CERTIFICATION OF COMPLIANCE OF THE USER S DESIGN SPECIFICATION

Transcription

1 CERTIFICATION OF COMPLIANCE OF THE USER S DESIGN SPECIFICATION I, the undersigned, being experienced and competent in the applicable field of design related to pressure vessel requirements relative to this User s Design Specification, certify that to the best of my knowledge and belief it is correct and complete with respect to the Design and Service Conditions given and provides a complete basis for construction in accordance with Part 2, paragraph and other applicable requirements of the ASME Section VIII, Division 2 Pressure Vessel Code, 2007 Edition with Addenda 2008 and Code Case(s) NONE. This certification is made on behalf of the organization that will operate these vessels (company name) Certified by: Title and areas of responsibility: Date: Professional Engineer Seal: Date:

2 CONTRACT NO: JOB NO: AB-001 PAGE NO. 2 OF 14 USER S DESIGN SPECIFICATION FOR AIR BUFFER TANK VESSEL TAG NO. AB Issued for Purchase REV DESCRIPTION OF REVISIONS PREPARED CHECKED APPROVED DATE

3 CONTRACT NO: JOB NO: AB-001 PAGE NO. 3 OF 14 REVISION DETAILS Rev. Section Revision Description 0 All Issued for Purchase

4 CONTRACT NO: JOB NO: AB-001 PAGE NO. 4 OF 14 TABLE OF CONTENTS No. DESCRIPTION PAGE NO 1. INTRODUCTION 4 2. INSTALLATION SITE Location 2.2 Jurisdictional Authority 2.3 Environmental Conditions 3. VESSEL IDENTIFICATION Vessel identification 3.2 Service Fluid 4. VESSEL CONFIGURATION Outline Drawings 4.2 Vessel Orientation 4.3 Vessel openings & Identification 4.4 Principal Component Dimensions 4.4 Support Methods 5. DESIGN CONDITIONS Specified Design Pressure 5.2 Design Temperature 5.3 Minimum Design Metal Temperature 5.4 Dead, Live & Other Loads 6. OPERATING CONDITIONS 7 7. DESIGN FATIGUE LIFE 7 8. MATERIALS OF CONSTRUCTION 9 9. LOADS & LOAD CASES OVERPRESSURE PROTECTION ADDITIONAL REQUIREMENTS CERTIFICATION COMPLIANCE 12

5 CONTRACT NO: JOB NO: AB-001 PAGE NO. 5 OF 14 1 INTRODUCTION This specification, together with the related drawings, codes and standards constitutes a complete User s Design Specification as required by ASME VIII Div 2 Ed. 2007, Add 2008 Code. 1.1 PURPOSE This specification covers all the requirements outlined in ASME VIII, Div 2 Code, Part for the design and construction of Air Buffer Vessel (Item No AB-001). Any proposed deviation from this specification by the Supplier is to be made by written request for approval by the User and for a revision of this specification including recertification when this document is revised. 1.2 DEFINITIONS The following terms and definitions shall be used: COMPANY: ABC CONSULTANTS and their nominated or designated Engineering Contractor ENGINEERING CONTRACTOR: party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation / maintenance of a company facility. SUPPLIER: organization supplying equipment, materials or services as per the terms of this document and company purchase order The USER, as referred to in the ASME code, is ABC CONSULTANTS, the firm or organization who will own and/or operate the vessel. The INSPECTOR is the person who carries out all the inspections as specified in ASME Sec VIII Div. 2. The word CODE indicates the ASME VIII Div.2, Ed. 2007/Add 2008 & other reference Codes The word shall indicates a mandatory requirement. The word should indicates a recommendation. 1.3 REFERENCE STANDARDS ASME Section VIII Division 2, Edition 2007 Addenda 2008 ASME Section IX, Edition 2007 Addenda 2008 ASME Section II Part A, C, D (Metric), Edition 2007 Addenda 2008 ASME Section V, Edition 2007 Addenda 2008 ASME B Pipe Flanges and Flanged Fittings

