with the understanding that ASTM A123 / A153 may be substituted by SANS 121:2000.

f) Installation information for hangers and supports to the piping installation team shall at least be provided in a semi-engineered, but preferably to a fully engineered, format to SP-58 section 14.2 and 14.4. Anchors and anchor position information shall be provided in a fully engineered format to retain the engineers flexibility scheme.

g) All anchors shall be of the clamp-on type only. No anchors shall be welded to the pipes due to the hot dip galvanised coatings of both component types.

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7 MAIN COMMERCIAL COMPONENT SPECIFICATIONS

7.1 Compressor Specifications

7.1.1 Conditions

The compressor shall operate under the following conditions:

a) Atmospheric Pressure 83.9 kPa(abs) b) Inlet air temperature 35°C c) Relative Humidity 60% d) Cooling water temperature 30°C e) Medium voltage (3300V 50Hz) supply

7.1.2 Requirements

The air compressor shall meet the following requirements:

a) Oil free delivery turbocompressor with tolerances according to ISO 5389 b) Rated for continuous duty (24 hr/day) c) Inlet filtration dry type remote mount with 98%@2micron efficiency d) Discharge pressure (after check valve) 720 kPa(g) e) Rated capacity 2300 Nm3/hr. f) Turndown capacity 2100 Nm3/hr. g) Air discharge temperature 185°C (max) h) Cooling water flow 260 L/min (max) i) Cooling water temp. rise 15°C (max) j) Cooling water supply pressure 250/520 kPa (min/max) k) Cooling water pressure losses 100 kPa (max) l) Air outlet line size DN100 with FF flanges to ASME B16.5 Class 150 m) Cooling water inlet/outlet line size DN80 with FF flanges to ASME B16.5 Class 150

7.2 Dryer and Post-Filter Specifications

7.2.1 Conditions

The dryer shall operate under the following conditions:

a) Inlet pressure 720 kPa(g) b) Inlet air temperature 185°C (max) c) Coolant temperature 30°C d) Low voltage (220/380V 50Hz) supply

7.2.2 Requirements

The dryer and after-filter as a unit shall meet the following requirements:

a) Heat of compression type regenerative desiccant dryer b) Rated inlet flow 2300 Nm3/hr c) Outlet pressure dew point at rated flow -30°C (max) d) After-filter remote or integral mounted

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e) Output air quality to meet ISO 8573-1:2010 [4:2:2] at rated flow f) Pressure drop across dryer and filter combined at rated flow 20 kPa (max) g) Purge air consumption 2.5% of rated flow (max) h) Coolant Flow Rate 170 L/min (max) i) Cooling water temp. rise 15°C (max) j) Cooling water supply pressure 250/520 kPa (min/max) k) Cooling water pressure losses 100 kPa (max) l) Air inlet/outlet line size DN100 with FF flanges to ASME B16.5 Class 150 m) Cooling water inlet/outlet line size DN80 with FF flanges to ASME B16.5 Class 150

7.3 Coolant Pump Specification

7.3.1 Conditions

The coolant pumps shall operate under the following conditions:

a) Pumped medium is coolant water, a mixture of de-ionised water with (TBS)% anti-corrosion agent (TBS).

b) Static inlet head 0 – 10m c) Coolant inlet temperature 30°C d) Low voltage (380V 3ph 50Hz) supply

7.3.2 Requirements

The coolant pump shall meet the following requirements:

a) Outlet pressure at rated flow 320 kPa(g) b) Outlet flow delivery at rated pressure 115 m3/hr c) Pump and motor to be skid mounted d) Direct coupled motor (no belt drives) e) Pump speed not to exceed 1500 rpm f) All components to be selected for at least 100 000 hours L10 life g) Cooling water inlet/outlet line size DN100 with FF flanges to ASME B16.5 Class 150

