Jacobs (HPCL) Standard On Pressure Vessel & He PDF

Page 1 of 52
HINDUSTAN PETROLEUM CORPORATION LTD.

MUMBAI
DIESEL HYDROTREATER PROJECT
TITLE:
ENGINEERING DESIGN BASIS PRESSURE VESSELS &

HEAT EXCHANGERS
DOCUMENT NO : 44LK-5100-V.02-0001-A4
REV
NO.
ISSUE
DATE
PAGES
REV DESCRIPTION
PREPARED
CHECKED
APPROVED
BY
BY
BY
15.02.2008
52
Issued for Clients approval
SNK
CR
HSC
10.09.2008
52
Clients comments incorporated &

issyed
SNK
CR
HSC
JACOBS
Engineering Design basis for
HPCL-MUMBAI
44LK5100
Page 2 of 52
Pressure vessels & heat exchangers
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
TABLE OF CONTENTS
CODES & STANDARDS
1.1
CODES
1.2
STATUTORY REQUIREMENTS
1.3
INTERNATIONAL REQUIREMENTS
2.0
DESIGN BASIS GENERAL
2.1
SIZING OF EQUIPMENT
2.2
SHELL/ HEAD THICKNESS
2.3
VESSEL END CLOSURES
2.4
DESIGN PRESSURE
2.5
DESIGN TEMPERATURE
2.6
HYDRO TEST PRESSURE
2.7
CORROSION ALLOWANCE
2.8
WIND LOADING CONSIDERATION
2.9
SEISMIC LOADING CONSIDERATION
2.10
CAPACITY
2.11
SUPPORTS
2.12
MANHOLES
2.13
FLOATING ROOF
2.14
NOZZLE SIZE
2.15
FLANGES
2.16
INTERNALS
2.17
GASKETS
2.18
PIPE DAVIT
2.19
SPARES
2.20
VENT/ DRAIN/ VENTILATION NOZZLE CONNECTION
2.21
IMPORTANT CONSIDERATIONS
3.0
DESIGN REQUIREMENTS SPECIFIC APPLICATIONS
3.1
TALL COLUMNS
3.2
STORAGE TANKS
3.3
HYDROGEN BULLETS
3.4
REACTORS
3.5
SHELL & TUBE HEAT EXCHANGERS
3.6
3.7
3.8
3.9
ADDITIONAL REUIREMENTS FOR SPECIAL TYPE HIGH PRESSURE HEAT EXCHANGERS

AIR COOLED HEAT EXCHANGERS
DOUBLE PIPE HEAT EXCHANGERS
PLATE HEAT EXCHANGERS
TABLE 1
DETAIL & WEIGHT OF COLUMN ATTACHMENTS
TABLE 2
ALLOWABLE STRESS FOR COMBINED LOADING
TABLE- 3
MATERIAL SELECTION CHART
Section B
TRAYS AND TOWER INTERNALS
JACOBS
HPCL-MUMBAI
44LK5100
Page 3 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
1.0
CODES & STANDARDS
1.1
CODES
The following applicable codes, Licensors Global Practices (GPs) Applicable rules and
regulations and laws of India and their applicable standards in their latest edition including
latest addenda shall be followed unless otherwise specified for the design, fabrication,
inspection and testing of Vessels, Columns, Reactors, Storage Tanks, Shell & Tube heat
exchangers, High pressure heat exchangers, Air cooled heat exchangers, Double pipe
exchangers, Plate heat exchanger, Steel Flare/ Vents Stacks :
ASME SEC. VIII DIV. 1
For Pressure Vessels
ASME SEC. VIII DIV. 2
For Pressure Vessels (as specified in bid package for

high shell wall thickness of equipment)
ASME SEC VIII DIV 3
For very high pressure Vessel
TEMA CLASS R, 1999 EDITION.
For Shell & tube Heat Exchangers
ASME SEC. VIII DIV. 2/PD 5500
Mounded Vessels / Bullets.
ASME SEC.V
For non-destructive testing
TEMA, 1999 EDITION / IS 800
For double pipe exchanger (To the extent applicable)
ASME SEC. II Part A, B, C, D
For material specification & allowable stresses
ASTM/ IS
For material specification for Tanks
ASME Sec. IX
For welding
ASME B 16.5
For flanges
ASME B 16.47
For large diameter flanges
ASME B 16.20 / API 601
For gaskets
ASME B 96.1
Welded Aluminum alloy storage tank
ANSI B1.1/IS 4218
For bolting specification
ASME B 16.28
For elbows & return bends
ASME SEC. VIII Div. 1
For workmanship of Vessels not categorized under any

other code
API 650
For Storage Tanks
API Standard 661 / IS 800 Latest

edition
For Air cooled exchangers
API 620
For Low Pressure Storage Tanks
IS: 6533
For steel vent stacks etc
JACOBS
HPCL-MUMBAI
44LK5100
1.2
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Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
IS: 9178/DIN 1055
For Silos, Hoppers and, Bins
IS: 875/ Site Data
For wind load consideration
IS: 1893/ Site Data
For seismic design consideration
IBR
For steam producing, steam storage, catch water

vessels, condensate flash drums and similar vessels
STATUTORY REQUIREMENTS
National laws and statutory requirements such as of Indian Boiler Regulations and
requirements of Department of Explosives, Nagpur, India together with any local by-laws for
the state shall be complied with. Static and Mobile Pressure Vessel (SMPV) rules and
Petroleum rules, Directorate (OISD) etc. as applicable shall also be complied with.
1.3
INTERNATIONAL PUBLICATIONS
NACE MR 0175
Sulfide Stress Cracking Resistant Metallic Materials for

Oil Field Equipment
NACE TM 0284
Evaluation of Pipeline and Pressure Vessel Steel for

Resistance to Hydrogen Induced Cracking.
NACE TM 0177
Laboratory Testing of Metals for Resistance to Sulfide

Stress Cracking in Hydrogen Sulfide Environment
NACE RP 0472
Methods & controls to prevent in service cracking of

CS welds in P1 materials in corrosive petroleum
refining environments
WRC Bulletin # 107
Local Stresses in Spherical & Cylindrical Shells due to

External Loadings
WRC Bulletin # 297
Local Stresses in Cylindrical Shells due to External

Loadings on Nozzles
WRC Bulletin # 368
Stresses in intersecting Cylindrical Shells subject to

pressure
API-RP-945
Avoiding environmental cracking in Amine Units
API-950
Survey of construction Materials and corrosion in sour

water stripper
JACOBS
HPCL-MUMBAI
44LK5100
2.0
Page 5 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
DESIGN BASIS GENERAL

All equipment shall be designed in accordance with the latest design codes, and applicable
standards/ specifications. Design calculations shall be made considering all loads for
Erection, Operating and Hydro test conditions (ref. Para.3.2.2)
2.1
SIZING OF EQUIPMENT
All equipment columns, clad/lined vessels, vessels (including thickness 50 mm), tanks,
bullets & all others vessels shall be sized on THE basis of internal diameter only.
2.2
SHELL/HEAD THICKNESS (Minimum)
2.2.1
For columns of carbon and low alloy steel, minimum thickness shall be 8 mm (including
corrosion allowance up to 3.0 mm).
The minimum thickness of carbon and low alloy steel vessels shall be 6.0 mm (including
corrosion allowance not exceeding 3.0 mm) but shall not be less than calculated as per
following formula :
For diameter less than 2400mm:
Wall thickness = Dia + 1.5 + Corrosion Allowance.

1000
For diameter 2400mm and above:
1000
All dimensions are in mm. Above formula is applicable for both columns & vessels.
2.2.2
For columns of stainless steel and high alloy steel, minimum thickness shall be 5mm.
Corrosion allowance shall be added in this minimum thickness as specified in process data
sheet.
The minimum thickness of stainless steels & high alloy vessels shall be 3.0mm but shall
not be less than calculated as per following formula:
For diameter more than 1500 mm
1000
Corrosion allowance (if any) shall be added to minimum thickness as specified. Above
formula is applicable for both columns & vessels.
2.2.3
Tangent to tangent height (H) to diameter (D) ratio (H/D) greater than 5 shall be considered
as tall column and designed accordingly.
JACOBS
HPCL-MUMBAI
44LK5100
Page 6 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
2.3
VESSEL END CLOSURES
2.3.1
Deep torispherical dished end with 80% crown radius and 15% knuckle radius or
alternatively 2:1 semi-ellipsoidal dished end shall be used for pressure vessels unless
otherwise specified. Seamless dished ends shall be used for specific services as per
process licensor requirement.
2.3.2
Unless specified otherwise, hemispherical ends shall be used when the thickness of shell
exceeds 70 mm.
2.3.3
For atmospheric vessels, flat covers may be used.
2.3.4
For vessels diameter < 600 mm, without any internals, pipe caps may be used.
2.3.5
Manholes will be provided for all process vessels over 36 inches (760 mm) in diameter.
Smaller vessels will normally be provided with hand holes or a flanged head, depending
upon access requirements for the particular service. Manhole where provided must have
minimum 19 inch ID unless a larger dia manhole is indicated in the data sheet.
Body flanges may be provided in lieu of Man holes for vessels with dia 760 mm.
2.3.6
All process vessels that have a manhole will also be specified to have a vessel vent to
provide ventilation for maintenance. This vessel vent will be located at the top, or a
minimum distance from top of vessel. Size of this vent shall be as follows.
Vessel capacity
Upto 200 m3
3
200-400 m
3
400-700 m
>700 m3
2.3.7
size of vent (NB)

3 inch
4 inch
6 inch
8 inch
All tower and drums will be provided with valved drain connections, terminating in a line
size block valve and blind. The drain will be provided from a bottom draw off line of at least
equal size. Vessel drain sizing will be per the following :
Vessel volume (m^3 )
Upto 200 m^3
200-400 m^3
400-700 m^3
>700 m^3
process drain inches

3
3
4
6
2.3.8
If the equipment process data sheet indicates sour service (alkaline or wet H2S service),
the equipment materials, their testing , their post weld heat treatment and any other
recommendations of the NACE materials recommended by the licensor and pertinent
publications like NACE MR 175 shall be complied without exception.
2.3.9
For Vessels/ Columns of Diameter < 900 mm with internals, flanged covers may be used.
JACOBS
HPCL-MUMBAI
44LK5100
Page 7 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
2.3.10
Columns less than 900 mm diameter shall be provided with intermediate body flanges.
Number of intermediate body flanges shall be decided based on column height and type of
internals. Trays and other column internals installation shall be given consideration in
deciding the size and location of manholes, hand holes or body flanges as the
requirements may be at the initial design itself.
2.4
DESIGN PRESSURE
Design pressure shall be calculated based on the following general guide lines unless
otherwise specified elsewhere. When specified in the Process Data Sheet same shall be
followed: 1
2.4.1
When operating pressure is up to and including 70 kg/cm2 g

= operating pressure + 10% (minimum 2.0 kg/cm2 g)
Design pressure
2.4.2
When operating pressure is above 70kg/cm2 g