6 CONTRACT NO: JOB NO: AB-001 PAGE NO. 6 OF INSTALLATION SITE 2.1 LOCATION Company s facility at located at in country 2.2 JURISDICTIONAL AUTHORITY 2.3 ENVIRONMENTAL CONDITIONS WIND DESIGN LOADS ASCE ; WIND SPEED -160 km/hr; IMP FACTOR 1.15, Exposure C EARTHQUAKE DESIGN LOADS Earthquake Loads: UBC 1997; ZONE 1; Soil Profile Sc, IMP FACTOR SNOW LOADS LOWEST ONE DAY MEAN TEMPERATURE FOR LOCATION 5 deg. C as per Meteorological data available Minimum Design Metal Temperature to be considered for the vessel shall be 0 (Zero) degree C. 3. VESSEL IDENTIFICATION 3.1 VESSEL NUMBER & IDENTIFICATION Air Buffer Tank (Vessel Tag No AB-001) 3.2 SERVICE FLUIDS & PROPERTIES Service Fluid: Compressed Air. Operating Liquid:. Design Liquid Level:. Design Density: Nil 4. VESSEL CONFIGURATION AND CONTROLLING DIMENSIONS 4.1 OUTLINE DRAWINGS Refer attached schematic sketch (Sketch No. ABC/U2-01 Rev 0) 4.2 VESSEL ORIENTATION (VERTICAL or HORIZONTAL) Horizontal 4.3 OPENINGS, CONNECTIONS & CLOSURES INCLUDING QUANTITY & LOCATION Nozzle N1 DN 80, 600#, WNRF INLET Shell top Nozzle N2 DN 50, 600#, WNRF PRESS. RELIEF VALVE Shell Nozzle N3 DN 50, 600#, WNRF VENT Shell Top Nozzle N4 DN 50, 600#, WNRF DRAIN Shell Bottom Nozzle M DN 600, 600#, WNRF MANWAY WITH BLIND FLANGE Shell

7 CONTRACT NO: JOB NO: AB-001 PAGE NO. 7 OF PRINICIPAL DIMENSIONS Size: 3000 mm inside Diameter x 5000 mm Tan Line / Tan Line End Closure Type: 2:1 Ellipsoidal heads on both ends. Internal Volume: m3 (Approx.) 4.5 SUPPORT METHOD Saddle supports: 2 nos. 5. DESIGN CONDITIONS 5.1 SPECIFIED DESIGN PRESSURE Design Internal Pressure: Maximum Allowable Working Pressure: Design External Pressure: MPa (820 psig) MPa (Considered same as Design Pressure) 5.2 DESIGN TEMPERATURE Design Temperature: 80 C at specified coincident internal design pressure of MPa Design Temperature for External Pressure:. 5.3 MINIMUM DESIGN METAL TEMPERATURE (MDMT) MDMT: 0 C at specified coincident internal design pressure of MPa 5.4 DEAD, LIVE & OTHER LOADS Nozzle Load: Except for the manhole and nozzles of size DN 50(2 ) NPS or less (vent & drain), all nozzles shall be designed for the additional loads as per Attachment 1 of this document: Static Loads Approximate dead weight, hydro-test and operating loads are as follows (to be confirmed by the supplier in his design calculations): Weight Fabricated Weight Operating Weight Hydrostatic (Shop) Kg Kg Kg All loads and load case combinations are detailed in 9.0 below 6. OPERATING CONDITIONS 6.1 OPERATING PRESSURE Operating Pressure: MPa (650 psig) 6.2 OPERATING TEMPERATURE Operating Temperature: 50 C 6.3 TRANSIENT THERMAL GRADIENT ACROSS VESSEL (Steady State Design Temperature condition)