7.4 Coolant Cooler Specification

7.4.1 Conditions

The coolant coolers shall operate under the following conditions:

a) Atmospheric Pressure 83.9 kPa(abs) b) Ambient air temperature 40°C (max) c) Relative humidity 60% at maximum ambient temperature d) CC Cooling water inlet temperature 41°C (max) e) OC Cooling water inlet temperature 30°C (max) f) Low voltage (380V 3ph 50Hz) supply

7.4.2 Requirements

The coolant coolers as a unit shall meet the following requirements:

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a) Cooler unit to be integrated unit of closed primary circuit with secondary induced counter draft evaporative open circuit type

b) CC coolant water outlet temperature at maximum flow and ambient conditions 30°C (max) c) CC coolant water flow 75 m3/hr (max) d) CC coolant water inlet pressure 170 kPa(g) max e) CC coolant water pressure drop at maximum flow 40 kPa(g) (max) f) CC coolant water is a mixture of de-ionised water with (TBS)% anti-corrosion agent (TBS). g) CC cooling water inlet/outlet line size DN100 with FF flanges to ASME B16.5 Class 150 h) OC coolant water is potable water with (TBS)% anti-fungal agent (TBS). i) OC coolant potable make-up water inlet connection to be DN25 FF Flanges to ASME B16.5

Class 150 j) OC coolant water drain connection DN50 FF or backing flanges to ASME B16.5 Class 150

7.5 Make-up Tank Specification

7.5.1 Conditions

The storage tank for the closed circuit coolant make-up water shall operate under the following conditions:

a) Contain mixture of de-ionised (DI, demineralised) water and (TBS)% anti-corrosion chemical (TBS).

b) Installed indoors in the compressor house on steel structure.

7.5.2 Requirements

The storage tank for the closed circuit coolant make-up water shall meet the following requirements:

a) Storage capacity of 1000 L before overflow b) Mounted on engineer certified steel structure at a height of 7m (TBC) above compressor

house floor level. Structure to include cat ladder and sufficient working space with railings around tank.

c) All tank materials to be fully resistant to the CC coolant mixture as well as to pure de-ionised water. Preference will be given to tanks moulded in a suitable polymer.

d) A protruding access hole of at least 500mm diameter with a non-fixable over-the-edge cover/lid in the top of the tank for cleaning and inspection purposes

e) DI water inlet, coolant outlet, and overflow connections DN50 FF or backing flanges to ASME B16.5 Class 150

f) Dosing chemical inlet connection DN25 FF or backing flange to ASME B16.5 Class 150 g) Level sensing vertical nozzle in the top surface DN(TBS) with FF or backing flange to ASME

B16.5 Class 150

7.6 Chemical Dosing (CC) Unit Specification

7.6.1 Conditions

The CC Chemical Dosing Unit shall operate under the following conditions:

0635-302B CI Sheet E533941-2




a) Anti-corrosion chemical (TBS) b) Installed indoors in the compressor house. c) Low voltage (220/380V 50Hz) supply

7.6.2 Requirements

The CC chemical dosing system for the closed circuit coolant make-up water shall meet the following requirements:

a) Integral unit with all components mounted on single skid type frame b) Two fully redundant 100% duty pumps with selection valves c) Dosing rate of (TBS) L/min d) Dosing accuracy of (TBS)% e) Dosing chemical storage tank size (TBS) L with level sensing and feedback f) All materials to be fully resistant to specified dosing chemical. g) Outlet pressure minimum 100 kPa but restricted to not exceed 200 kPa. h) Outlet connection DN25 (TBS)

7.7 Chemical Dosing (OC) Unit Specification

7.7.1 Conditions

The OC Chemical Dosing Unit shall operate under the following conditions:

a) Anti-fungal chemical (TBS) b) Installed outdoors next to the compressor house. c) Low voltage (220/380V 50Hz) supply