2
= operating pressure + 5% (minimum 7 kg/cm g)
Design pressure
Operating pressure should be maximum operating pressure for clause 2.4.1 and 2.4.2.
2.4.3
Design pressure shall be at the top of vertical vessel or at the highest point of horizontal
vessel.
2.4.4
The design pressure at any lower point shall be calculated by adding the highest operating
liquid head (and any pressure drop within the vessel) to the calculated hydro-test pressure.
2.4.5
Equipment with steam out condition shall be designed for full vacuum condition.
2.4.6
Equipment operating under vacuum / partial vacuum shall be designed for an external
pressure of 100 kPa (15 psi g) 1
2.4.7
Vessels shall be designed for steam out conditions if specified on process data sheet.
2.4.8
Minimum design pressure shall be 3.5 kg/cm g for any equipment except API storage
tanks.
2.4.9
All storage tanks shall be designed as per code considering full height & using specific
gravity 1.0 if not specified.
2.4.10
Pressure chambers of combination units in equipment shall be designed for testing

independently without pressure in the adjacent chamber in corroded condition, unless
otherwise specified elsewhere.
2.5
DESIGN TEMPERATURE
2.5.1
For vessels operating at 0 C and above, if not specified in the Process Data Sheet,
Design temperature
2.5.2
= maximum operating temp. + 15 C (subject to a min of 65 C)
For Vessels operating below 0 oC if not specified in the Process Data Sheet,
Design temperature
= lowest operating temperature
JACOBS
HPCL-MUMBAI
44LK5100
Page 8 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
2.5.3
Minimum Design Metal Temperature (MDMT) shall be lower of minimum atmospheric

temperature and minimum operating temperature encountered during operation.
2.5.4
Un-insulated vessels containing LPG and similar fluids shall be designed for maximum &
minimum temperature as recommended by SMPV rules.
2.6
HYDRO TEST PRESSURE
2.6.1
Equipment shall be hydro tested in the fabricators shop as per applicable design code &
specification requirements. However care shall be taken that hydrostatic temperature shall
be at least 6 degree centigrade higher than critical exposure temperature (CET) for vessel
thickness up to 50 mm and minimum 17 degree centigrade higher than the CET where
CET is minimum design metal temperature (MDMT). However, if code requirement is found
to be stringent, than the same shall be followed.
2.6.2
All vertical vessels, columns and horizontal vessels (in full corroded condition) shall also be
designed for site testing of the equipment with water at the test pressure on the top of the
equipment considering 50% of design wind load.
2.6.3
All equipment foundation shall be designed and constructed for water full condition when
equipment is new with 50% of design wind load.
2.6.4
Open atmospheric vessels shall be tested by filling water up to the top curb angle.
2.6.5
Pressure chambers of combination units that have been designed to operate

independently shall be hydro tested to code test pressure as separate vessels i.e., each
chamber shall be tested without pressure in the adjacent chamber.
When pressure chambers of combination units have their common elements designed for
maximum differential pressure, the common elements shall be subjected to test pressure
equivalent to the differential pressure multiplied by a factor as per applicable design code.
2.6.6
Coils shall be hydro tested to code test pressure separately.
2.6.7
Unless otherwise specified in applicable design code allowable stress during hydro test in
tension shall not exceed 90% of yield stress point.
2.6.8
Storage tanks shall be tested as per applicable code.
2.7
CORROSION ALLOWANCE
2.7.1
3.0 mm minimum corrosion allowance for carbon steel columns, vessels and atmospheric
vessels shall be used unless otherwise specified.
2.7.2
1.5 mm minimum corrosion allowance for low alloy steel columns and vessels
used unless otherwise specified.
2.7.3
No corrosion allowance for stainless steel columns & vessels shall be used unless
otherwise specified.
2.7.4
For cladded/lined vessels, no corrosion allowance is required on the base material.

Minimum 3.0 mm cladding (undiluted) shall be considered as corrosion allowance unless
shall be
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HPCL-MUMBAI
44LK5100
Page 9 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
2.7.5
If it is agreed to develop the cladding by weld overlay method , then it shall be ensured to
have undiluted chemistry of the cladding upto specified thickness of cladding. Surface
texture requirement if applicable shall also be ensured. Code requirements of PWHT and
any specified NDT shall also be complied .
2.7.6
For storage tanks, minimum corrosion allowance shall be as follows unless otherwise
specified:
Bottom plate
= 3.0 mm
First shell course
= 3 mm
Subsequent shell courses
= 1.5 mm
Floating roof/fixed roof
= 0.5mm
2.7.7
Buried vessels shall have 1.5mm external corrosion allowance. Vessel shall also be
applied with a proven external corrosion resistant coating.
2.7.8
Spheres / mounded bullets shall have 1.5 mm corrosion allowance.
2.7.9
Cladding or lining thickness shall not be included in strength calculations? (stress analysis)
2.7.10
Corrosion allowance for nozzles including manholes shall be at least equal to that specified
for the vessel. No corrosion allowance is required for standard flange face.
2.7.11
Corrosion allowance for gasket faces of girth/ body flange or specially designed non
standard flanges shall be used equal to that specified for vessel.
2.7.12
Corrosion allowance for support skirts of columns & vertical vessels shall be 1.0 mm
(minimum) unless specified otherwise.
2.8
WIND LOADING CONSIDERATION
2.8.1
Design basis for wind loads shall be as per IS: 875. As per IS-875 (Part-3), 1987 definition
of basic wind speed shall be peak gust velocity averaged over 3 second time interval at 10
m height above mean ground level with 50 years mean return period.
Values of coefficients K1, K2 (or K2 for gust factor method of wind load calculation), K3 (as
in IS: 875 Part 3) for the project site (Mumbai) shall be considered as under.
2.8.1.1
Probability Factor K1
The design life of all equipment shall be taken as 50 years. The mean return period of all
equipment shall be 50 years except for flare stack/ chimney for which the mean return
period shall be taken as 100 years.
Values of K1 for mean probable design life of equipment shall be as follows:
(i)
1.0 for 50 years mean return period
(ii) 1.09 for 100 years mean return period

(iii) K1 (columns and stacks height greater than 30 m ) = 1.09
2.8.1.2
Terrain, height and structure size factor, K2
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HPCL-MUMBAI
44LK5100
Page 10 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
These factors are to be taken from IS 875 (Part 3) 1987 for relevant class of the
structures with respect to the actual height of the structures.
Terrain category shall be considered as 2 for columns and stacks height greater than 30 m
and 3 for other equipment in units
2.8.1.3
Topography factor, K3 = 1
Surface area of piping, platforms and other attachments fixed to the equipment (Vessel /
Column) exposed to wind shall be accounted
2.8.2
Drag coefficient for cylindrical vessels shall be 0.7 minimum
2.8.3
Drag coefficient for spherical vessel shall be 0.6 minimum
2.8.4
Contingency factor of 1.1 shall be used on wind pressure if required.
2.9
SEISMIC LOADING CONSIDERATION

Seismic loads shall be in accordance with design requirements for earthquake conditions
for Zone III as per IS 1893.
2.10
CAPACITY
2.10.1
Tank
Capacity shall be specified as Nominal capacity and stored capacity.
Nominal capacity for fixed roof tanks shall be volume of cylindrical shell.
Stored capacity for fixed roof tanks shall be equal to nominal capacity minus free board
volume (equivalent to 500mm of shell height) or location of fixing of lowest roof structure
member
Nominal capacity (also the stored capacity) for floating roof tanks shall be volume of
cylindrical shell minus free board volume. (equivalent to minimum 1500mm of shell height).
Nominal capacity (also the stored capacity) for fixed cum floating roof tanks shall be
volume of cylindrical shell minus free board volume. (equivalent to minimum 2500 mm of
shell height).
2.10.2
Bullets (above ground or under ground)

Nominal capacity is the geometric capacity of bullet.
Stored capacity shall be 85% of nominal capacity at maximum design temperature.
2.10.3
Sphere
Nominal capacity is the geometric capacity of sphere.
Stored capacity shall be 85% of nominal capacity at maximum design temperature.
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HPCL-MUMBAI
44LK5100
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Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
2.11
SUPPORTS
2.11.1
Skirt supports shall be provided for all l tall columns (refer cl.2.2.3) and reactors. Small
vertical vessels may be supported on legs (pipes or structural section) or brackets.
JACOBS
HPCL-MUMBAI
44LK5100
2.11.2
Page 12 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
All Cr-Mo steel reactors shall be supported on skirts.

Welding of external cleats on Cr-Mo steel reactors shall be avoided wherever possible.
2.11.3
Skirt thickness
The minimum thickness for the skirts shall be greater of:
(a) The thickness required by stress analysis with a minimum of 6 mm inclusive corrosion
allowance
(b) 1/3 of the shell wall thickness with a maximum of 30 mm
Corrosion allowance of 1.0 mm minimum shall be considered for skirts unless otherwise
specified.
2.11.4
Columns with diameter larger than 900 mm shall be self supported unless the process data
sheet indicates a guide supported design.
2.11.5
Columns with diameter less than & including 900mm shall be supported by superimposed
structure around the column covering the entire height. Guy wires shall not be used to
support any equipment. Supporting of columns by superstructure require prior approval
from Jacobs
2.11.6
In special cases, columns with diameter up to 900mm and height not exceeding 20m
(including skirt height) can be self-supported and heights exceeding 20m shall be
supported by super imposed structure around the column covering the entire height.
2.11.7
Flare and vent stacks shall be supported structurally by superimposed structure around for
complete height.
2.11.8
Storage spheres shall be supported on pipe leg supports with tie rod bracing and turn
buckles.
2.11.9
Buried vessels shall be suitably anchored to prevent the uplift due to water table. Anchor
bolts shall have corrosion allowance of 6mm. Buried vessels shall be supported on
concrete saddles with anchoring bracket support at the centre line of the vessel.
2.11.10
All vertical equipments shall be provided with suitable lifting arrangements.
2.11.11
All skirt supported columns/equipments with height 20 m and above and weight 50 MT and
above are to be provided with tailing lug.
2.12
MANHOLES
2.12.1
Manhole size less than 480 mm ID shall be avoided. If the dia of vessel is small, check if a
hand hole or a body flange can be considered however, Vessels less than 900 mm ID shall
be provided with hand holes or flanged heads, depending upon access requirement for the
particular service Vessels and columns with diameter 900mm shall be provided with 450
NB (Min ID 432 mm) manhole unless otherwise specified. Vessels and column with
diameter greater than 1000mm and upto 1500mm shall be provided with 500 NB (Min ID
480 mm) man way. Vessels and columns with diameter 1500mm and above may be
provided with 600 NB man way. However, when inside diameter of manholes are specified,
then Inside diameter shall be considered as minimum required & a mandatory requirement.
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HPCL-MUMBAI
44LK5100
Page 13 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
Size of manholes shall be as per licensor drawing.
2.12.2
For storage tanks minimum number of manholes (size 600mm) shall be as follows:
Tank diameter
Shell manhole
Flush type clean

