DESCON ENGINEERING LIMITED FZE Humriyah COMPRESS Pressure Vessel Design Calculations Item. : Glycol Reboiler and stripping Gas Heater Vessel Tag No. : 607-E-1105/2105/3105 Contractor / Client. : ADMA Proposal Number. : 11924 Designer: IUH Date: Thursday, October 30, 2014 This Document is the exclusive property of DESCON ENGINEERING LTD. and may not be copied, exploited, duplicated, reproduced or communicated to a third party in any form without the prior written approval of DESCON ENGINEERING LTD. Table of Contents General Arrangement Drawing.....................................................................................................................................1 Deficiencies Summary...................................................................................................................................................2 Nozzle Schedule.............................................................................................................................................................4 Nozzle Summary............................................................................................................................................................5 Pressure Summary........................................................................................................................................................6 Revision History.............................................................................................................................................................9 Settings Summary........................................................................................................................................................10 Radiography Summary................................................................................................................................................12 Thickness Summary....................................................................................................................................................14 Weight Summary..........................................................................................................................................................15 Long Seam Summary..................................................................................................................................................16 Hydrostatic Test...........................................................................................................................................................18 Vacuum Summary........................................................................................................................................................20 Front Channel...............................................................................................................................................................21 Shell #1..........................................................................................................................................................................23 Rear Channel................................................................................................................................................................25 Front Head....................................................................................................................................................................27 Straight Flange on Front Head....................................................................................................................................29 Straight Flange on Rear Channel Head......................................................................................................................31 Rear Channel Head......................................................................................................................................................33 6" Two Nozzles (N3 A/B)..............................................................................................................................................35 6" Two Nozzles (N4 A/B)..............................................................................................................................................53 8" Two Nozzles (N1 A/B)..............................................................................................................................................71 8" Two Nozzles (N9).....................................................................................................................................................88 Shell Side Flange (front)............................................................................................................................................105 Shell Side Flange (rear).............................................................................................................................................112 Tube Side Flange (front)............................................................................................................................................119 i Table of Contents Tube Side Flange (rear).............................................................................................................................................126 Saddle.........................................................................................................................................................................133 Baffle Summary Report.............................................................................................................................................139 Data Inputs Summary................................................................................................................................................141 Design Conditions Summary....................................................................................................................................142 Materials and Gaskets Summary..............................................................................................................................143 Shell and Tubes..........................................................................................................................................................145 Tubes...........................................................................................................................................................................155 Tubesheet -- ASME....................................................................................................................................................157 Tubesheet -- TEMA.....................................................................................................................................................186 Tubesheet Maximum Pressure Report.....................................................................................................................191 ii General Arrangement Drawing 1 Deficiencies Summary Deficiencies for 6" Two Nozzles (N3 A/B) Nozzle weight has been increased to account for the additional 1 nozzles specified for costing. This weight is assumed to act at the location of this nozzle. Deficiencies for 6" Two Nozzles (N4 A/B) Nozzle weight has been increased to account for the additional 1 nozzles specified for costing. This weight is assumed to act at the location of this nozzle. Deficiencies for 8" Two Nozzles (N1 A/B) Nozzle weight has been increased to account for the additional 1 nozzles specified for costing. This weight is assumed to act at the location of this nozzle. Deficiencies for Heat Exchanger TEMA A.23: Tube longitudinal compressive stress is excessive (Operating). ASME VIII-1, Table A-2 note (7): Ratio of tube OD/ID requires that factor fr be determined by test. Warnings Summary Warnings for 6" Two Nozzles (N3 A/B) ASME B16.5: External loads have not been considered in the flange pressure rating. (warning) Part of the pad width is beyond the limits of reinforcement. (warning) Warnings for 6" Two Nozzles (N4 A/B) ASME B16.5: External loads have not been considered in the flange pressure rating. (warning) Part of the pad width is beyond the limits of reinforcement. (warning) Warnings for 8" Two Nozzles (N1 A/B) ASME B16.5: External loads have not been considered in the flange pressure rating. (warning) Warnings for 8" Two Nozzles (N9) ASME B16.5: External loads have not been considered in the flange pressure rating. (warning) Warnings for Front Head UCS-79: The extreme fiber elongation exceeds 5 percent and the thickness exceeds 16 mm;. Heat treatment per UCS-56 is required if fabricated by cold forming. (warning) Warnings for Heat Exchanger UG-6(c): Tubesheet forging must meet the requirements of UG-6(c). (warning) Warnings for Rear Channel Head UCS-79: The extreme fiber elongation exceeds 5 percent and the thickness exceeds 16 mm;. Heat treatment per UCS-56 is required if fabricated by cold forming. (warning) Warnings for Shell Side Flange (front) Jawad and Farr Guidebook, 4.3.1.3: To prevent gasket crushout a different gasket material should be used. As an alternative (space permitting) the gasket width could be increased to 14.04 mm. (warning) UG-6(c): Forging must meet the requirements of UG-6(c). (warning) UG-6(c)(1): Forging must be subject to one of the austenitizing heat treatments permitted by the specification. (warning) Warnings for Shell Side Flange (rear) Jawad and Farr Guidebook, 4.3.1.3: To prevent gasket crushout a different gasket material should be used. As an alternative (space permitting) the gasket width could be increased to 14.04 mm. (warning) UG-6(c): Forging must meet the requirements of UG-6(c). (warning) UG-6(c)(1): Forging must be subject to one of the austenitizing heat treatments permitted by the specification. 