7.7.2 Requirements

The OC chemical dosing system for the closed circuit coolant make-up water shall meet the following requirements:

a) Integral unit with all components mounted on single skid type frame b) Two fully redundant 100% duty pumps with selection valves c) Dosing rate of (TBS) L/min d) Dosing accuracy of (TBS)% e) Dosing chemical storage tank size (TBS) L with level sensing and feedback f) All materials to be fully resistant to specified dosing chemical. g) Outlet pressure minimum 100 kPa but restricted to not exceed 200 kPa. h) Outlet connection DN25 (TBS)

0635-302B CI Sheet E533941-2




8 APPENDIX 1: FLUID SERVICE SHEETS

See Appendix 2 for Piping Specifications (P-Spec) specified in fluid service sheets.

0635-302B CI Sheet E533941-2




8.1 Fluid Service Sheet FS001: Air (Compressed / Plant)

General Information

Material P-Spec C.A.** Design Pressure Design Temperature Additional Requirements

Carbon Steel Pipe PS001-B 0.8mm 150 psig

1 034 kPag

400°F

204°C

All piping HDG after welding and/or threading

Gaskets

Material Max Pressure Max Temperature Flange Face Finish Additional Requirements

NBR Bonded Aramid Fibre 150 psig

1 379 kPag

400°F

204°C

125 – 250 µ.in

Ra 1.6 – 3.2 µm after HDG

Raised Face flanges (at least one side) only

Viton 80 IRHD 150 psig

1 034 kPag

392°F

200°C

250 – 500 µ.in


Full Face flanges / gaskets only

EPDM 70 IRHD 150 psig

1 034kPag

200°F

93°C

250 – 500 µ.in



Notes 1) Piping runs can utilise butt welded flanges and fittings (≥DN25), slip-on welded flanges (≥DN25), or threaded connections (≤DN50). 2) No threaded flanges allowed.

Valves

Feature Feature Specification

Acceptable Standard Listed Code Valve

0635-302B CI Sheet E533941-2




Body Material Carbon Steel A105 or A216WCB, Stainless Steel CF3, CF8(M), F304(L), F316(L)

Pressure Class 150

End Connection: ≥DN25 Flanged, Wafer

End Connection: <DN25 Threaded

Type of Valve: ≥DN50 Butterfly, Gate, Globe, Swing Check, Poppet Check

Type of Valve: <DN50 Ball (Full Flow), Ball Check, Poppet Check

Packing Material Graphite, Teflon, Nylon, Viton, EPDM

Body Gasket Teflon, Nylon, Viton, EPDM

** C.A. = Corrosion Allowance

0635-302B CI Sheet E533941-2




8.2 Fluid Service Sheet FS002: Water (DI)

General Information


Stainless Steel Pipe PS002-A 0mm 195 psig

1 345 kPag

200°F

93°C

Gaskets



690 kPag

200°F

93°C

250 – 500 µ.in

Ra 3.2 – 6.3 µm



Valves


Acceptable Standard Listed Code Valve, Non-Listed Rated Valve approved by Owner

Body Material Stainless Steel CF3(M), CF8(M), F304(L), F316(L)

Pressure Class 150



0635-302B CI Sheet E533941-2









0635-302B CI Sheet E533941-2




8.3 Fluid Service Sheet FS003: Water (Cooling)

General Information


Carbon Steel Pipe PS001-B 0.8mm 100 psig

690 kPag

200°F

93°C

All piping HDG after welding and/or threading

Gaskets



690 kPag

200°F

93°C

250 – 500 µ.in




Valves



Body Material Brass, Bronze, Carbon Steel A105 or A216WCB, Stainless Steel CF3(M), CF8(M), F304(L), F316(L)

Pressure Class 150



0635-302B CI Sheet E533941-2









0635-302B CI Sheet E533941-2




8.4 Fluid Service Sheet FS004: Water (Treatment Chemicals)

General Information


u-PVC Pipe PS003 0mm 100 psig

690 kPag

100°F

38°C

Ultraviolet Inhibitor

Gaskets



690 kPag

200°F

93°C

250 – 500 µ.in

Ra 3.2 – 6.3 µm

Full Face or backing flanges / gaskets only

Notes 1) Piping runs can utilise solvent welded flanges and fittings and/or threaded connections. 2) No threaded flanges allowed.