out fittings
(if specified)
Roof manhole
Dia. 12 m.
NIL
> 12m <Dia. 45m dia
45m < Dia. 61m.
Dia. >61m
For floating roof tank 1no. 750 mm NB manhole with internal ladder shall be provided as
per fabricators standard.
2.12.3
Size of clean out doors fittings for tanks shall be 900mm x 1200mm.
2.13
FLOATING ROOF
2.13.1
Floating roof shall be of following construction unless specified otherwise.
2.13.2
Tank diameter
Type of roof
12 m
Double deck type (due to construction limitations)
12 m < 60 m
Pontoon type
60 m
Double deck type (for proper balancing)
(a) Primary and secondary seal to be provided for Naphtha, MS & Diesel service floating
type roof tanks. Internal floating roof shall have single seal.
(b) The roof drain shall be pivot master type.
2.14
NOZZLE SIZE
2.14.1
- Minimum nozzle size
40 NB
- Minimum nozzle size for clad vessels / columns
80 NB
- Safety valve nozzle
Based on I.D.
- Self reinforced nozzle neck
Based on I.D.
2.14.2
Nozzles and manholes including self reinforced type shall be set in type attached to
vessel with full penetration welds unless otherwise specified.
2.15
FLANGES
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HPCL-MUMBAI
44LK5100
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Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
2.15.1
Nozzle flanges upto 600 NB shall be as be ASME / ANSI B16.5 and above 600 NB shall be
as per ASME / ANSI B 16.47 (SERIES B).
2.15.2
Nozzle flanges shall be welding neck flanges unless specified otherwise. Nozzles less than
50 NB shall be of long weld neck type .
2.15.3
Slip on flanges shall not be used in Lethal, Hydrogen, Amine, Caustic, severe cyclic
service, sour service, HIC (Hydrogen induced cracking) service and corrosive service
where corrosion allowance is more than 3 mm.
2.15.4
Specially designed flanges for process nozzles shall not be used.
2.15.5
Girth flanges and intermediate body flanges shall be of weld neck type only.
2.15.6
Flange rating shall be established based on design pressure, design temperature and
considering all external loads (moments and axial force). Nozzle flanges 900# rating &
above shall also be designed as per ASME SEC. VIII DIV.1 appendix-2 considering design
pressure and design temperature. Change in basic constructional features of the flanges is
not permitted.
2.16
INTERNALS
All removable internals shall be bolted type and bolting shall be SS type 304 unless
specified otherwise.
2.17
GASKETS
2.17.1
Service gaskets supplied shall not be used for hydro testing purpose. Gasket used for
hydro testing of equipment shall be of same specification as that of service gaskets for all
nozzles, manholes and body/girth flanges. Gasket seating face of flanges shall have finish
as per gasket specified.
2.17.2 0
All SS spiral wound gaskets shall be provided with outer and inner rings
2.17.3 0
When RTJ type of facing is provided, gasket shape shall be round and not hexagonal, in
order to avoid sharp edges in the groove
2.18
PIPE DAVIT
All columns and Vertical vessels with internals & safety valve size 80 NB shall be provided
with pipe davit as per Jacobs standard.
2.19
SPARES
Gaskets: Four (4) sets for manholes, two (2) sets for other gasketted joint.
Fasteners: 10% (minimum 2 in each size)
Sight / Light glass: 4 sets for each installed glass.
Internals: (Valves for Trays, Bolts / Nuts, Clamp Assemblies)-10%, Sealing foils for
Cartridge Trays-200%
2.20
VENT / DRAIN / VENTILATION NOZZLE CONNECTIONS:
JACOBS
HPCL-MUMBAI
44LK5100
Page 15 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
All vent and drain lines of light HC like MS, naphtha, LPG, propylene, and H2 shall be
provided with double isolation valves with end flanges as per OISD. Dia. 15 NB and
above drain lines should be provided with end flanges.
All vessels shall be provided with one number vent / drain connection as per following
unless otherwise specified in process data sheet.
Vessel Volume
Less than 6.0 m3
6.0 15.0 m3
More than 15 m
Length (Horizontal
Vessel)
-
Vent
nozzle
40 NB
Drain nozzle
Ventilation nozzle
40 NB
50 NB
40NB
50 NB
80 NB
3000mm 4500mm
100 NB
4500mm 7500mm
150 NB
7500mm
200 NB
All vertical vessels not having any nozzle on the top shall be provided with 50 NB nozzles
for conducting hydro test in vertical conditions.
2.21
IMPORTANT CONSIDERATIONS
2.21.1
All vessels and columns shall be designed considering design pressure; maximum
operating liquid head and any pressure drop within the vessels/columns.
2.21.2
All columns and vessels shall be capable of withstanding water full condition during system
testing.
2.21.3
Vessels and columns shall be hydro tested at shop at pressure calculated as per
applicable code in new and cold condition.
2.21.4
Seismic design shall be carried out based on design requirement for earthquake.
2.21.5
Equipment covered under the purview of IBR (Indian Boiler Regulations) shall be designed
as per IBR regulations. However, design of components not covered in IBR Regulations
shall be designed in accordance with ASME SEC. VIII Div-1.
2.21.6
Detail stress analysis, local load analysis for loads due to piping and supported equipment
etc. shall be carried out for all equipment. Critical equipment shall be analyzed by using
finite element analysis methods (FEM) as defined in job specifications & reports shall be
submitted for Jacobs review. For allowable nozzle loads refer Jacobs standard
specification attached with BID package.
2.21.7
All nozzle necks, all nozzle flanges and blind flanges shall be of weld overlay construction
for clad equipment. Loose liners on nozzle necks and blind flanges are not permitted.
2.21.8
All vertical vessels and columns shall be provided with 2 lifting lugs/Lifting trunions. Lifting
lugs shall be designed with impact factor of two.
2.21.9
Mechanical design of self supporting Tall columns / tower shall be carried out for various
load combinations as per Clause 3.2
JACOBS
HPCL-MUMBAI
44LK5100
Page 16 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
2.21.10
Material of various parts of equipment shall be selected as per table given in TABLE 3
unless otherwise stated on process data sheets.
2.21.11
Local Stress analysis shall be carried out for nozzle to shell junction using maximum shear
stress theory for vessels and columns. Allowable stress intensity shall be as per ASME
SEC. VIII Div. 2 and non-destructive examinations shall be carried out for shell to nozzle
junction as per ASME SEC. VIII Div. 2.
2.21.12
Stress analysis of shell to skirt junction shall be carried out using maximum shear stress
theory for vessels and columns designed as per ASME Sec. VIII Div. 2. In case skirt shell
joint is of butt-welded construction, the same shall be 100% radiographed.
2.21.13
All vessel, columns and tanks shall be provided with earthing bosses as per Jacobs
standard. Body flanges of equipment shall have provision to provide jumpers for earthing.
2.21.14
Permanent fixed ladders shall be provided inside the skirt of columns/vertical vessels for
inspection of dome / dished end.
2.21.15
ODC/Very heavy equipment shall require special considerations for transportation and
erection by Contractor.
2.21.16
All equipment shall be painted as per Jacobs painting specification.
2.21.17
All equipment requiring insulation shall be provided with insulation support rings /cleats as
per Jacobs specifications.
2.21.18
All ladders and platforms shall be galvanized.
2.22
CATHODIC PROTECTION:
Impressed current cathodic protection system shall be designed and installed as per the
Jacobs specification
JACOBS
HPCL-MUMBAI
44LK5100
2.23
Page 17 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
EXTERNAL COATING:
Applied protection shall be designed and installed as per the Jacobs specification
2.24
INTERNAL COATING:
Bottom 90-degree of internal surface of vessel shall be coated with anti-corrosion coating
suitable for stored product.
2.25
LOCATION/SPACING OF VESSELS:
Minimum spacing of vessels and other safety regulations shall be as per OISD-STD-150.
3.0
DESIGN REQUIREMENTS-SPECIFIC APPLICATIONS
3.1
TALL COLUMNS
Mechanical design of self-supporting column and its anchorage block shall be carried out
considering combination of various loads.
3.1.1
Loadings:
The loadings to be considered in designing a self supporting column / tower shall include:
a) Internal and or external design pressure specified on process data sheets.
b) Self weight of column inclusive of piping, platforms, ladders, manholes, nozzles, trays,
welded and removable attachments, insulation and operating liquid etc. The weight of
attachments to be considered shall be as per Table1
c) Other loadings as specified in UG-22 of ASME SEC. VIII Div. 1 wherever applicable.
d) Seismic forces and moments shall be computed in accordance with design
requirement for earthquake. Unless otherwise specified importance factor and
damping coefficient shall be considered as 2 and 2% respectively.
e) Basic wind pressure and wind velocity (including that due to winds of short duration as
in squalls) for the computation of forces / moments and dynamic analysis respectively
shall be in accordance with IS 875 (latest edition)(Refer Clause 2.8 above). Additional
wind loading on column due to external attachments like platforms, ladders, piping and
attached equipment should be given due consideration.
Loadings resulting in localized and gross stresses due to attachment or mounting of reflux /
reboiler, condenser etc.
3.1.2.
Loading condition
3.1.2.1
Analysis shall be carried out for following conditions:

(a) Erection condition:
Column (uncorroded) erected on foundation without insulation,

platforms, trays, removable internals etc., but with welded
attachments plus full wind on column.
JACOBS
HPCL-MUMBAI
44LK5100
Page 18 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
(b)Operating condition:
Column in (corroded condition) under design pressure,

including welded items, trays, removable internals,
packing/catalyst piping, platforms, ladder, reboiler mounted on
column, insulation and operating liquid etc., plus full wind on
insulated column with all other projections open to wind or
earthquake forces.
(c) Test conditions
Column (in corroded condition) under test pressure, filled with

water plus 33% of specified wind load on uninsulated column
including all attachments shall be considered.
3.1.2.2
Earthquake and wind shall be considered not acting concurrently.
3.1.2.3
Cyclic loads if any to be considered.
3.1.3
Deflection of column:
Maximum allowable deflection at top of column shall be equal to total height (including skirt
height) of the column divided by 200 but shall not exceed 300 mm in any case.
3.1.3.1
If the deflection of column exceeds the above allowable limit, the thickness of skirt shall be
increased as first trial upto a maximum value equal to the column thickness and this
exercise shall be stopped if the deflection falls within allowable limit.
3.1.3.2
If the above step is inadequate, skirt shall be gradually flared to reduce the deflection.
Flaring of skirt shall be stopped if the deflection falls within limits or half angle of cone
reaches maximum limit of 9.
3.1.3.3
If the above two steps prove inadequate in limiting the deflection within allowable limits, the
thickness of shell courses shall be increased one by one starting from bottom course
above skirt and proceeding upwards till the deflection falls within allowable limits.
3.1.3.4
3.1.4
For tall equipment fabricated from stainless steels and other exotic materials, it shall be
examined if an external guide will be helpful in controlling the required thickness such that
the equipment along with its guide structure cost is economical than a free standing design
Stress Limits
The stresses due to design pressure, weights (erection/operating/hydrotest as the case
may be), wind/seismic loads shall be combined using maximum principal stress theory for
ASME SECTION VIII Div.1. Thicknesses are accordingly chosen to keep the stresses
within limits as per Table-2.
3.1.5
Skirt support base

Base supporting including base plate, anchor chairs, compression ring, foundation bolting
etc., shall be designed based on over-turning moment (greater of seismic or wind).
Minimum size of anchor bolts shall be M24.
A minimum number of 8 foundation bolts shall be provided. Numbers of foundation bolts
shall be in multiple of four. Skirt thickness shall also be checked to anchor chair reaction
forces. Anchor bolts shall be so spaced that there is no interference between fixing
arrangement, Anchor bolt sleeves etc.
JACOBS
HPCL-MUMBAI
44LK5100
3.1.6
Page 19 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
Hydro test pressure

Hydro test pressure shall be equal to Q (A factor depending on code of construction) x
design pressure x temperature correction factor as specified in ASME SEC. VIII
DIV.1(Clause UG-99) / DIV 2 at top of column unless specified otherwise. If column is
tested in horizontal position, hydro test pressure shall be increased in order to take the
effect of water head.
3.1.7
Dynamic analysis of column / Tower

Dynamic analysis of each column shall be carried out for stability under transverse wind
induced vibrations as per standard design practice and calculations for each column shall
be submitted to Jacobs for approval. The recommended magnification factor for unlined
towers / column shall be taken as 70 and allowable dynamic amplitude shall be limited to
tower diameter divided by 5.
3.2
STORAGE TANKS
3.2.1
Tank shell thickness calculation shall be carried out by the one - foot method as per API
650 for tank diameters less than and equal to 60m (200 feet).
3.2.2
Maximum height of un-stiffened shell shall be calculated based on the corroded thickness
of shell courses. Section modulus of wind girders shall also based on corroded thickness
of shell courses.
3.2.3
Shell thickness shall be calculated considering product liquid/water level up to top curb
angle for all tanks including floating roof tanks.
3.2.4
Seismic design as per API-650 (appendix-E) is mandatory for all storage tanks.
3.2.5
Annular bottom plates shall be provided for all storage tanks 12.0 m diameter.
3.2.6
All small tanks 10.0 m diameter shall be provided with anchor bolts to prevent uplift due
to wind.
3.2.7
Tanks having design temperature more than 100 C shall have thermal isolation barrier
(Suitable insulating fire bricks) between tank bottom and foundation.
JACOBS
HPCL-MUMBAI
44LK5100
Page 20 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
3.3
HYDROGEN BULLETS
3.3.1
Hydrogen bullets shall be designed as ASME Sec VIII div.1. However, all fabrication and
inspection requirements shall as per ASME Sec. VIII div.2.
3.4
REACTORS
a) The design shall be done based on process licensors specifications.
b) Material selection shall be strictly as per licensors specification.
c) Minimum thickness shall be strictly be as per Licensors specification
d) MDR and UDS as per ASME code shall be obtained by the fabricator.
e) FEM analysis shall be done for all process nozzles, shell to head junction Y
shaped skirt, welded/weld overlayed support rings and any other stressed point as
defined in licensors specification
f)
All internals shall have minimum thickness as given in process licensors

specification and shall be designed for loads defined in licensors drawings.
g) Thermal analysis for HOT box shall be conducted.

h) Reactors as well as internals shall be fabricated by process Licensors approved
vendors, HPCL/Jacobs approved vendors.
i)
Lifting arrangement shall be as defined by process Licensors drawings.
j)
Floating type insulation support shall generally be provided.
k) Reactor to be designed for minimum 25 years of life..
JACOBS
HPCL-MUMBAI
44LK5100
3.5
Page 21 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
SHELL & TUBE HEAT EXCHANGERS

DENOTES APPLICABILITY
3.5.1.0
THERMAL DESIGN CRITERIA

Thermal design criteria shall be as per process design basis.
3.5.1.1
SELECTION OF TUBE SIZE

Selection of tube size and tube length shall be as per process design basis
3.5.1.2
TEMA TYPE SELECTION

Selection of TEMA type and preference shall be as per process design basis
Preferred exchanger for refinery services shall be horizontal, single pass shell, floating head
tube bundle (TEMA type S) arranged with two or more tube passes per shell.
3.5.1.3
OVERDESIGN MARGIN
Over design margin shall be as per process data sheet
3.5.1.4
MINIMUM FLUID VELOCITY LIMITATIONS, IF ANY, shall be as per process data sheet
3.5.1.5
UTILITY SPECIFICATIONS shall be as per process data sheet
3.5.1.6
CORROSION ALLOWANCE
CA is not applicable to tubes and baffles
3.5.1.7
OTHER REQUIREMENTS
3.5.1.7.1
MOC for Sea water cooled heat exchangers shall be as follows:

1)
2)
For exchangers where H2 / H2S is present

Tubes, Tube sheets, Floating head,
Super Duplex
Baffles, Support Plates, tie rod, spacers etc.
Super Duplex
For exchangers where H2 / H2S is not present

Tubes
Welded Titanium (0.9mm wall thk)
Tube sheet, floating head, baffle, tie rod

Spacers
Ni-Al-Br
3.5.2.7.2
Do not stack exchangers when individual shell isolation and bypasses are provided.
3.5.2.7.3
Minimum design metal temperature (MDMT)
0C
JACOBS
HPCL-MUMBAI
44LK5100
Page 22 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
. (specify)
3.5.2.0
MECHANICAL DESIGN CRITERIA
3.5.2.1
Bolting ( except nozzle bolting )

Inch
TEMA Metric
3.5.2.2
Bolt loads
Full
Average
Forged (hubbed)
Plate
Shall be considered (in the same unit

only) to the extent possible.
Not required
2 x Tube OD (Preferred)
1.5 x Tube OD (Min.)
3.5.2.3
3.5.2.4
3.5.2.5
Main Girth Flange
Bundle interchangeability
Radius of U-bends
3.5.2.6
Pulling of removable bundle (at both

fixed and floating tubesheets)
Eyebolts for pulling out bundle shall be

provided.
3.5.2.7
Min. flange connection size (except

Multi-Purpose connection)
1 NB
2 NB

8 NB
_____ NB
10 NB & above
_____ NB
Extended
Non-extended
Non-extended for Stab-in-bundles of B

type stationary head.
For CLAD EXCHANGERS
3.5.2.8
Nozzles from Seamless pipe upto
Nozzles may be rolled from plate

(with 100% X-ray)
3.5.2.9
3.5.2.10
Tubesheet type for Floating head and

U tube exchangers
Multi-Purpose (MP) Connection for

PG/TI
One 2 NB connection on each process

nozzle with blind flange
For OTHERS
One 1 NB connection on each process
nozzle with blind flange
JACOBS
HPCL-MUMBAI
44LK5100
3.5.2.11
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
Minimum rating for Multi-Purpose

/Instrument connection
3.5.2.12
Vent and Drain
3.5.3.0
MISCELLANEOUS ASPECTS
3.5.3.1
Davits
3.5.3.2
3.5.3.3
Page 23 of 52
Spares (Mandatory)
Testing Accessories
Same as Process nozzle
Same as Process nozzle with minimum #

300.
1 NB nozzle
(Separate vent and drain will not be
provided if vented/drained by other
nozzles or through MP connection,
unless required by process datasheet /
P&ID. In case MP connection provided
on piping separate vent & drain on shell
to be provided.
Shall be provided for channel cover and

shell covers for exchangers
Not required
400% Gaskets
20% Bolting (Min. 4 studs and 8 nuts per

joint)
Client to indicate additional requirement

(if any)
Test rings shall be provided on all

floating S & T type head type
exchangers.
Dummy shell shall be provided for fixing

test ring for exchangers such as kettle
type or floating head without shell covers
or stab in bundle where shell side design
pressure is higher than tube side
pressure.
Test flanges shall be provided.
For exchangers with removable bundle

and bonnet (type channel)
For exchanger with removable bundle
and channel with flat cover if tube side
pressure is greater than shell side
pressure
Minimum number of test rings/test

flanges/dummy shells shall be one per
bundle.
JACOBS
HPCL-MUMBAI
44LK5100
Page 24 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
For shell side interconnected and

stacked exchangers the minimum
number of test rings shall be equal to the
number of exchangers in one stack.
For U tube & floating head exchanger

with Bonnet type channel, number of test
flanges shall be equal to number of
exchanger in one stack.
Yes as applicable (Water coolers are to

be provided with sacrificial anodes.
Inside channel box, channel cover and
floating head covers to be painted with
two coats of epoxy zinc phosphate
primer and two coats of coal tar epoxy
painting as per finish. For Duplex tubes
use Aluminum sacrificial anode.
As per Bidder Qualification Criteria
3.5.3.5
Cathodic protection
3.5.3.6
Vendor selection
Notes
1)
Hydro testing of stacked exchangers shall be carried out in stacked condition.
2)
All the tube bundles of heat exchangers, coolers, and condensers should have
impingement plate at the inlet side wherever possible.
3)
Admiralty brass/Cupro nickel tube bundles should be used in case of coolers and
condensers. If brass tube bundle is not suitable due to process medium containing
ammonia, hydrogen sulphide or due to temperature limitation, then duplex stainless
steel or other suitable metallurgy shall be considered depending upon service.
All licensor requirements shall be complied with. However in case of any contradiction
same to be resolved in consultation with the Owner/PMC/Licensor.
3.6
ADDITIONAL REQUIREMENTS FOR SPECIAL TYPE HIGH PRESSURE EXCHANGERS
3.6.1
Heat exchangers can be Screw Plug or Breech-Lock type or modified TEMA DEU type.
3.6.2
CORROSION ALLOWANCE:
3.6.3
1.
Corrosion allowance for pressure retaining parts shall conform to Process Data sheet.
2.
Weld overlay or cladding thickness shall be considered corrosion allowance. Unless

otherwise specified on process data sheet, undiluted thickness of weld overlay shall be
minimum 3 mm. Cladding minimum thickness shall not be less than 3 mm.
3.
No credit for strength shall be taken for cladding/weld overlay in the design.
4.
Corrosion allowance as specified on Process data sheet shall be added to all exposed
surfaces of channel internals.
VACCUM CONSIDERATIONS:
The exchanger including the channel internals shall be designed for full vacuum when
specified.
JACOBS
HPCL-MUMBAI
44LK5100
Page 25 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
3.6.4
All inlet and outlet nozzles shall be designed as self reinforced nozzles with integral flanges.
3.6.5
Exchanger shall be designed considering external loads due to piping.
3.6.6
Nozzle flanges of higher ratings which are not covered in ASME B16.5 shall be designed as
per ASME Sec. VIII Div. I.
3.6.7
Where units are stacked, the lower shell shall be designed to carry super-imposed load (full
of water) of the upper shell. The corrosion allowance shall be deducted from the shell
thickness before determining the external loading. In addition to the normal design loads,
exchangers shall be designed to withstand a horizontal pulling load of twice the bundle
weight.
3.6.8
U-bend radius shall be 2 times the tube OD minimum. The minimum thickness at U-bend
after thinning shall not be less than the minimum thickness required by code. Tube thickness
specified in data sheet for the exchangers is minimum to be adopted. Tube thickness if
required for thinning allowances at U-Bend shall be increased.
3.6.9
Tube to tube sheet joint for all exchangers shall be strength welded.
3.6.10
Wherever applicable, longitudinal Baffle to tubesheet joint shall be full penetration weld with
groove in tubesheet.
3.6.11
HYDROSTATIC TESTS
3.6.11.1
Procedure for hydro testing of the exchangers designed with differential pressure shall be as
follows:
a)
Pressurize only shell side to Q (A factor depending on code of construction) x

differential design pressure x temperature correction factor as specified in ASME SEC.
VIII DIV.1 (Clause UG-99 / DIV 2) and check tube to tube sheet joint and tube sheet to
shell gasket leakage.
b)
Pressurize only tube side to Q (A factor depending on code of construction) x

differential design pressure x temperature correction factor as specified in ASME SEC.
VIII DIV.1 (Clause UG-99) / DIV 2 and check for tube to tube sheet joint leakage and
tube sheet to shell gasket leakage.
c)
Pressure both shell side and tube side simultaneously to Q (A factor depending on
code of construction) x design pressure x temperature correction factor on each side
ensuring their differential pressure between the two sides, at no time to exceed Q (A
factor depending on code of construction) times the differential design pressure
corrected for temperature.
3.6.11.2
All vertical exchangers shall be tested in vertical position. Alternately, exchanger may be
tested in horizontal position with test pressure modified with prior approval of Designer.
3.6.11.3
Stacked exchangers with nozzles interconnected shall be hydro tested in stacked condition
except when the hydro test pressure of the individual exchanger is different.
3.6.12
Vendor shall supply required accessories for handling & maintenance including accessories /
attachments for shell/ bundle pulling and accessories required for dismantling of Highpressure channel internals of all exchangers. Vendor shall supply fixtures required for
dismantling channel cover.
JACOBS
HPCL-MUMBAI
44LK5100
Page 26 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
3.6.13
Vendor to supply one set of torque wrenches for bolt size M38 (1 ) to M56 (2 ) and a
set of hydraulic bolt tensioner for bolt sizes greater than M56 (2 ) in case these bolt sizes
are being used in exchangers covered in the requisition.
3.6.14
SPARES.
BOLTING
20% set screws, studs and nuts but not less than 4 studs (with 2
nuts for each stud) for each joint.
PUSH RODS
100% push rods (In case of Screw plug / Breech Lock exchangers)
SEALING STRIPS
100% Lamiflex sealing strips as applicable.
GASKETS
400% gaskets other than those used for hydro-testing and

dispatch for each joint.
Spare bolting and gaskets shall be provided for all joints of girth flanges, channel cover,
tubesheet, interconnecting nozzles, nozzles with blind flange etc.
3.6.15
Gasket Register for high pressure exchangers shall be maintained.

All licensor requirements shall be complied with.
However in case of any
contradiction same to be resolved in consultation with the Owner/PMC/Licensor.
JACOBS
HPCL-MUMBAI
44LK5100
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
3.7
AIR COOLED HEAT EXCHANGERS
3.7.1.0
THERMAL DESIGN CRITERIA
3.7.1.1
Design air temperature
3.7.1.2
3.5.1.1.2
Page 27 of 52
Type of Draft
As per process package
As per basic engineering design basis
Forced
TUBE
DIAMETER
TUBE
THICKNESS
TUBE
THICKNESS
FOR IBR
TUBE LENGTH
Carbon Steel
25
2.77
2.77
8.5/10.5/12.5 m
Stainless Steel
20
2.11
2.3
8.5/10.5/12.5 m
High alloy Steel
20
2.11
2.3
8.5/10.5/12.5 m
TUBE
MATERIAL
Higher tube OD may be used where design constraints exist.

3.7.1.4
Tube Length (TL)
If on piperack, TL = piperack width +

0.5m
If on technological structure, suitable

tube length shall be adopted.
Note : Standard lengths are 8.5m, 10.5m and 12.5m

3.7.1.5
Fin Data
Aluminium G type (embedded) fins upto

0
400 C fin design temperature (maximum 9
fins/inch)
3.7.1.6
Width of bundle (Max.)
3.7.1.7
Type of Header :
3.0 m
Cover Type Header to be used for design pressure < 50 Kg/cm2g and fouling resistance
2 0
0.0004 Hr m C/K.Cal. For all other cases and H2 service (H2 partial pressure > 7
2
kg/cm g), plug type header to be used.
3.7.1.8
Split Header
If inter pass temperature difference

exceeds 1100C or if design temperature
0
exceeds 180 C.
JACOBS
HPCL-MUMBAI
44LK5100
3.7.1.9
Page 28 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
Corrosion Allowance
3mm for Carbon steel/Low alloy steel

NIL for Stainless steel/High Alloy Steel
(Note : Higher/lower value for CA to be considered if specified in process datasheet).