8 CONTRACT NO: JOB NO: AB-001 PAGE NO. 8 OF DESIGN FATIGUE LIFE 7.1 Company has no past experience with this type of vessel and the supplier shall evaluate if fatigue analysis is required for this vessel as per the provisions of & of the Code. 7.2 The vessel design life to be considered is 20 years. 7.3 The vessel can be considered as Integral construction type as there are: No pad type reinforcement for nozzles. All nozzles are of self reinforced type forgings No threaded connections on the vessel No stud bolt type attachments All welds are of full penetration type No major thickness change between the members No attachment or nozzles in the head knuckle portion. 7.4 The material specified for shell & head is SA 516M Gr This material has a minimum specified tensile strength of 485 MPa, which does not exceed 552 MPa. Fatigue screening criteria of Part Method A can be applied. 7.5 The vessel normally operates in the static state condition. However the following loading history can be considered for the purpose of fatigue evaluation: Planned annual shutdown requiring full depressurization: 2 per year Unplanned shutdown requiring full depressurization during first year of operation: 6 Unplanned shutdown requiring full depressurization after first year of operation: 2 per year Automatic shut down requiring full depressurization due to fire/emergency condition: 1 per year The vessels normal operating pressure is MPa. The actual pressure variation shall be within ±10% of this pressure. However the HP compressor may trip during the operation and can cause pressure variation exceeding 20% of operating pressure. Such trips are not expected to be more than 6 per year. The vessels normal operating temperature is 50 o C and no fluctuations in temperature are expected during normal operation. However the shutdown conditions may cool down the vessel to ambient temperature of not less than 5 o C. The vessel is of carbon steel and has no metals which have different coefficient of thermal expansion. 8. MATERIALS OF CONSTRUCTION 8.1 VESSEL MATERIALS: Materials of constructions: Material Type 1 (Table 4.2.3) P-No. 1 Gr 2 Shell / Heads SA 516M Gr 485 (Gr 70) Nozzle Flanges / Forged Necks Fasteners SA 105M (Self Reinforced type) SA 193M Gr B7 / SA 194M Gr 2H Saddle wear plates & Name plate bracket SA 516M Gr 485 (Gr 70) Saddle & base plates & other attachments SA 36 Gaskets SS316L GRAPHITE FILLED SPIRAL WOUND GASKETS WITH SS INNER & CS OUTER RINGS

9 CONTRACT NO: JOB NO: AB-001 PAGE NO. 9 OF CORROSION AND EROSION 3.0 mm internal corrosion allowances shall be considered. Erosion of the vessel due to fluid motion is not applicable (Compressed Air Service). The external surfaces of the vessel shall be painted. No external corrosion allowance. 8.3 SERVICE CONDITIONS AFFECTING SELECTION OF MATERIAL Service Duty Lethal Service / Sour Service Hydrogen Service Specific Toughness Requirement Special filler metal requirements Continuous None None To be evaluated by supplier None 9. LOADS AND LOAD CASES 9.1 Applicable Loads (As per Table of Code): Design Load Parameter P Description Applicability / Remarks Internal Maximum Allowable Working Pressure Applicable External Maximum Allowable Working Pressure Ps Static head from liquid or bulk materials (e.g. catalyst) D Dead Weight of the vessel, Contents and Appurtenances, including the following: Weight of vessel including internals, supports. Weight of vessel contents under operating & test conditions. Refractory Linings, Insulation. Static Reactions from weight of attached equipment. Applicable Applicable L Appurtenances Live Load Effect of Fluid Flow E Earthquake Loads Applicable W Wind Loads Applicable S Snow Loads 9.1 Applicable Design Load Combinations (As per Table of Code) : SR. NO. Design Load Combinations General Primary Membrane Allowable Stress 1 P + Ps + D S P + Ps + D + (W or 0.7 E) S P + Ps + D (W or 0.7 E) L S S Notes: 1) 0.9 P is an Operating Pressure Condition. 2) S is Allowable Stress of material at applicable Temperature (Design / Operating). 9.2 Calculation Method: Vessel Calculations to be performed as per PART-4 of the Code (Design by Rules method)