2 (warning) Warnings for Tube Side Flange (front) Jawad and Farr Guidebook, 4.3.1.3: To prevent gasket crushout a different gasket material should be used. As an alternative (space permitting) the gasket width could be increased to 14.04 mm. (warning) UG-6(c): Forging must meet the requirements of UG-6(c). (warning) UG-6(c)(1): Forging must be subject to one of the austenitizing heat treatments permitted by the specification. (warning) Warnings for Tube Side Flange (rear) Jawad and Farr Guidebook, 4.3.1.3: To prevent gasket crushout a different gasket material should be used. As an alternative (space permitting) the gasket width could be increased to 14.04 mm. (warning) UG-6(c): Forging must meet the requirements of UG-6(c). (warning) UG-6(c)(1): Forging must be subject to one of the austenitizing heat treatments permitted by the specification. (warning) 3 Nozzle Schedule Nozzle Impact Service Size Materials Normalized Fine Grain Flange Blind mark Tested Nozzle SA-106 B Smls. Pipe No No No NPS 8 Class 600 N1 A/B 8" Two Nozzles NPS 8 Sch 80 (XS) DN 200 No WN A105 Pad SA-516 70 No No No Nozzle SA-106 B Smls. Pipe No No No NPS 6 Class 600 N3 A/B 6" Two Nozzles NPS 6 Sch 80 (XS) DN 150 No WN A105 Pad SA-516 70 No No No Nozzle SA-106 B Smls. Pipe No No No NPS 6 Class 600 N4 A/B 6" Two Nozzles NPS 6 Sch 80 (XS) DN 150 No WN A105 Pad SA-516 70 No No No Nozzle SA-106 B Smls. Pipe No No No NPS 8 Class 600 N9 8" Two Nozzles NPS 8 Sch 80 (XS) DN 200 No WN A105 Pad SA-516 70 No No No 4 Nozzle Summary Reinforcement Shell Pad Nozzle OD tn Req tn A1? A2? Corr Aa/Ar mark (mm) (mm) (mm) (mm) (%) Nom t Design t User t Width t pad (mm) (mm) (mm) (mm) (mm) N1 A/B 219.08 12.7 11.61 Yes Yes 25 23.89 75 25 3 100.0 N3 A/B 168.27 10.97 10.54 Yes Yes 25 24.2 75 20 3 100.0 N4 A/B 168.27 10.97 10.54 Yes Yes 25 24.2 75 20 3 100.0 N9 219.08 12.7 11.61 Yes Yes 25 23.89 75 25 3 100.0 t : Nozzle thickness n Req t : Nozzle thickness required per UG-45/UG-16 n Nom t: Vessel wall thickness Design t: Required vessel wall thickness due to pressure + corrosion allowance per UG-37 User t: Local vessel wall thickness (near opening) A : Area available per UG-37, governing condition a A: Area required per UG-37, governing condition r Corr: Corrosion allowance on nozzle wall 5 Pressure Summary Pressure Summary for Tube side chamber P T T Identifier MAWP MAP MAEP e MDMT MDMT Impact Design Design ( kPa) ( kPa) ( kPa) external ( °C) Exemption Tested ( kPa) ( °C) ( °C) Front Head 7,700.01 85 8,252.97 9,398.41 N/A 85 -29 Note 1 No Straight Flange on Front Head 7,700.01 85 7,926.8 9,088.91 N/A 85 -29 Note 2 No Front Channel 7,700.01 85 8,290.65 9,452.05 N/A 85 -29 Note 3 No Tubesheet 7,700.01 85 8,970.11 9,665.9 17,365.01 85 -49 Note 4 No Rear Tubesheet 7,700.01 85 8,970.11 9,665.9 17,365.01 85 -49 Note 4 No Rear Channel 7,700.01 85 8,290.65 9,452.05 N/A 85 -29 Note 3 No Straight Flange on Rear Channel Head 7,700.01 85 7,926.8 9,088.91 N/A 85 -29 Note 2 No Rear Channel Head 7,700.01 85 8,252.97 9,398.41 N/A 85 -29 Note 5 No Tubes 7,700.01 85 26,176.67 26,176.67 18,298.14 85 -105 Note 6 No Tube Side Flange (front) 7,700.01 85 7,961.61 7,961.61 N/A 85 -29 Note 7 No Tube Side Flange (front) - Flange Hub 7,700.01 85 8,290.65 9,452.05 N/A 85 -29 Note 3 No Tube Side Flange (rear) 7,700.01 85 7,961.61 7,961.61 N/A 85 -29 Note 7 No Tube Side Flange (rear) - Flange Hub 7,700.01 85 8,290.65 9,452.05 N/A 85 -29 Note 3 No Nozzle Note 8 No 8" Two Nozzles (N1 A/B) 7,700.01 85 8,116.25 9,048.06 N/A 85 -29 Pad Note 9 No Nozzle Note 8 No 8" Two Nozzles (N9) 7,700.01 85 8,116.25 9,048.06 N/A 85 -29 Pad Note 9 No Chamber design MDMT is -29 °C Chamber rated MDMT is -29 °C @ 7,926.8 kPa Chamber MAWP hot & corroded is 7,926.8 kPa @ 85 °C Chamber MAP cold & new is 7,961.61 kPa @ 25 °C This pressure chamber is not designed for external pressure. 6 Pressure Summary for Shell side chamber P T T Identifier MAWP MAP MAEP e MDMT MDMT Impact Design Design ( kPa) ( kPa) ( kPa) external ( °C) Exemption Tested ( kPa) ( °C) ( °C) Tubesheet 7,700.01 85 17,365.01 18,255.68 8,970.11 85 -49 Note 4 No Shell #1 7,700.01 85 8,290.55 9,452.05 N/A 85 -29 Note 3 No Rear Tubesheet 7,700.01 85 17,365.01 18,255.68 8,970.11 85 -49 Note 4 No Tubes 7,700.01 85 18,298.14 18,298.14 26,176.67 85 N/A N/A No Shell Side Flange (front) 7,700.01 85 7,961.61 7,961.61 N/A 85 -29 Note 10 No Shell Side Flange (front) - Flange Hub 7,700.01 85 8,290.65 9,452.05 N/A 85 -29 Note 3 No Shell Side Flange (rear) 7,700.01 85 7,961.61 7,961.61 N/A 85 -29 Note 10 No Shell Side Flange (rear) - Flange Hub 7,700.01 85 8,290.65 9,452.05 N/A 85 -29 Note 3 No Saddle 7,700.01 85 7,961.61 N/A N/A N/A N/A N/A N/A Nozzle Note 11 No 6" Two Nozzles (N3 A/B) 7,700.01 85 7,999.13 9,025.34 N/A 85 -29 Pad Note 12 No Nozzle Note 11 No 6" Two Nozzles (N4 A/B) 7,700.01 85 7,998.49 9,024.71 N/A 85 -29 Pad Note 12 No Chamber design MDMT is -29 °C Chamber rated MDMT is -29 °C @ 7,961.61 kPa Chamber MAWP hot & corroded is 7,961.61 kPa @ 85 °C Chamber MAP cold & new is 7,961.61 kPa @ 25 °C This pressure chamber is not designed for external pressure. 7