3.7.1.10
As per Process data sheet & P&ID.
Auto-variable fans
Variable speed motors
Provision of Louvre
3.7.1.11
Maximum fan horsepower
3.7.2.0
MECHANICAL DESIGN CRITERIA
3.7.2.1
40 kW
Bolting (except nozzle bolting)

Metric
Inch
3.7.2.2
Construction of Header
Plate
3.7.2.3
Minimum flange connection size (except

Multi-Purpose connection)
1 NB
3.7.2.4
Construction of nozzles
Upto 12 NB
From seamless pipe
14 NB and above
When made from plate, weld seam of

nozzle to be 100% radiographed
3.7.2.5
Nozzle Flanges
Forged weld neck.
3.7.2.6
Multi-Purpose connections
One on one of the inlet & one on one of the

outlets of each header size 1.5NB flanged
with BF, rating will be same as process
nozzle. If it is not possible to provide on
process nozzle then it shall be provided on
header. One nozzle at inlet and one
nozzle at outlet of the shell /channel box to
be provided for hydro testing of the shell in
addition to MP connection
Note : Any special recommendation regarding vent & drain connection shall be followed as
per process data sheet requirement/P&IDs.
3.7.2.7
Tube to tubesheet joint
Expanded (into two grooves) upto design

2
pressure of 70 kg/cm g for non lethal
service.
For design pressure above 70 kg/cm2g and

for lethal service, tube to tubesheet joint
shall be Strength welded with contact
expansion.
JACOBS
HPCL-MUMBAI
44LK5100
Page 29 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
3.7.2.8
Noise Level
The noise level shall be limited to 85 dB(A)

max. measured at the header access
platform walkways and one meter from the
bay limit on motor maintenance platform.
The noise level within the air cooler bay
shall be 90 dB(A) maximum, at locations
defined as per API.
3.7.2.9
Positioner for Autovariable fan
Integral type positioner shall be provided.
3.7.2.10
Loss of signal air to Auto fan
Blades of the fan shall lock in the

maximum flow condition unless specified
otherwise.
3.7.2.11
Type of Drives (Speed Reducers)
HTD/PGGT of GATES or Torque Drive

Plus belts of FENNER, UK upto 40 kW.
3.7.2.12
Access Platform
Shall be provided wherever possible on all

the four sides, (width=900mm) with stair on
one side and ladder on other side.
3.7.2.13
Maintenance Platform
Shall be provided full length

fans/motors (min. width 1000mm).
3.7.2.14
Fan blade material
FRP
3.7.3.0
MISCELLANEOUS ASPECTS
3.7.3.1
Spares (Mandatory)
400% gasket for header cover &

nozzles
200% gasket for plugs
20% plugs
100% belts, 100% bearings
One set of blade for each size/type

of fan
20% bolts & nuts for all nozzle with

BF & cover plate
One set of diaphragm actuator with

positioner for each type of auto
variable pitch fan
Additional fan spares (as

supplier recommendations).
Motor spares (as per engineering

design basis)
Required
3.7.3.2
3.7.3.3
Spares(Additional)
Roof of bundle
for
per
JACOBS
HPCL-MUMBAI
44LK5100
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0

3.7.3.4
Page 30 of 52
Hot dip galvanizing

structurals
of
air
cooler
Not required
Air cooler structurals shall be hot dip

galvanised for the following :i.
Plenum chambers, bundle frames.
ii.
Motor suspension structure, fan

guards, gratings for stairs and
platforms.
All bolts/nuts for structures.
iii.
(Main structure and all other surfaces not

indicated above shall be given one coat of
primer).
Note:
Whenever hot dip galvanizing is used, additional hot dip coat shall be provided on
the surfaces. 1
3.7.3.5
Final Painting
All header boxes shall be finally painted as

per JE spec. at vendors shop.
3.7.3.6
Protective Covering (for finned tubes) on

bundle bottom/top
Yes
3.7.3.7
Vendor selection
As per Bidder Qualification Criteria

JACOBS
HPCL-MUMBAI
44LK5100
Page 31 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
3.9
PLATE HEAT EXCHANGERS
3.9.1.0
GENERAL REQUIREMENT
3.9.1.1
Plate heat exchangers shall be designed and fabricated as proprietory equipment meeting
the thermal, material and end connections requirement of the data sheet. Vendor shall be
fully responsible for all aspects of design and construction of the plate heat exchanger as per
the governing code.
3.9.1.2
End nozzles of the exchanger shall conform to ASME B 16.5 standard. Gasket surface for
the end connection nozzle shall be suitable for specified gasket compatible soft gaskets
between the plate pack shall be provided by vendor meeting fluid compatibility requirement.
3.9.1.3
Endoscopy with VCR and camera control shall be supplied along with the equipment for
inspection of plate type heat exchangers.
3.9.1.4
Close circuit cleaning facility to be provided.
3.9.2.0
PROCESS REQUIREMENT
3.9.2.1
In general, the exchanger shall be a single pass, counter flow design to facilitate access to
the plate pack for maintenance.
3.9.2.2
The frame of the exchanger shall be designed to permit future installation of a minimum of
20% additional plates.
3.9.2.3
Ports shall be sized so that combined entrance and exit plus nozzle losses do not exceed
30% of the total pressure drop.
3.9.2.4
Vendor shall use the specified fouling factor. If it is not specified in the data sheet, he shall
indicate the fouling factor used by him in arriving at the offered design before award of
contract.
JACOBS
HPCL-MUMBAI
44LK5100
Page 32 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
TABLE 1
DETAILS AND WEIGHT OF COLUMN ATTACHMENTS
1.
Shape factor
calculations)
2.
for
0.7
Weight of trays (with liquid) to be considered
120 kg / m
3.
Weight of plain ladder
15 kg / m
4.
Weight of caged ladder
35 kg / m
5.
Equivalent projection to be considered for

wind load on caged ladder.
300 mm.
6.
Distance of platform below each manhole
Approx. 1000 mm
7.
Maximum
platforms
5000 mm.
8.
Projection of platform
900 mm up to 1.0 m dia. Column and 1.2

m for column dia.>1m from column
insulation surface
9.
1) Equivalent height of platform (for wind load

computation)
1000 mm.
2) Shape factor for platform
1.0
10.
Weight of platforms
100 kg/m .
11.
Platform shall be considered as below:

Top and bottom
All around
Intermediate
Half
distance
shell
(for
between
wind
load
consecutive
TABLE-2
ALLOWABLE STRESS FOR COMBINED LOADING
Vessel condition / temperature type of
stresses
New or corroded
Conditions
Erection
New
Operating
Corroded
Test
Corroded
Temperature
Ambient
Design
Ambient
Longitudinal
KxSxE
KxSxE
0.90xY.P.xE
Longitudinal compressive stress
KxB
KxB
JACOBS
HPCL-MUMBAI
44LK5100
Page 33 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
Where
S =
B =
E =
K =
Y.P. =
Note:
Basic allowable tensile stress as per Clause UG 23(a) of ASME SEC.VIII Div.1
B value calculated as per clause UG-23 (b)
Weld joint efficiency of circumferential weld, depending on extent of radiography.
Factor for increasing basic allowable value when wind or seismic load is present.
Yield point stress
Allowable stresses in skirt to shell joint shall be as per following:
0.49S, if joint is shear type.

0.70S, if joint is compression type.
TABLE- 3
MATERIAL SELECTION CHART
The following table gives general guidelines for material selection chart for various pressure parts /
non pressure parts of the equipment:-
PRESSURE PARTS
DESIGN
TEMP.-C
PLATE
PIPE
(SEE NOTE
8)
TUBES,
SPACERS (SEE
NOTE-11)
NON PRESSURE PARTS

FORGING
(SEE NOTE 12)
BOLTS/
STUDS/
NUTS
EXTERNAL
(SEE NOTE
13)
STRUCTURAL
ATTACHMENT
WELDED TO
PRESSURE
PARTS,
BAFFELS,
SUPPORTS,
TIE RODS,
SEALING,
SLIDING
STRIPS ETC.
INTERNAL
PIPES
STUDS BOLTS
NUTS
INTERNAL
TIE RODS
CRYOGEN IC
FROM
-254 UPTO
-196
SA240
GR.304L,
304, 316,316L
347 (IMPACT
TESTED)
SA312 TYPE
304
304L,316,
316L,347
SA213 TYPE
304 304L,316,
316L,347
SA 182,GR F
304,304L,316
347,316L
SA320 GR
B8,8C,8T
STRAIN
HARDENED
ABOVE
-196 UPTO
80
SA240
GR.304L,
304,
316,316L
321,347
SA 353/553
GR.A
SA312 TYPE
304
304L,316,
316L,321,
347
SA333GR.8
SA213 TYPE
304 304L,316,
316L,321,
347
SA334 GR.8
SA 182,GR F
304,F304L,
F316L,316 321
347,
SA522
SA194GR.8,
8C,8T
SAME AS PRESSURE PARTS
SS GRADE
SAME AS
TUBES
JACOBS
HPCL-MUMBAI
44LK5100
Page 34 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
LOW TEMP.
ABOVE
-80 UPTO 60
SA 203 GR E
IMPACT
TESTED (SEE
NOTE-1)
SA333GR.3
SA334GR.3
SA350 GR.LF3
SA 320 L7
SA194GR.4
OR GR7
SA 203 GR E
SA333GR.3
SA193GR.B8 SA
194 GR.8
CS KILLED
ABOVE
-60 UPTO 45
SA537CL.1
IMPACT
TESTED
(SEE NOTE-1)
SA333GR.3
SA334GR.3
SA350 GR.LF3
SA 320 L7
SA194GR.4
OR GR7
SA 537 CL.I
SA333GR.3
SA193GR.B8 SA
194 GR.8
CS KILLED
ABOVE
-45 UPTO
-29
SA 516 (ALL
GRADES)
IMPACT
TESTED
(SEE NOTE-I)
SA333GR.6
OR GR.I
SA334GR.6 OR
GR.I
SA350 GRLF2
SA 320
GRL7 SA194
GR.4 OR
GR7
SA-516(INALL
GRADES)
SA333GR.6
SA193GR.B8 SA
194 GR.8
CS KILLED
ABOVE
-29 UPTO
0
SA 516 (ALL
GRADES)
(SEE NOTE3)
SA 106 GR.B
(SEE NOTE
3)
SA334GR.6 OR1
(SEE NOTE 3)
SA105/ SA266
(SEE NOTE 3)
SA-516(INALL
GRADES)
SA 106 GR.B
SA-193GR.B8
SA-194GR.8
CS KILLED
IS- 2062
(WELDABLE
QUALITY)
SAME GRADE
AS PRESSURE
PARTS
SA-193 GRB7
SA-194 GR2H
INTERMEDIATE TEMPERATURE
ABOVE 0
UPTO 343
ABOVE
343 UPTO
427
SA 516 (ALL
GRADES),
SA 106GR.B
SA179,
SA 210 Gr. A1
SA-105 SA-266,
SA-193B7
SA-194 GR2H
IS-2062
(PLATES)
SA 106GR.B
SA-193GR.B7
SA-194GR.2H
SA 240 TYPE
304L,316, 321
(SEE NOTE 4)
SA-312 TP
304L, 316L,
321 SA-376
TP321
SA-213 TP 304L
316L, 321
SA182F
304L,316L,
321
SA-193B7
SA-194GR2H
SAME AS
PRESSURE
PARTS
SA 106GR.B
SA-193GR.B8
SA-194GR.8
SA 204GR.B
SA335GRP1
SA 209 GR T1
SA182GR.F1
SA193GR.B7
SA194GR.4
SA387GR11
CL.1/CL.2
SA335
GR.P11
SA213 GR.T11
SA182 GR.F11
SA193GR.B7
SA194GR.4
SA 240
TYPE
304L,316L,
321(SEE
NOTE 4)
SA312 TYPE
304L, 316L,
321 SA376
TYPE 321
SA 213 TYPE
304L, 316L, 321
SA182F 304L,
316L, 321
SA193GR.B7
SA194GR.4
SAME AS
PRESSURE
PARTS
SAME AS
PRESSURE
PARTS
SAME AS
PRESSURE
PARTS
SAME AS
PRESSURE
PARTS
SAME AS
PRESSURE
PARTS
SAME AS
PRESSURE
PARTS
SA-193GR.B8
SA 194 GR.8
SA-193GR.B8, B8M
SA 194 GR.8, 8M
SA-193GR.B8, B8T
SA 194 GR.8, 8T
C-V-, Mo
(COMML.
QLTY)
1%Cr.1/2Mo
(COMML.
QLTY)
SA479
Gr.304L,
316L, 321
ELEVATED TEMPERATURE
ABOVE
427 UPTO
538
SA387GR.11
CL.1/CL.2
SA387GR.12
CL.I/CL.2
SA335P11
SA335P12
SA213T11
SA213T12
SA182GR F11
SA182 GR.F12
SA193
GR.B16
SA194GR.4
SAME AS
PRESSURE
PARTS
SAME AS
PRESSURE
PARTS
SA-193GR.B8
SA 194 GR.8
V/a-VMo
(COMML.
QTLY)
ABOVE
427 UPTO
500
SA 240
TYPE
304,316,321
(SEE NOTE
4)
SA312/
SA376 TYPE
304,316,321
SA213TP
304,316,321
SA182F304,
316,321
SA193
GR.B16
SA194GR.4
SAME AS
PRESSURE
PARTS
SAME AS
PRESSURE
PARTS
SA-193GR.B8
SA 194 GR.8
SA 193 GR. B8M
SA 194 GR. 8M
SA479Gr.
304L,316L,
321
ABOVE
538 UPTO
593
SA387GR.22
CL.1/CL.2
SA387GR.21
CL.1/CL.2
SA 335 P22
SA213T22
SA182GR F22
SA 336 GR
F22
SA193GRB5
SA194GR.3
SAME AS
PRESSURE
PARTS
SAME AS
PRESSURE
PARTS
SAME AS
PRESSURE
PARTS
2%Cr.1 Mo
(COMML.
QLTY)
ABOVE
500 UPTO
815
SA240
GR.304H,
316H 321H,
A312/ SA376
TYPE 304H,
316H, 321H
SA213 TYPE
304H,
316H,321H
SA182 GRADES
304H,
316H,321H
SA193GRB8
SA 194 GR.8
(STRAIN
HARDENED
)
SAME AS
PRESSURE
PARTS
SAME AS
PRESSURE
PARTS
SAME AS
PRESSURE
PARTS
SA479Gr.
304H, 316 H,
321 H.
NOTES
1.0
Pressure vessel steel plates are purchased to the requirement of the standard ASME SA-20
which requires testing of individual plates for low temperature service. Carbon steel material is
ordered to meet the impact requirements of supplement S5, of standard ASME SA 20. Typical
material specification is as follows. SA516 Gr.60 normalised to meet impact requirements per
supplement S5 of SA 20 AT -50 oF.
2.0
All permanent attachments welded directly to 9% nickel steel should be of the same material or
of an austenitic stainless steel type which can not be hardened by heat treatment.
JACOBS
HPCL-MUMBAI
44LK5100
Page 35 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
3.0
Check for impact testing requirement as per UCS-66 for coincident temperature and part
thickness.
4.0
Selection of stainless steel material shall be based on process recommendation / process