Valves



Body Material PVC with Ultraviolet Inhibitor

Pressure Class 150

End Connection: ≥DN25 Flanged, Threaded


0635-302B CI Sheet E533941-2




Type of Valve: ≤DN50 Ball (Full Flow), Ball Check, Poppet Check




0635-302B CI Sheet E533941-2




8.5 Fluid Service Sheet FS005: Water (Drains)

General Information


u-PVC Pipe PS003 0mm 100 psig

690 kPag

100°F

38°C

Ultraviolet Inhibitor

Gaskets



690 kPag

200°F

93°C

250 – 500 µ.in

Ra 3.2 – 6.3 µm

Full Face or backing flanges / gaskets only

Notes 1) Piping runs can utilise solvent welded flanges and fittings or threaded connections. 2) No threaded flanges allowed.

Valves



Body Material PVC with Ultraviolet Inhibitor

Pressure Class 150

End Connection: ≥DN25 Flanged, Threaded


0635-302B CI Sheet E533941-2




Type of Valve: ≤DN50 Ball (Full Flow), Ball Check, Poppet Check




0635-302B CI Sheet E533941-2




9 APPENDIX 2: PIPING SPECIFICATIONS

0635-302B CI Sheet E533941-2




9.1 Piping Specification PS001*: Carbon Steel (Normal Fluid Service)

Design Parameters

P_Spec PS001-A, -B, -C, -D Calculation Reference 00-00-CALC-M-0004-R0

(LANL, to be verified)

Design Pressure

(psig)

(kPag)

285

1 965

260

1 793

230

1 586

200

1 379

170

1 172

140

965

125

862

Code of Reference ASME B31.3-2010

Design Temperature

(°F)

(°C)

100

38

200

93

300

149

400

204

500

260

600

316

650

343

Fluid Service Normal

Minimum Temperature

(°F)

(°C)

-20

-29

-20

-29

-20

-29

-20

-29

-20

-29

-20

-29

-20

-29

Material Carbon Steel

Minimum Test Pressure

(psig)

(kPag)

430

2 965

390

2 689

345

2 379

300

2 068

270

1 862

245

1 689

220

1 517

Pressure Rating Class 150

Maximum Test Pressure

(psig)

(kPag)

820

5 654

External Pressure Rating 15 psi / 100 kPa

Allowable Pipe Materials

Component Size Rating Standard Material Grade Additional Requirements

Piping DN10 – DN300 Schedule Table ASME B36.10M ASTM A53 B Type E (ERW), Type S (Seamless)

Piping DN10 – DN300 Schedule Table ASME B36.10M ASTM A106 B Seamless

0635-302B CI Sheet E533941-2




Required Schedules for Non-Threaded Pipe

P-Spec C.A.** Size DN10 DN15 DN20 DN25 DN40 DN50 DN80 DN100 DN125 DN150 DN200 DN250 DN300

A 0 mm Schedule 40 40 40 40 40 40 40 40 40 40 40 40 40

B 0.8 mm Schedule 40 40 40 40 40 40 40 40 40 40 40 40 40

C 1.6 mm Schedule 40 40 40 40 40 40 40 40 40 40 40 40 40

D 3.2 mm Schedule - 160 160 160 160 80 80 40 40 40 40 40 40

Required Schedules for Threaded Pipe

P-Spec C.A.** Size DN10 DN15 DN20 DN25 DN40 DN50 DN80 DN100

A 0 mm Schedule 80 80 80 80 80 40 40 40

B 0.8 mm Schedule 80 80 80 80 80 40 40 40

C 1.6 mm Schedule 80 80 80 80 80 80 80 40

D 3.2 mm Schedule - 160 160 160 160 160 80 80

Fittings


Socket-Weld Fittings DN10 – DN50 3000#, 6000# ASME B16.11 ASTM A105 WP Use 6000# for PS001-D

