Beruflich Dokumente
Kultur Dokumente
REM-1
TECHNICAL SPECIFICATION
HIGH PURITY
for
in
HYDRO-CHEM,
A DIVISION OF LINDE ENGINEERING NORTH AMERICA, INC
HOLLY SPRINGS, GEORGIA USA
1.1 GENERAL
This proposal is for the design, fabrication and FCA (Hydro-Chem or Hydro-Chem
Vendor shops) delivery of a modular hydrogen plant.
Some of the CO2 is removed from synthesis gas upstream of PSA using an amine
system. The energy for CO2 regeneration is provided by process heat and steam
generated in the plant.
Fuel for the reformer furnace is a combination of vent gas from the PSA System and
natural gas / refinery fuel gas.
Steam required by the process comes from recovering waste heat at various points in
the Hydrogen Plant.
The plant is highly automated allowing operation and production rate changes from a
central control point.
Hydrogen product conditions, flow, purity, utility consumption, items of supply and
services to be performed by Hydro-Chem are further defined in this proposal.
The following items are outside the scope of this proposal and are to be furnished by the
Purchaser:
1. Provide an accessible level site for plant installation free of underground and
above ground obstructions.
2. Provide construction utilities (power, water, and nitrogen).
3. Provide utilities as shown in Section 2.0 of this proposal.
4. Provide chemicals and lubricants as required.
5. Provide any fire proofing or fire protection, as required.
6. Provide any item not specifically shown as Hydro-Chem supply.
7. Provide operator and maintenance personnel for training during the
commissioning, start-up and operating phase of the project.
8. Provide labor and materials for installation.
The plant is designed to produce hydrogen by steam reforming of natural gas or naphtha.
2.1 PRODUCTS
The plant is designed to produce high purity gaseous hydrogen and steam as follows:
2.1.1 Hydrogen
Temperature, C max 40
Pressure, barg min 24.5
Temperature, C
minimum 230
normal 260
maximum 271
Quality
pH 8 9.5
Fe, ppmv <0.02
SiO2, ppmv <0.02
Cu, ppmv <0.03
Cl, ppmv <0.01
Conductivity, micro S/cm <5
Note: Export steam shall be desuperheated via a boiler feed water quench to
the minimum temperature.
Note: The total inerts in CO2 (H2, CH4, N2, and CO) would be less than 0.1 mol%
dry.
Composition, mol %
Methane 88.35
Ethane 10.51
Propane 0.10
Nitrogen 0.80 (1.0% max)
Carbon Dioxide 0.24
Total 100.00
Moisture, mg/NCM 65
Case 1 Case 2
Temperature, C 43 38
Pressure, barg min 4.9 4.9
IBP 49.1 -
5% 49.3 -
10% 51.4 49.6
20% 60.0 -
30% 66.5 -
40% 67.8 -
50% 69.3 67.6
60% 71.3 -
70% 72.9 -
80% 74.0 -
90% 79.9 77.4
95% 81.9 -
100% 95.9 -
EBP - 81.5
Temperature, C 40
Pressure, barg normal 2.45
max 3.43
2.3.1 Fuel
Makeup fuel for the reformer is natural gas, while natural gas is feed to the plant
or refinery offgas while naphtha is feed to the plant, as shown in Section 2.2.
Fuel for the burner pilot is natural gas / refinery offgas. No coalescing filter is
provided for refinery fuel gas.
Demineralized water is used for BFW makeup. It is also used in amine system.