licensor.
5.0
This table is not applicable for atmospheric / low pressure storage tanks. Materials shall be
selected as per API 650 / API 620 as applicable.
6.0
Materials for caustic service, sour service, or sour service + HIC shall be selected based on
specific recommendation of process licensor & considering chemical composition, hardness,
Vacuum degassing requirements & heat treatment requirements.
7.0
Material for pressure vessels designed according to ASME SEC VIII DIV. 2 shall be given special
consideration as per code.
8.0
All pipes shall be of seamless construction.
9.0
Non-ferrous material and super alloys are not covered above and shall be selected based on
specific recommendation.
10.0
Material for vessel / column skirt shall be the same material as of vessel / column shell for upper
part with a minimum of 500mm.
11.0
All tubes shall be of seamless construction. Materials used for IBR equipment shall meet all
requirements of Indian Boiler Regulations.
12.0
SA 336 shall be used for Heat Exchanger non-standard SS/LAS forgings.
13.0
Internal bolting shall be selected on the basis of shell side material solid or clad as follows:
SHELL MATERIAL
STUD
NUTS
Carbon steel &up to 1% Cr.
ASTM A 193 Gr B-7
5% Chrome
A 193 Gr B5
A 194 Gr 3
13% Chrome
A 193 Gr B6X
A 194 Gr 6
Stainless Steel
A 193 Gr*
A 194 Gr*
ASTM A-194 Gr 2H
For low temperatures, min. quality of bolting material shall be as specified for external bolting and
shall be improved if shell side materials are better.
* Compatible / same grade of SS.
All licensor requirements shall be complied with. However, in case of any contradiction
same to be resolved in consultation with the Owner/Jacobs
JACOBS
HPCL-MUMBAI
44LK5100
Page 36 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
SECTION B
TRAYS AND TOWER INTERNALS
JACOBS
HPCL-MUMBAI
44LK5100
Page 37 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
1.0
INTENT
1.1
The intent of this specification is to define basis to be followed for Mechanical Design,
engineering,. fabrication, inspection/testing, supply and installation (inside the columns
at site) of Trays, Packed Column Internals and Tower Packings separately
and collectively known as "Internals". For licensed units, in case the requirements
specified here are in conflict with licensor's specifications, licensor's requirements shall
govern.
1.2
In case of any conflict between various documents, resolution shall be in accordance

with the following order of preference:
2.0
Data Sheets/P&lD's/Design Basis

Job Specifications
Standard Specifications/Engineering Standards.
PROCESS PARAMETERS, DESIGN

INTERNALS
CONDITIONS & SELECTION
OF
As per Process Datasheets

3.0
USAGE OF EXISTING INTERNALS

For revamp jobs, all "As-Built" drawings of Columns, Tray/Internals as well as Tower
Attachments shall be provided by Client, which shall be the basis of revamp to be
JACOBS
HPCL-MUMBAI
44LK5100
Page 38 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
carried out by Jacobs. However in case drawings provided by Client are not
Built", same shall be treated as base document for proceeding further
engineering. Wherever drawings of existing internals are not available,
internals will be considered including replacement of existing support ring/bolting
to suit the new configurations.
"Aswith
new
bars
All existing internals found adequate with/without any modifications will be retained
presuming:
(a)
(b)
(c)
All such internals are in good physical conditions and can be retained.
All the existing internals are in good physical condition to permit partial
modifications as necessary to make it suitable for revised conditions.
No mechanical design checks of existing internals being retained will be
carried out unless explicitly asked/required by Client based on operating feed
back.
4.0
DESIGN
4.1
Materials
4.1.1
All materials shall conform to those specified in the respective process drawings or
data sheets.
No substitution of material will be permitted without the written consent of
Owner/Jacobs in required formats as per procedure. In case substitution of
material is proposed, vendor shall clearly indicate the reasons for requiring such
change and give chemical and physical properties of the proposed alternate
material with their standard specification number.
All the material supplied by vendor shall be new and of first quality supported with mill
test certificates.
Unless specified in data sheets, Material shall be as per clause from 4.1.2 to 4.1.7.
4.1.2
13 Cr Stainless Internals.
All sheet and plate material shall be in accordance with SA 240 Type 410S or 410
or 405 having No.1 finish only for thickness more than 4mm. For thickness up to and
including 4 mm, No. 2B/2D finish is also acceptable.
All bolting material shall be SA 193 Gr B6X or B6 for bolts and SA 194 Grade 6 for
nuts and lock-nuts.
4.1.3
18 Cr - 8Ni Stainless Internals.

All sheet and plate material shall be in accordance with SA 240 Type 304 having No.
1 finish only for thickness more than 4mm. For thickness up to and including 4 mm, No.
2B/2D finish is also acceptable.
AH bolting material shall be SA 193 Gr B8 for bolts and SA 194 Gr B for nuts and
lock-nuts.
4.1.4
Monel Internals
JACOBS
HPCL-MUMBAI
44LK5100
Page 39 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
All sheet and plate material shall be in accordance with SB127 in hot rolled, annealed
and pickled condition.
All bolting material shall be Monel, made from rod or bar stock, SB 164.
4.1.5
Carbon Steel Internals

Unless otherwise specified, sheets and plates shall be procured in hot rolled
conditions and shall be free of mill scale. Material shall be suitable for bending. The
bend test specimens shall stand being bent cold through 180 degree without cracking
on outside of the bent portion, to an inside diameter equal to or less than twice the
thickness of the specimen or as per relevant material specification, whichever is severe.
All sheet, plate material shall conform to SA285, SA283 or better unless specified
otherwise on the data sheets/drawings.
All fasteners including clamps, material shall be as per clause 4.1.2 above, unless
specified otherwise.
4.1.6
Gaskets
Trays gasketing material shall be woven tape, fabricated from Asbestos Free
Material such as Woven Fiber-glass Tape (Amatex-G36-P752 or equal), Woven
Teflon Tape, Woven Expanded Graphite Tape or Ceramic Fiber Tape etc. and shall
be suitable for process fluid and column design temperature, unless specified
otherwise in the Data Sheets/Purchase Specifications. The thickness of the woven
tape shall be 1.5 mm minimum. The use of Woven Asbestos Tape or Wire shall be
subject to JACOBS/Owner's prior approval only.
4.1.7
Support Rings/Bolting Bars/Support Cleats

Support rings, downcomer or up comer bars and other parts welded to vessel shall be
of same metallurgy as that of vessel. Minimum thickness excludine corrosion
allowance of welded parts shall be 6 mm for vessel diameter up to 3000 mm and
10 mm for higher diameter. Corrosion allowance as specified in vessel data sheets
shall be added on both sides of Support Ring, Bolting Bar and other welded parts.
4.2
Thickness of Internals
4.2.1.
Minimum thickness of lnternals:

Corrosion allowance, wherever specified in the data sheets for Intemals in excess of
corrosion allowance as indicated in clause 4.2.2 shall be added to the minimum
thickness specified below:
i)
Deck plates, seal pans, draw-off

Pans, weirs/seal plates, other removable
Components
ii)
Welded deck plates, downcomer aprons and other

welded components
Alloy
2.0
CS
3.5*
3.0
3.5*
JACOBS
HPCL-MUMBAI
44LK5100
Page 40 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
iii)
Downcomer/Internal pipes
2.0
3.5*
iv)
Bubble Caps
1.6
2.0
Risers (fixed)
2.0
3.5*
Risers (removable)
1.6
2.0
v)
Valves
1.6
(will not be used)
vi)
Structured Packings
0.15
(will not be used)
vii)
Support Grid for Structured Packings
5.0
8.0
viii)
Locating Grid/Retaining Grid/Bed Limiter
5.0
8.0
ix)
Grid Packings
(a)Bottom-most layer
5.0
8.0
(b)Next Five Layers
2.0
(As per vendors standard)
(c)Balance Layers
1.6
x)
Random Packings
xi)
Loose Beams
xii)
Lattice Girders
xiii)

To suit
Load
To suit Load
(a) Primary Members
5.0
6.0
(b) Secondary Members
3.0
4.0
(c) Gusset Plates
10.0
10.0
(d) Downcomer bolting bars
5.0
10.0
Z-Bars
5.0
8.0
(*10 USSG is also acceptable in lieu of 3.5 mm)

All bolting shall be minimum M10 for Internals and M16 for Lattice Girders. All bolt
head/nuts shall be hexagonal.
JACOBS
HPCL-MUMBAI
44LK5100
Page 41 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
Minimum corroded thickness of the internals for the loading condition as

per Clause 4.3.3. (i) and (ii) below, shall be 3.0 mm.
4.2.2
Corrosion Allowance
The following corrosion allowance shall be added to calculate thickness of Internals
unless otherwise specified on data sheets or bid specification.
i)
No corrosion allowance is required for Monel or Stainless steel alloy assemblies.
ii)
The corrosion allowance for all surfaces of floor of Carbon Steel assembly shall
be 1.5 mm (total).
4.2.3
Unless specified on the data sheets or bid specifications, corrosion allowance shall be
higher of 1.5 mm (total) or one quarter of the vessel corrosion allowance on each
surface of trays and its components.
4.2.4
Beams, trusses and other support members shall have total corrosion allowance equal
to vessel corrosion allowance for removable type construction and twice the vessel
corrosion allowance for non-removable type construction through vessel man-hole.
4.3.0
Design Loadings
4.3.1
Design loads for tray assemblies shall be based on a liquid height of 50 mm liquid
2
above weirs plus self weight of deck plates and beams or live load of 150 kg/m
whichever is severe. In case liquid density is less than water, 1000 kg/m3 shall be
considered for purpose of calculating liquid load.
4.3.2
Under-down-flow plates and seal pans shall be designed to withstand a weight of liquid
equal to half the normal tray spacing (excluding the locations where tray spacing has
been increased to accommodate manholes/feed pipes etc.) or 300 kg/m2 whichever is
severe plus self weight of udf plates and beams. In case liquid density is less than
water, 1000 kg/m3 shall be considered for purpose of calculating liquid load.
4.3.3
Five trays above/below 2-phase feed inlets and in bottom zone of column wherever
process steam or two-phase feed is admitted shall be provided with lock nuts. These
trays shall be capable of sustaining a net thrust of
2
i)
1465 kg/m and with shear clips for Vacuum Columns.
ii)
1000 kg/m2 and with shear clips for Crude Column/Main Fractionator Columns.
ii)
450 kg/m for all other services
4.3.4
One tray above and below the intermediate vapor/liquid feeds shall also be provided
with locknuts.
4.3.5
The packing support plate shall be designed to support the maximum expected load of
tower packings, liquid hold-up (min 10 percent). In case of liquid density is less than
3
water. 1000 kg/m shall be considered for purpose of calculating load due to liquid
hold-up.
Bed limiters frame shall be strong enough to take care of surges/uniformly distributed
2
load of 100 kg/m and 135 kg concentrated load at any point.
4.3.6
JACOBS
HPCL-MUMBAI
44LK5100
Page 42 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
4.3.7
Hold down plate shall exert sufficient static load on the bed to restrict movement of the
2
packing. The hold down plate shall be designed for exerting a load of 100 kglm
minimum on the packed bed.
4.3.8
Liquid distributors/Redistributor shall be designed for self weight plus maximum

expected liquid load.
4.3.9
All Internals assemblies except cartridge tray assemblies shall be able to withstand
the self-weight plus the following number of 135 kg concentrated loads
(maintenance loads) at ambient temperature.
Vessel Diameter
Up to 1200 mm
Up to 3600 mm
Over 3600 mm
Number of 135 kg loads