Threaded Fittings DN10 – DN100 2000#, 3000# ASME B16.11 ASTM A105 WP Use 3000# for PS001-D

Buttweld Fittings DN10 – DN300 Schedule Tables ASME B16.9 ASTM A234 WPB

Buttweld Fittings DN10 – DN300 Schedule Tables ASME B16.28 ASTM A234 WPB

0635-302B CI Sheet E533941-2




Flanges


Socket-Weld Flange DN15 – DN50 Class 150 ASME B16.5 ASTM A105 N/A

Threaded Flange DN15 – DN100 Class 150 ASME B16.5 ASTM A105 N/A

Weldneck Flange DN15 – DN300 Class 150 ASME B16.5 ASTM A105 N/A

Slip-on Flange DN15 – DN300 Class 150 ASME B16.5 ASTM A105 N/A

Blind Flange DN15 – DN300 Class 150 ASME B16.5 ASTM A105 N/A

Back-up Flange DN15 – DN300 Class 150 ASME B16.5 ASTM A105 N/A

Mechanical Fasteners

Component Size Standard Material Grade Additional Requirements***

Fasteners ½” – 1” ASME B18.2.1 ASTM A193

ASTM A193

ASTM A354

B7-HH

B8 Cl.2-HH

BC-HH

Only Studs - No HDG

Only Studs

Only Studs - HDG

Nuts ½” – 1” ASME B18.2.2 ASTM A194

ASTM A194

ASTM A563

2H-HH

8F-HH

DH-HH

No HDG

Use nickel based anti-seize

HDG

*Based on LANL Piping Specification 101 (Rev.0) **C.A. = Corrosion Allowance *** Only kind with kind allowed

0635-302B CI Sheet E533941-2




9.2 Piping Specification PS002*: Stainless Steel 304L (Normal Fluid Service)

Design Parameters

P_Spec PS002-A, B Calculation Reference 00-00-CALC-M-0004-R0


Design Pressure

(psig)

(kPag)

230

1 586

195

1 345

175

1 207

160

1 103

145

1 000

140

965

125

862


Design Temperature

(°F)

(°C)

100

38

200

93

300

149

400

204

500

260

600

316

650

343


Minimum Temperature

(°F)

(°C)

-325

-198

-325

-198

-325

-198

-325

-198

-325

-198

-325

-198

-325

-198

Material Stainless Steel 304L


(psig)

(kPag)

345

2 379

295

2 034

265

1 827

255

1 758

245

1 689

240

1 655

230

1 586

Pressure Rating Class 150


(psig)

(kPag)

440

3 034

External Pressure Rating 15 psi / 100 kPa



Piping DN10 – DN100 Schedule Table ASME B36.19 ASTM A312 TP304L Welded, Seamless

0635-302B CI Sheet E533941-2




Required Schedules for Non-Threaded Pipe

P-Spec C.A.** Size DN10 DN15 DN20 DN25 DN40 DN50 DN80 DN100

A 0 mm Schedule 10S 10S 10S 10S 10S 10S 10S 10S

B 0.8 mm Schedule 10S 10S 10S 10S 10S 10S 10S 10S

Required Schedules for Threaded Pipe

P-Spec C.A.** Size DN10 DN15 DN20 DN25 DN50

A 0 mm Schedule 40S 40S 40S 40S 40S

B 0.8mm Schedule 40S 40S 40S 40S 40S

Fittings


Socket-Weld Fittings DN10 – DN50 3000# ASME B16.11 ASTM A182 F304L

Threaded Fittings DN10 – DN50 2000# ASME B16.11 ASTM A182 F304L Use nickel based anti-seize