SiO2, ppb 10
Total Hardness, ppm CaCO3 0.01
Iron, ppm as Fe 0.02
Sodium, ppb as Na 50
pH range 6.5-8.5
Pressure, barg min 2
Temperature, C 10
480V, 3 Phase, 60 Hz
2.3.5 Nitrogen
Composition, mol %
CH4 7.5
C2H6 4.9
C3H8 2.9
C4H10 1.3
C5H12 0.9
H2 82.4
HCl, ppmv max 0.5
Analysis
Supply Temp, C 29
Temperature Rise, C 11
Electric Power, KW
I.D. Fan 190 190 190
F.D. Fan 70 70 70
BFW Pumps 100 100 100
Condensate Pumps 25 25 25
Naphtha Feed Pumps - 30 30
NG Compressors 120 - -
H2 Recycle Compressors 10 10 10
Amine Pumps 70 70 70
Reflux Pumps 10 10 10
Naphtha Slop Air Cooler Fans - 5 5
Amine Charge Pump 5 5 5
Miscellaneous 20 25 25
Total 620 540 540
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2.4.3 Following are the estimated utilities @ 700 kg/hr H2 production.
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2.4.4 Estimated utilities - Startup
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2.4.5 Startup Time, Rate Changes, Switchover of Feed and Operability
2.4.5.3 Operability
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2.5 PERFORMANCE GUARANTEES
TPD 115
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2.6 OTHER DESIGN PARAMETERS
Seismicity
Seismic Zone 3
Zone Factor (Z) 0.4 g
Use Factor (U) 1.5
Land Profile (S) S3
2.6.2 Reformer furnace fuel consumption is based on the design conditions for
combustion shown above, 25 KMPH wind velocity, 5% radiant section heat loss,
10% excess air to the burner. A 56C flue gas temperature loss is allowed to
account for convection section heat losses.
2.6.8 Basis of acoustical plant design is to limit the noise exposure for personnel to an
eight-hour time weighted average of 80 dB(A) according to Directive 2003/10/EC
of the European Parliament and of the Council on minimum health and safety
requirements regarding exposure of workers to the risk arising from physical
agents (noise).
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Because process area and large machinery installations are generally
unoccupied and, furthermore, because the period of attendance of personnel on
their control rounds in the plant is limited, no permanent working places inside
the plant are to be taken into consideration.
There are a few areas where the combined sound pressure level inside the plant
will be higher than 90 dB(A) at 1m distance. These areas are mainly found at
large machinery as well as equipment installations. These areas will be
signposted as restricted areas. Noise protection equipment which would be
necessary to reduce the noise level of this equipment will hinder access for
maintenance of the equipment (e.g. enclosures) and therefore will not be
foreseen. Furthermore the stay time of personnel here is limited normally. At
these "restricted areas" the use of personnel ear protection for short times is
required for the advantages of easier access and better maintenance to the
equipment.
Noise limits for the environment outside battery limit are not defined.
The acoustic design applies to normal rate operation of equipment. Start-up,
shut-down and other abnormal or transient operation conditions and emergency
equipment are not considered.
As noise level varies in intensity both in the vicinity of machinery and at other
localities, where a worker or operator might find himself throughout his shift, the
noise exposure is to be measured with a personal noise exposure meter meeting
IEC 1252. Distance to sounding components is 1 m at a minimum.
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2.7 ESTIMATED EFFLUENTS
The following effluents are based on producing 1150 kg/hr of hydrogen, with natural gas
as feed and fuel.
Temperature, C 161
Flow, kg/hr
Normal 44840
Maximum 54000
(1) Particulate emissions are only for particulates created during the combustion
process. It does not include particulates from the air or insulation.
(2) All emission testing is done by the client.
(3) These guarantees are passed through from the burner vendor.
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Source - Relief Header (max flow)
Frequency - upset
Temperature, C 38
Flow, kg/hr
Normal 9840
Maximum 12000
Temperature, C 108
Flow, kg/hr
Normal 475
Maximum 750
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2.7.2 Liquid Effluents
Temperature, C 52
Flow, kg/hr
normal 615
maximum 3075
Reforming Ni 7.4 5
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2.8 CODES, STANDARDS, AND SPECIFICATIONS
The plant is designed and built in accordance with the applicable Hydro-Chem and
Praxair specifications. In addition, the design would conform to following codes and
standards, as applicable.