1 (at center of diameter)
2 (at center and 1/4 point of diameter)
3 (at center and 1/4< points of diameter)
4.3.10
Design loads for Chimney/Collector trays shall be based on dead weight plus live
load of liquid height equivalent to riser height or 50mm more than weir height. In case
liquid density is less than water, 1000 kg/m3 shall be considered for purpose of
calculating liquid load.
4.3.11
For Chimney trays, layout shall be made in such a way that there will be adequate space
available on the tray for a person to get inside and attend to erection of upper trays. Vendor
shall check the constructability of all trays with respect to location of man ways, location of
down comers and space availability. 0
4.4
Allowable Stress and Deflection
4.4.1
Allowable stresses for all Internals shall be as per ASME Sec. II. Part D, latest edition.
4.4.2
The maximum deflection of tray/tower internal assembly shall not exceed 1 mm per
meter of column diameter or 7.5 mm, whichever is lower for the design loadings given
in clause 4.3.1 and 4.3.2 above. Deflection for distributor assembly shall be limited so
that overall liquid maldistribution does not exceed the limit as per clause 4.5.18(v).
Deflection for support plate and seal pans shall be limited to U400, where L is the
length of individual component.
4.4.3
Deflection as per clause 4.4.2 may be ignored for trays designed based on design
loadings as per clause 4.3.3 and 4.3.9.
4.4.4
For large diameter vessels, initial camber may be made in the principal support
members of the assemblies so as to limit the deflection as specified in clause 4.4.2
above.
4.5
Arrangement/Details of Internals
4.5.1
All assemblies except one piece cartridge type trays for column ID less than or equal to
750mm shall be of removable type unless otherwise indicated. The general design,
number, type and spacing shall be established on the individual vessel drawing/data
sheets. Cartridge type trays shall be designed to rest on four support cleats.
4.52
Each removable section shall be so dimensioned / sized to permit passage through

vessel manhole and shall be suitable for assembly/ dismantling from upper side in so far
as structural contingencies permit. Maximum diagonal dimension of the components shall
be restricted to vessel manhole ID - 12mm clearance.
JACOBS
HPCL-MUMBAI
44LK5100
Page 43 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
4.5.3
Internals support trusses supporting more than one Internal, as are commonly used in
large diameter columns and which cannot be installed through manholes, shall be split
into sections for access through manhole and minimizing welding work inside the
column.
4.5.4
Internals decks shall have a maximum length of 3000 mm. To achieve this maximum
distance between main support beams or girders shall be limited to 3000 mm.
However, the main support beams or girders having length more than 3000 mm shall
be provided with one butt joint with splice plates of the same thickness as the main
member up to 6000 mm length and two butt joints with splice plates of the same
thickness as the main member for more than 6000 mm length and so on. The butt joint
shall be provided inclined at 45 degrees.
4.5.5
Man ways
4.5.6
i)
One man way in single cross flow decks, two man way in double flow decks '
and so on shall be provided. These man way shall be freely removable from top
and bottom. Man way shall be in the same vertical line for a set of trays. These
shall be at such a location and of a shape and size to permit easy access to every
area of the tray. Man way of different set of trays (about 20 trays) shall be
staggered to each other. Minimum clear opening on tray shall be 380mm x
450mm. In case same can not be provided due to design conditions, minimum
man way size (clear opening) of 360 x 500 or 330 x 550 can be accepted as a
special case.
ii)
Where man way cannot be provided, decks shall be split (turn-up - turndown) to
provide suitable access for Inspection and assembly from top as well as bottom.
Unless specified otherwise, support rings, bolting bars, support bracket/cleats when
required, shall be designed for welding to the vessel. All other parts shall be designed
for bolting or clamping in place. Clamping shall be used on Tray floor and all
downcomer/up-comer shall be through bolted.
Spacing of bolting or clamping shall be close enough to ensure optimum liquid tight
construction but shall not exceed 125 mm on deck portion in downcomer area/liquid
holding area/downcomer apron bolting etc. and 150 mm in active area. All joints and
seams of trays specified to be liquid tight without gasketted joints shall be seal welded
at site. Maximum spacing for clamps/bolting for gasketted construction shall be
restricted to 100 mm. For revamp jobs, use of Z-Bars shall be maximized to minimize
welding/cutting of TSR/BB on the shell, wherever possible.
4.5.7
Drawings and instructions for installation and fabrication of support ring, bolting
bar and support bracket/cleats welded to vessel shall be furnished by Internals
supplier. They shall show clearly the type, size and extent of welding. All support
rings and bolting bars shall be continuously welded on both sides. All support brackets
shall be welded all around.
4.5.8
Gasketting need not be used in the design or installation of Internals except for bubble
cap trays, all liquid holding portions (e.g. seal pans, draw-offs), collector trays,
distributors and redistributors. Fabrication shall provide tight metal-to-metal joints.
Metal seal plates shall be used to close construction joints where necessary.
JACOBS
HPCL-MUMBAI
44LK5100
Page 44 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
4.5.9
All stiffeners and support members shall be located on the underside of the tray
floor with the exception of open type trusses supporting two trays. Stiffeners and
support members in {\ areas shall not exceed 75 mm in width and shall be
designed so as not to impede or channel the liquid flow on the tray. Depth of
stiffeners and support members transverse and parallel to the liquid flow shall not
exceed 20 and 30 percent respectively of tray spacing.
4.5.10
A minimum of 20 mm overlap shall be provided between tray floor section and

support members.
4.5.11
Trays and seal pans not specified to be liquid tight, and of a design which would not
easily drain shall be provided with one or more 12mm diameter/square drain holes/slots
located in the outlet weir directly above the tray flow. Size and number of drain
hole/slot may be reduced depending upon liquid rate. Draw off sumps shall be located
flush with the invert inside of draw off nozzles to allow complete draining of sumps.
4.5.12
All the three (3) and four (4) pass trays shall have pressure equalizing pipes (vent tubes)
across the downcomers.
4.5.13
Bubble Cap Trays

Risers
Fixed risers shall be used unless otherwise specified in the data sheets. Riser shall be
expanded into upward flanged opening in the deck plates and then stitch welded to
upturned edges of the opening. Always riser shall not be welded to the bubble cap. 0
Bubble Cap
Bubble caps are to be furnished in Full Annealed and scale free bright condition.
4.5.14
Valve Trays
Valve assemblies of proprietary trays shall be provided with following features.
i) A means of preventing the orifice covers from adhering to tray floor.
ii) A means of preventing the orifice covers with integral guide legs and lift stops from
popping out of place during operation.
4.5.15
Sieve Trays
All perforations shall be punched and made from top side and burr side on tray decks
must be downwards when installed, unless specified otherwise. In case of liquid-liquid
extractor column trays, punching direction shall depend on the direction of liquid flow of
continuous phase.
4.5.16
Burrs shall be removed from all perforated areas and edge of internal sections.
JACOBS
HPCL-MUMBAI
44LK5100
4.5.17
Page 45 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
Distributors/Redistributors
Distributors of liquid feed to packed beds, unless otherwise specified in data sheets, shall
be gravity flow type (e.g. orifice drip trays, tubed drip trays, trough type, orifice header
laterals) in accordance with following requirements:
i)
Orifice for liquid distributor shall preferably be minimum 8.4 mm diameter and shall
be arranged on an approximate equal spacing throughout the distributor. Distributor
supports shall be designed and arranged so as not to interfere with flow from
orifices.
In case orifice diameter calculated is less than 8.4 mm, then antifouling covers shall
be provided on each orifice. Orifice below 6mm diameter shall be preferably provided
at an elevation in drip tube or in side of trough with guide tubes.
ii)
Vapor risers shall have a total cross sectional area as per Vendor's design but not
less than 15 percent of vessel cross sectional area. Number, size and arrangement
of vapour risers shall be such so as not to affect the orifice spacing and liquid
distribution to the packings.
iii) Distributor joints shall be gasketted to be liquid tight. Gasket material used shall be
suitable for service and soft enough for leak tight joint.
iv) iDistributor shall be capable of performing satisfactorily for the range of loadings
specified to cover entire range of plant operation.
v)
Flow variation from orifice to orifice shall not be more than 10 percent at turndown
condition.
vi) Feed pipe shall form part of Distributor supply.
4.5.18
Packing Support Plate

Packed bed support plate shall be vapor-injection type, providing separate passage
for liquid and vapor flow. The support plate shall have at least 90 percent free area
based on cross sectional area of vessel. Slot size shall be so selected to avoid any
sneak through of packings from slots.
4.5.19
Bed Limiters/Bed Retainers

Bed Limiters/Bed Retainers shall be located just above top of packings to avoid
fluidizing of bed and shall be fixed in position so as not to be moved by the packings
and shall be designed so as not to affect distribution from the liquid distributor to the
packings. Bed Limiters/Bed Retainers for use with spray nozzle distributor shall be
designed with major structural support on the underside of the retainer so as not
to affect the spray distribution on the packings. Expanded metal with equal opening
area is also acceptable in lieu of wire mesh.
4.5.20
Hold Down Plates

Hold down plates shall be provided on the top of ceramic or carbon tower packings.
The hold-down plate shall directly rest on the bed without any support cleats.
Hold-down plate shall exert sufficient static pressure on the bed to restrict movement
JACOBS
HPCL-MUMBAI
44LK5100
Page 46 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
of the bed. Care shall be taken not to use hold-down grid with metallic or plastic
tower packings.
4.5.21
Flash Feed Distributor

Flash feed distributor for flashing or mixed phase, vapour and liquid feeds to
packed bed shall be designed to separate the two phases and distribute the liquid
phase on distributor/redistributor. If flashing feed gallery is used, riser area shall be
50% of vessel cross sectional area.
4.5.22
Tower Packing
If type of packings is not specified in the process data sheets, following shall be
taken as guidelines:
i)
ii)
iii)
4.5.24
5.0
For wash zone of vacuum column, Grid Packings shall be used.

For all other applications preferably Pall Rings shall be used. If pall rings are
not expected to perform to desired performance, proprietary random
Packings like Intalox saddle of Norton/Koch-Glitsch or similar.
If structured packing has been specified, it shall preferably be from the
identified source
The maximum allowable pressure drop for a packed bed shall include packed
bed support, bed limiter and distributor.
FABRICATION AND SUPPLY
Tolerances
All sections shall be truly flat within 2 mm and shall be tree from burrs and welds
spatters.
Tolerances wherever unspecified shall be taken as 1 mm and not to be accumulative,
except on thickness and assembly diameter. Tolerances on thickness shall be as per
applicable specification and tolerances on assembly diameter shall be as below:
5.2.0
Welding
5.2.1
All welding shall be done by metal arc welding. For welding on thinner gauge sheets
TIG welding is preferred.
5.2.2
Gas or Carbon arc welding shall not be used.
JACOBS
HPCL-MUMBAI
44LK5100
5.2.3
Page 47 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
Welding electrodes of composition similar to Internals material shall be used except

austenitic electrodes of higher chromium and nickel content such as AWS A5.4, ASME
SFA 5.4 class E309 and E310 may be used for 12Cr stainless steel. For dissimilar
material welding, electrode composition shall be similar to nobler material being
welded. Following electrodes shall be used unless specified otherwise:
E 7018
for all CS materials
E308
for all SS 304 to SS 304
E 308L
for all SS 304L to SS 304L
E 309MoL
for SS 410S to SS 410S, SS to CS, SS 410S to SS 304, 304L,316,