10 CONTRACT NO: JOB NO: AB-001 PAGE NO. 10 OF OVERPRESSURE REQUIREMENTS 10.1 Company shall be responsible for design, construction and installation of Pressure Relief Valve & meeting the requirement of the Code Pressure Relief Valve suitable for Compressed Air Service shall be provided on Nozzle N2. Type of over-pressure protection system: Pressure Relief Valve Requirement of any Jurisdictional Acceptance: Being a normal Air Buffer Tank in compressed air service, any Jurisdictional Acceptance is not required before operation of the vessel. 11. ADDITIONAL REQUIREMENTS: 11.1 Requirement related to NDE, Restrictive Chemistry & Heat Treatment: Examination Group 1a as per Table 7.1 of the Code is applicable. Inspection of weld joint shall be as per Table 7.2 and shall as a minimum meet the following: WELD CATEGORY TYPE REQUIRED NDE EXAMINATION A 1 100% RT & 10% MT B 1 100% RT & 10% MT C 1 100% RT & 10% MT D 7 100% UT & 10% MT E 7 100% MT Additionally all welds shall be visually examined on internal & external surface as per of Code. Post Weld Heat Treatment is required for complete vessel as per Part & Table 6.8 of the Code. Impact testing requirements for materials and welds shall be evaluated by the supplier as per 3.11 of the Code. Impact testing is however mandatory for the hub type forgings. Impact test shall be carried out at MDMT or colder temperature and shall meet the Code requirements. All material shall comply with applicable material specifications and Part 3 of the Code. Code marking shall comply with Part 2.F.1 of Code. Additionally the supplier shall provide a name plate showing name of the company, name of the supplier, Item number and date of hydrostatic test. Vessel shall be Hydro tested at supplier s facility before dispatch. Hydrostatic test media shall be water and metal temperature during test shall not be less that 17 deg C. After Hydro test vessel shall be fully drained, cleaned & dried. Complete external surface of vessel including saddle assembly & bottom of base plate shall be painted as per the painting specification provided with the contract.

11 CONTRACT NO: JOB NO: AB-001 PAGE NO. 11 OF 14 ATTACHMENT 1 NOZZLE LOADS FOR VESSELS (HORIZONTAL AND VERTICAL) 1.0 GENERAL 1.1 The criteria specified shall apply to nozzles above 2 in. NB for vessels constructed of carbon steel and low alloy steels. 1.2 The forces contained herein are considered minimum criteria in order to allow for an economical design of the connecting piping. 1.3 Nozzle loading geometry is shown below for reference

12 CONTRACT NO: JOB NO: AB-001 PAGE NO. 12 OF EXTERNAL FORCES AND MOMENTS ON NOZZLES 2.1 Each nozzle shall be capable of withstanding forces from external piping under the design conditions and considered to be acting at the intersection of nozzle and shell in corroded condition. 2.1 The value "D" in the formula below is the nominal nozzle diameter in inches. The Z-values in the formula depend on the rating of the nozzle flange and are as follows: ASME B16.5 FLANGE RATING Z Values for calculating loads Nozzle in Shells Type of load Formula Units Longitudinal bending moment M L = Z*130*D 2 Nm Circumferential bending moment M Φ = Z*100*D 2 Nm Resultant bending moment 2 M b = (M L + M 2 Φ ) ½ = Z*164* D 2 Nm Torsional moment M t = Z*150* D 2 Nm Longitudinal shear force F L = Z*2000*D N Circumferential shear force F Φ = Z*1500*D N Resultant shear force 2 F r = (F L + F 2 Φ ) ½ = Z*2500* D N Axial Tension of compression force F a = Z*2000* D N 2.3 Nozzle in Heads Type of load Formula Units Resultant bending moment 2 M b = (M x + M 2 z ) ½ = Z*164* D 2 Nm Torsional moment M t = Z*150* D 2 Nm Resultant shear force 2 F r = (F x + F 2 z ) ½ = Z*2500* D N Axial Tension of compression force F a = Z*2000* D N