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3.0 PROCESS DESCRIPTION
The following process description can be reviewed in conjunction with the attached
preliminary process flow diagrams.
Natural gas is supplied to the plant as main feedstock at 21.8 barg and split into two
streams: one flowing to the reformer burner manifold, and one flowing as feed gas to the
process. The feed gas is mixed with recycle hydrogen and is compressed to 32 barg by
the Natural Gas Compressors C-101 A/B. The compressed feed gas is heated to 385C
in the Feed Preheater (HX-101), using process heat downstream of the Shift Converter
(V-102).
3.2 Hydro-desulfurization
Sulfur compounds are poisons to the reformer catalyst. The organic sulfur should be
hydrotreated to hydrogen sulfide and removed prior to reforming.
The heated feed gas is passed up through the Hydrotreater (V-100). The vessel has
Co-Mo hydrotreating catalyst. The Co-Mo catalyst converts organic sulfur compounds to
hydrogen sulfide. In addition, any olefins present are converted to saturated
hydrocarbons.
Hydrotreated feed is then passed through the Desulfurizers (V-101 A&B) containing the
chloride guard and zinc oxide. The chloride guard bed converts chlorine to hydrogen
chloride. The zinc oxide adsorbs the hydrogen sulfide. The desulfurizer beds are
designed for a minimum catalyst life per bed (based on the 5-ppmv sulfur in the natural
gas feed).
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3.3 Pre-reforming
The desulfurized feed is mixed with steam, superheated and fed to the Pre-reformer (R-
100) at 450C in down flow direction. The pre-reformer vessel has nickel catalyst.
All the heavier hydro-carbons are converted to CH4, H2, CO & CO2 in the pre-reformer.
3.4 Reforming
The pre-reformer effluent is fed to the catalyst tubes in an upfired, upflow, cylindrical
Reformer (R-101).
Each reformer tube is packed with nickel catalyst. The following reactions occur:
Reaction (1) is reforming; reaction (2) is shift conversion. Both reactions are equilibrium
limited based on the outlet temperature and pressure. The reformer exit conditions are
843C and 28 barg.
The overall reaction is endothermic, requiring heat supplied by the burner. The vent gas
from the PSA system meets most of the fuel requirement for the burners. The rest is
supplied by natural gas while feed to the plant is natural gas or RFG while feed to the
plant is naphtha.
The flue gas leaving the furnace is used to superheat the preformer feed, export steam,
to generate steam in the Flue Gas Steam Generator (WH-102), and to preheat boiler
feed water before being sent to the atmosphere.
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3.5 Shift Conversion
The reformer exit process gas is cooled to about 343C in the Reformer Effluent Steam
Generator (WH-104) before entering the Shift Converter (V-102). The Shift Converter
contains chromium-promoted iron oxide catalyst. Most of the carbon monoxide in the
process gas is converted to carbon dioxide and hydrogen by the following reaction:
CO + H2O = CO2 + H2
The shift exit process gas is cooled to 38C by the Feed Preheater (HX-101), Boiler
Feed Water Exchanger (HX-102), Amine System Reboiler (HX-114A), DA Exchanger
(HX-103), and the Process Cooler (HX-104). The hot condensate is separated in the Hot
Condensate Separator (V-103). The cold condensate is separated in the Cold
Condensate Separator (V-104). Part of the syngas is sent to the Amine System for CO 2
recovery. The rest of the syngas is mixed with the treated gas (CO2 removed) and sent
to the PSA System.
The demineralized make-up water (from the Client) is heated in the DA Exchanger (HX-
103) and sent to the Deaerator (V-106). The hot and cold condensates are sent to a
separate Steam Drum (V-107B).
The PSA system is supplied by Linde. The PSA purification system uses five vessels,
each having a bed of activated alumina, carbon and molecular sieve. The system
operates on a repeated cycle having two basic steps: adsorption and regeneration.