Buttweld Fittings DN10 – DN100 Schedule Tables ASME B16.9 ASTM A403 WP304L

Buttweld Fittings DN10 – DN100 Schedule Tables ASME B16.28 ASTM A403 WP304L

Flanges


Socket-Weld Flange DN15 – DN50 Class 150 ASME B16.5 ASTM A182 F304L

Threaded Flange DN15 – DN50 Class 150 ASME B16.5 ASTM A182 F304L Use nickel based anti-seize

0635-302B CI Sheet E533941-2




Weldneck Flange DN15 – DN100 Class 150 ASME B16.5 ASTM A182 F304L

Slip-on Flange DN15 – DN100 Class 150 ASME B16.5 ASTM A182 F304L

Blind Flange DN15 – DN100 Class 150 ASME B16.5 ASTM A182 F304L

Back-up Flange DN15 – DN100 Class 150 ASME B16.5 ASTM A105 N/A Temp. range -20 to 650°F only.


Component Size Standard Material Grade Additional Requirements

Fasteners ½” – 1” ASME B18.2.1 ASTM A193 B8 Cl.2-HH Only Studs

Nuts ½” – 1” ASME B18.2.2 ASTM A194 8F-HH Use nickel based anti-seize

*Based on LANL Piping Specification 200 (Rev.0) **C.A. = Corrosion Allowance

0635-302B CI Sheet E533941-2




9.3 Piping Specification PS003*: PVC (Normal Fluid Service)

Design Parameters

P_Spec PS003 Calculation Reference 00-00-CALC-M-0004-R0


Design Pressure

(psig)

(kPag)

150

1 034


Design Temperature

(°F)

(°C)

100

38


Minimum Temperature

(°F)

(°C)

0

-18

Material u-PVC


(psig)

(kPag)

225

1 551

Pressure Rating 150 psig


(psig)

(kPag)

290

2 000

External Pressure Rating N/A



Piping DN10 – DN50 Schedule Table ASME D1784 ASTM D1784 12454-B, 12454-C Ultraviolet inhibitor

0635-302B CI Sheet E533941-2




Required Schedules for All Pipe

P-Spec C.A.** Size DN10 DN15 DN20 DN25 DN40 DN50

003 0 mm Schedule 40 40 40 40 40 40

Fittings


Threaded Fittings DN10 – DN50 Sch. 40 ASTM D2467 ASTM D1784 12454-B, 12454-C Ultraviolet inhibitor

Solvent-Welded Fittings DN10 – DN50 Sch. 80 ASTM D2467 ASTM D1784 12454-B/-C Ultraviolet inhibitor

Flanges


Solvent-Welded Flanges DN10 – DN50 Sch. 80 ASME B16.5 (150#) ASTM D1784 12454-B, 12454-C Ultraviolet inhibitor


Component Size Standard Material Grade Additional Requirements

Fasteners ½” ASME B18.2.1 ASTM A354 BC-HH Only Studs - HDG

Nuts ½” ASME B18.2.2 ASTM A563 DH-HH HDG

*Based on LANL Piping Specification 500 (Rev.0) **C.A. = Corrosion Allowance

0635-302B CI Sheet E533941-2




10 APPENDIX 3: FULL FACE RESTRICTION ORIFICES FOR COOLANT LINE

0635-302B CI Sheet E533941-2




11 APPENDIX 4: PIPE ROUTING PLAN VIEW (INFORMATIVE ONLY)

0635-302B CI Sheet E533941-2




12 APPENDIX 5: INSTRUMENT AIR AND PULSE JET AIR RECEIVER MINIMUM WALL THICKNESS

12.1 BOTH RECEIVERS

Internal Design Pressure (DP) = 800 kPa

External Design Pressure (P) = 100 kPa

Design temperature = 65°C

Materials = SA516 Grade 70

Min Tensile Strength = 70 ksi = 483 MPa

Min Yield strength = 38 ksi = 262 MPa

Weld efficiency (E) = 0.85

Corrosion Allowance = 3mm (inside) and 1mm (outside)