13 CONTRACT NO: JOB NO: AB-001 PAGE NO. 13 OF 14 FATIGUE SCREENING CRITERIA as per Part , Method A: STEP 1: The following loading history has been provided in the UDS The vessel normally operates in the static state condition. However the following loading history can be considered for the purpose of fatigue evaluation: Planned annual shutdown requiring full depressurization: 2 per year Unplanned shutdown requiring full depressurization during first year of operation: 6 Unplanned shutdown requiring full depressurization after first year of operation: 2 per year Automatic shut down requiring full depressurization due to fire/emergency condition: 2 per year The vessels normal operating pressure is MPa. The actual pressure variation shall be within ±10% of this pressure. However the HP compressor may trip during the operation and can cause pressure variation exceeding 20% of operating pressure. Such trips are not expected to be more than 6 per year. The vessels normal operating temperature is 50 o C and no fluctuations in temperature are expected during normal operation. However the shutdown conditions may cool down the vessel to ambient temperature of not less than 5 o C. The vessel is of carbon steel and has no metals which have different coefficient of thermal expansion. STEP 2: The expected pressure cycles N Δ FP are estimated on the following basis: i) As per operating procedure, this plant does require annual shutdown. Consider 2 shutdowns in a year. Therefore total cycles for 20 years of plant life will be 40 (Total - 40) ii) Unplanned shutdown requiring full depressurization of Air Buffer Tank during first year of operation do not exceed 1 per 2 months (Total - 6) iii) Unplanned shutdown requiring full depressurization of Air Buffer Tank after the first year of operation do not exceed 2 per year. (Total - 38) iv) Automatic shutdown requiring full automatic depressurization of the Air Buffer Tank 1 per year (Total - 40) v) Total No. of pressure cycles N Δ FP are therefore = 124 STEP 3: The expected operating pressure cycles N Δ PO are estimated on the basis that during normal operating condition, Air Buffer Tank operates at MPa. However when the compressor trips due to any other faults the pressure exceeds 20% of operating pressure. Total such trips are expected not to exceed 6 (1 every 2 months) in a year. Hence cycles due to operating condition is 6 X 20 = Total 120 STEP 4: The expected temperature differential cycles N Δ TE are estimated on the basis that there will be always hot compressed air incoming to the Air Buffer Tank to avoid vessel cool down to ambient temperature. Only planned & unplanned shutdown may result in a cool down of the Air Buffer Tank. The temperature differential of 45 C will result in maximum factor of 1 as per Table 5.8. Total cycles therefore are estimated to be 124 x 1 = 124. N Δ STEP 5: The expected temperature cycles Tα are zero as there is no weld between metals which have different coefficient of thermal expansion. Total cycles are therefore estimated to be 0.

14 CONTRACT NO: JOB NO: AB-001 PAGE NO. 14 OF 14 The expected number of cycles per Para , Method A, for cycles Step 2 to Step 5 is as follows: Step 2: Full Range Pressure Cycles Step 3: Operating Pressure Cycles Step 4: Metal Temperature Differential Step 5: Metal Coefficient of Expansion Differential N Δ 124 FP N Δ 120 PO N Δ 124 TE N Δ 0 Tα N Δ FP + N Δ PO + N Δ TE + N Δ 368 Tα Check for Integral type construction: a) use of pad type reinforcements or of fillet welded attachments NO b) The use of pipe threaded connections NO c) The use of stud bolted attachments NO d) The use of partial penetration welds NO e) Major thickness changes between adjacent members NO f) Attachments and nozzles in the knuckle region of formed heads NO Hence the vessel meets the integral type construction requirements of the Code As per Table 5.9 of the Code, the maximum number of cycles permitted without carrying out fatigue analysis for integral type construction with no nozzles in the knuckle region of the head = 1000 which is > 368 Conclusion: No fatigue analysis is required for this vessel as the intended vessel operation satisfies the Part of ASME code section VIII Div. 2 for the considered vessel design life of 20 years.