3l6L
E316
for all SS316
E316L
for an SS316L
E Ni Cu7
for Monel to Monel and Monel to CS/SS
5.2.4
Welding wherever specified, is to be done by qualified and approved welders using the
suitable fillers and fluxes recommended for the materials in the fabrication drawings.
For welding the stud on tray decks and support beams, use of stud welding gun with
suitable flux is acceptable. In manually welding the studs, care should be taken to
minimize the weld spatter and the outside diameter of the weld so that it should not foul
with tray deck or washer. For stud welding, proper welding procedure shall be
established. Torque required for welding failure shall be higher than the torque
required for failure of the stud.
5.2.5
A proposed Welding Procedure Specification (WPS) shall be submitted to AlA for his
approval. On approval, a Procedure Qualification Test (PQT) shall be conducted which
shall be witnessed by AlA. On acceptance of all tests as per ASME Section IX, a final
WPS along with Procedure Qualification Record (PQR) shall be submitted. Production
welding shall start only after approval of final WPS/PQR and qualification of welders as
per ASME Section IX. AlA may accept previously qualified WPSIPQR at his sole
discretion.
5.3
Miscellaneous
5.3.1
All parts fabricated shall be smooth, true, clean and free from burrs, grease and dents.
Openings for passage of workman must have exposed edges rounded.
5.3.2
All support rings, bolting bars, beams support brackets and other components which
are integral and therefore welded to the column shell inside, shall be supplied and
installed by column fabricator.
5.3.3
Total draw-off trays shall be designed for zero leakage construction and may be seal
welded (if required) at site to attain zero leakage.
5.3.4
Seal welds shall have a throat thickness at least equal to the specified corrosion
allowance.
5.3.5
All stainless steel tray assemblies/internals and their components (e.g. Bubble caps,
valves etc.) shall be pickled and passivated. Pickling and Passivation shall be as per
ASTM 380.
JACOBS
HPCL-MUMBAI
44LK5100
Page 48 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
5.3.6
All parts shall be fabricated in accordance with good shop practice and in uniformity so
that all corresponding parts will be inter-changeable.
5.4
Spares
Following spares shall be included as part of the supply:
5.4.1
Constructional Spares
The supply shall include the following as constructional spares:
Bolts/Nuts
10% of total for each size

(Minimum 10 nos. of each size)
Clamp assemblies
10% of total for each type and size

(Minimum 10 nos. of each size)
Valves for trays
5% of each type
Bubble caps
5% of each type and size
Gasketing or tapes
100% of each type and size
Sealing foils for

cartridge trays
200% of each size
V-clamps
10% of each t ype and size or

minimum
10 nos. whichever is
Tower Packings
10% for Metallic and Plastic Packings
(Only random packings) 15% for Carbon and Ceramic Packings
Spray Nozzles
5.4.2
Up to 25 Nos. (of each type)- 100%

More than 25 (or each type) - 25%
(subject to minimum of 25 Nos.)
Vendor shall submit list of spares recommended for two years of satisfactory operation.
However, following operational spares as a minimum shall be supplied as Mandatory
Spares:
i.
ii.
Valves for Trays

Bolts/Nuts
iii.
iv.
v.
vi.
Clamp Assemblies
Gaskets or Tapes
Sealing foils for Cartridge Trays
Spray Nozzles
vii. Tower Packings
10% of each type

10% of total for each type/size
(minimum 10 nos. of each size)
- do 100% of each type and size
200% of each size
25% subject to minimum 5 Nos. of
each type and size.
5% of each type and size. (Only
JACOBS
HPCL-MUMBAI
44LK5100
Page 49 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
Random Packings)
If desired by owner, item wise price for above spares shall be furnished after award of
the job.
6.0
INSPECTION AND TESTING
6.1
General
6.1.1
The materials, fabrication, testing and trial assemblies are subject to inspection by
Owner/JACOBS, at shop floor before shipment and during installation.
6.1.2
Any rejection made by Inspector shall be final. Approval/Inspection by

Jacobs/Owner and/or their designated representative shall in no way relieve the
Vendor of his responsibility to meet all the requirements of the Purchase Order.
6.1.3
Owner/Jacobs authorized Inspector shall have free entry to the Vendor's shop at all
times where and while the work is being performed. The Vendor shall offer the inspectors
all reasonable facilities to satisfy them that the materials are being furnished in
accord3nce in accordance with the specifications.
6.1.4
Vendor shall notify the Owner/JACOBS sufficiently in advance of any fabricating

operations to permit the Inspector to arrive at the Vendor's shop.
6.2
Stage Inspection during Fabrication
6.2.1
Dimensions
The inspector will check that the thickness and the dimensions of all parts for the
Decks, Weirs, Seal and Draw off pans, Down comers, Draw off pipes, Supports,
Beams, Valves, Bubble caps, Clamps, Studs, Bolts, Nuts, Risers, Washers and Gaskets
etc. are as per the approved drawings.
6.2.2
Fabrication
The inspector shall check each individual part of the equipment fabricated as per
approved drawings and specifications. For instance, for the Bubble cap dimensions,
height, width and number of slots, heights, O.D. and I.D. or riser and cap, shroud ring
height, exit and inlet weirs height etc. shall be measured. The inspector will check that
all identical parts shall be interchangeable.
Inspector shall check that the sharp edges on the internal components; man way covers,
weirs, downcomers etc. are properly removed. Also that all burrs from punched holes
and loose weld slags and materials are removed from all components. Stage-wise
inspection during fabrication will be thoroughly carried out.
Before starting welding, welders' qualification test will be carried out, if required, as
per ASME Sec. IX. Where numbers of similar items are to be made, inspector shall
give the clearance for the fabrication of the lot only after checking and approving the first
sample piece.
6.3
Trial Assembly
JACOBS
HPCL-MUMBAI
44LK5100
Page 50 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
Trial assembly of one tray of each type and size with its accessories shall be carried out
inside the fabricators' shop as floor mock-up. The components for such an assembly
will be taken at random from each lot of identical items.
The assembled tray will be carefully checked for its dimensions, tolerances, number
and arrangement of perforation, the working of the valves in case of valve trays, Vnotch or Blocked Weir, adjustability of weir, vent tube details, downcomer clearance,
weir heights, downcomer length and width, number of clamps, gaps and potential
leakage points etc.
The assembly shall also be checked for each type and size of packed tower internals.
Inspector will also check the flatness and deflection of the trays, internals, beams, tray
edges and beam ends clearance.
Leak Testing
Bubble cap, Collector trays, Liquid holding portion of other trays such as Seal pans,
Recessed 'seal pans, Draw off pans, Distributors/Redistributors shall be subjected to
leakage test at shop floor (by internals vendor) and in the field (by installation
contractor) by filling water up to weir level or up to normal liquid level as the case may
be.
However, in case site installation of these is also included in internals vendor's scope
of work, leak testing at shop floor for items in single piece construction is not required.
Appropriate ring fixture or a portion of column shell with supports for seal pan/recessed
seal pans/draw off box etc. shall be made by Internals Vendor to facilitate leak testing in
the shop.
Leak testing shall be carried out with service gaskets and drain holes temporarily
plugged.
All distributors/redistributors shall be leak tested with all holes temporarily
plugged. It shall be ensured that leakage is uniform and not from few concentrated
places/corners. All plugs shall be removed after leak testing is over.
Leakage rate shall not exceed 0.5 percent of design liquid flow rate unless
6.5
Distributor Testing
6.5.1
Vendor's Proprietary Liquid distributors/redistributors shall be water tested in the

vendor's shop only by the following procedure at 50%, 100% and 110% of the design
liquid volumetric flow rate. The vendor shall certify to the purchaser at the time of
bidding that they believe their equipment can meet the testing requirements listed
below:
(i) If the distributor contains a pre-distributor, it shall be tested first to ensure that it has
a CV of 5 or less at the design flow rate. Each orifice in the pre-distributor shall be
tested. The CV is defined as the ratio of the standard deviation to the sample mean,
expressed as a percent.
(ii) The distributor/re-distributor itself shall be tested and the CV determined. To
determine the CV, at least 30 pour points or at least 10% of the pour points
JACOBS
HPCL-MUMBAI
44LK5100
Page 51 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
(whichever is higher) shall be randomly selected and tested. If the CV specified

below cannot be met, the vendor will correct the problem at its expense.
(a) For orifice pans, tubed drip pans and other similar devices, a CV of 10 or
less must be achieved at the design liquid volumetric flow rate.
(b) Four orifice parts, tubed drip pans or trough distributors that employ a
modular (sectional) design, (wherein many pieces are geometrically
identical) all pieces of the same geometry shall be treated as one group or
strata. One piece from each strata shall then be tested by the procedure
outlined above.
(c) The average flow rate per pour point for any grouping of 10 of the tested
pour points from a single area should differ by no more than 5% from the
average for the group or strata being tested.
(d) The test results shall be furnished to Jacobs/Owner in a written report. This
report shall also contain a drawing of the distributor in plan view. This
drawing shall be broken down into 3 radial zones of equal area and the
location of pour points sampled in each zone.
In case vendor can demonstrate procedure establishing above quality
requirements, performance testing of distributors can be waived off.
6.5.2
SPRAY NOZZLE DISTRIBUTORS

Spray nozzle distributors shall not be tested in the vendor's shop but must be tested in
the tower prior to start-up to ensure that all nozzles are operable and develop the
desired spray pattern. This test shall be carried out as close to design rates as possible.
SPRAY NOZZLES
Apart from the usual material quality tests (chemical analysis and mechanical
properties) and manufacturing quality control tests, vendor shall include for & carry out the
testing of the spray nozzles with respect to the flow rates for specific P, spray angle,
spray coverage and distribution for the tip distance given in the data sheet. The testing
medium shall be water. These results shall be, submitted to Owner/JACOBS for
review. Tests and acceptance criteria is as below:
7.0
Flow rates
Spray angle
Flow variation
No. of nozzle to be tested
5% for specific P
50
As per vendor's Standard. (Data to be reported for
Information)
10% of each size and type. (Min. 2nos. of each
type & size)
SITE INSTALLATION AND SUPERVISION

For revamp jobs, cutting & removal of existing attachments, welding of new
attachments inside the existing columns and installation of new internals shall
preferably be done by column internals supplier. Alternatively, all these activities can
be included in the scope of Mechanical Contractor (covered in separate mechanical
tender) to have single point responsibility for complete Site Work. In such a case all
JACOBS
HPCL-MUMBAI
44LK5100
Page 52 of 52
Date: 10.09.2008
DOC.NO. 44LK5100-00-V.02-0001-A4
Rev. 0
such modifications, installation shall be carried out under the supervision of Internals
supplier so as to ensure guarantee of performance of column internals by supplier.
For new columns, installation of internals shall be done by column internals supplier
only.

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Page 1 of 52

HINDUSTAN PETROLEUM CORPORATION LTD.

ENGINEERING DESIGN BASIS PRESSURE VESSELS &

Issued for Clients approval

Clients comments incorporated &

Pressure vessels & heat exchangers

DESIGN BASIS GENERAL

SHELL/ HEAD THICKNESS

VESSEL END CLOSURES

HYDRO TEST PRESSURE

WIND LOADING CONSIDERATION

SEISMIC LOADING CONSIDERATION

VENT/ DRAIN/ VENTILATION NOZZLE CONNECTION

DESIGN REQUIREMENTS SPECIFIC APPLICATIONS

SHELL & TUBE HEAT EXCHANGERS

ADDITIONAL REUIREMENTS FOR SPECIAL TYPE HIGH PRESSURE HEAT EXCHANGERS

DETAIL & WEIGHT OF COLUMN ATTACHMENTS

ALLOWABLE STRESS FOR COMBINED LOADING

MATERIAL SELECTION CHART

TRAYS AND TOWER INTERNALS

Pressure vessels & heat exchangers

CODES & STANDARDS

For Pressure Vessels

ASME SEC. VIII DIV. 2

For Pressure Vessels (as specified in bid package for

ASME SEC VIII DIV 3

For very high pressure Vessel

TEMA CLASS R, 1999 EDITION.

For Shell & tube Heat Exchangers

ASME SEC. VIII DIV. 2/PD 5500

Mounded Vessels / Bullets.

For non-destructive testing

TEMA, 1999 EDITION / IS 800

For double pipe exchanger (To the extent applicable)

ASME SEC. II Part A, B, C, D

For material specification & allowable stresses

For material specification for Tanks

For large diameter flanges

ASME B 16.20 / API 601

Welded Aluminum alloy storage tank

ANSI B1.1/IS 4218

For bolting specification

For elbows & return bends

ASME SEC. VIII Div. 1

For workmanship of Vessels not categorized under any

For Storage Tanks

API Standard 661 / IS 800 Latest

For Air cooled exchangers

For Low Pressure Storage Tanks

For steel vent stacks etc

Engineering Design basis for

Pressure vessels & heat exchangers

IS: 9178/DIN 1055

For Silos, Hoppers and, Bins

IS: 875/ Site Data

For wind load consideration

IS: 1893/ Site Data

For seismic design consideration

For steam producing, steam storage, catch water

Sulfide Stress Cracking Resistant Metallic Materials for

Evaluation of Pipeline and Pressure Vessel Steel for

Laboratory Testing of Metals for Resistance to Sulfide

Methods & controls to prevent in service cracking of