12.2 IA RECEIVER VESSEL

12.2.1 Minimum wall thickness for internal pressure to ASME VIII Div 1

12.2.1.1 Circumferential Stress (Longitudinal Welds)

Inside radius R = 1220 mm

S = ASME II Allowable stress (-20 to 500°F or -29 to 260°C) = 20 ksi = 137.9 MPa

Tc = P*R/(S*E – 0.6*DP) = 800*1220/(137900*0.85-0.6*800) = 8.36mm

Corrosion allowance = 4mm

Tmin = 12.36 mm

12.2.1.2 Longitudinal Stress (Circumferential Welds)

Tl = P*R/(2*S*E + 0.4*DP) = 800*1220/(2*137900*0.85+0.4*800) = 4.15 mm

Minimum standard RSA plate thickness = 16 mm. Possible stock of 12.7mm (1/2”) plate may be available

12.2.2 External Pressure allowed at selected 16mm plate thickness

Do = Outside diameter = (1220+16)*2 = 2472 mm

Tmin = 16mm

Do/T = 2472/16 = 155

L from Fig UG-28.1 = Lt + 2h/3 = 6250 + 2*(2472/4)/3 = 6662 mm

L/Do = 6660/2472 = 2.695

A from Fig G in II.D.3 = 0.000186

B from CS-2 in II.D.3 = 2700 psi = 18616 kPa

0635-302B CI Sheet E533941-2




E = Modulus of Elasticity from II.D.2 = 28.8*103 ksi = 198.6*106 kPa

P = External Design Pressure = 100 kPa

Ro = Outside radius = 1236 mm

Pa = External Pressure allowed for T = 4*B/3*(Do/T) = 4*18616/(3*155) = 160.1 kPa

Vessel wall thickness of 16 mm sufficient for accidental vacuum

12.2.3 External Pressure allowed at reduced plate thickness of 12.7mm (1/2”) if available

Do = Outside diameter = (1220+12.7)*2 = 2455 mm

Tmin = 12.7mm

Do/T = 2455/12.7 = 193.3


L/Do = 6659/2455 = 2.71




P = External Design Pressure = 100 kPa


Pa = External Pressure allowed for T = 4*B/3*(Do/T) = 4*18616/(3*193.3) = 128.4 kPa

Vessel wall thickness of 12.7 mm also sufficient for accidental vacuum

12.3 PJ AIR RECEIVER VESSEL

12.3.1 Minimum wall thickness for internal pressure to ASME VIII Div 1

12.3.1.1 Circumferential Stress (Longitudinal Welds)

Inside radius R = 990 mm

S = ASME II Allowable stress (-20 to 500°F or -29 to 260°C) = 20 ksi = 137.9 MPa

Tc = P*R/(S*E – 0.6*DP) = 800*990/(137900*0.85-0.6*800) = 6.78mm

Corrosion allowance = 4mm

Tmin = 10.78 mm

12.3.1.2 Longitudinal Stress (Circumferential Welds)

Tl = P*R/(2*S*E + 0.4*DP) = 800*990/(2*137900*0.85+0.4*800) = 3.37 mm

Minimum standard RSA plate thickness = 12 mm.

0635-302B CI Sheet E533941-2




12.3.2 External Pressure allowed at selected 12mm plate thickness

Do = Outside diameter = (990+12)*2 = 2004 mm

Tmin = 12 mm

Do/T = 2004/12 = 167


L/Do = 4584/2004 = 2.29




P = external Design Pressure = 100 kPa


Pa = External Pressure allowed for T = 4*B/3*(Do/T) = 4*26200/(3*167) = 209 kPa

Vessel wall thickness of 12mm sufficient for accidental vacuum

0635-302B CI Sheet E533941-2