During the adsorption step, the process gas flows through an adsorber vessel. Each
adsorber runs for about 2 minutes. The adsorbents trap the impurities from the process
gas. The pure hydrogen product is available at 24.5 bar(g) at the PSA Outlet.
At the end of the adsorption step, the adsorbent is loaded with impurities and is switched
to the regeneration cycle. The regeneration consists of depressuring, purging and
repressuring. The offgas from the regeneration step is collected in the Vent Gas Drum
(V-105) and is used as primary fuel in the reformer.
PSA system is designed to process full CO 2 content from the reformer/shift when the
CO2 recovery system is not in operation.
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3.8 Waste Heat Recovery
The waste heat in the process gas and the reformer flue gas is used to generate steam
at 37 bar(g). This steam is generated in the Flue Gas Steam Generator (WH-102) and
the Reformer Effluent Steam Generator (WH-104) and Shift Effluent Steam Generator
(WH-105). Waste heat in the flue gas is also used to superheat the prereformer feed in
the Feed Superheater (WH-101), to superheat the export steam in the Export Steam
Superheater (WH-107) and to preheat boiler feed water in the Economizer (WH-103).
Most of the steam is used as process steam for reforming. Some of the steam is used in
the naphtha vaporizer, in the amine reboiler, and in the deaerator. The remainder of the
steam is exported to the client.
Low temperature demineralized water is sent to the Deaerator (V-106), through the DA
Exchanger (HX-103), as make-up for deaerator under level control.
The Deaerated boiler feed water is pumped to the Steam Drum (V-107A) by the BFW
Pumps (P-101 A&B) through BFW Exchanger (HX-102).
The Steam Drum (V-107A) supplies water to the Flue Gas Steam Generator (WH-102)
and the Shift Effluent Steam Generator (WH-105).
The condensate from Cold Condensate Drum (V-104) and Hot Condensate Drum (V-
103) is pumped by the Condensate Pumps (P-140A/B) and sent to the Steam Drum (V-
107B) through Economizer (WH-103).
The Steam Drum (V-107B) supplies water to the Reformer Effluent Steam Generator
(WH-104). The dirty steam generated form this unit is used as process steam.
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3.9 CO2 Removal System
The plant systems (PSA, Convection Section & Process Cooling) are designed to
process full CO2 generated in the plant in the event of CO2 removal shutdown.
However the plant can produce 80% H2 with naphtha feed and 90% H2 with natural gas
feed if convection section and process cooling section are not designed for full CO 2.
The CO2 removal system uses an MDEA solution (DOW) to absorb CO2 from the
process gas.
Significant portion of the process gas from the Cold Condensate drum (V-104) is
scrubbed with the amine solution in the Absorber (V-111). Rest of the process
gas is bypassed and sent to the PSA system.
The CO2 free gas in the top of the adsorber is sent to PSA system.
The rich amine from the absorber is heated in the Lean-Rich Exchanger (HX-
111) using the hot lean solution, and then sent to the CO 2 Stripper (V-113).
The CO2 is stripped from the solution, using energy from the reboilers (HX-
114A/B). The reboilers energy supplied by the process heat and steam. Steam
generated from the plant is also used when required. The stripper overhead is
condensed in HX-113. The condensate separated in V-114 and is recycled back
to the system. The CO2 product is sent to the client.
The lean amine from the bottom of the CO 2 stripper is cooled in HX-111 and in
the Lean Amine Cooler (HX-112), and pumped by the Amine Pumps (P-111
A&B) to the absorber. A portion of the amine solution is passed through activated
carbon in the Amine Filter (V-115), to remove any impurities in the amine
solution.
Amine Storage Tank (V-117) and Charge Pump (P-117) are provided for initial
and subsequent filling.
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3.9.5 Amine Collection
Amine Collection Tank (V-202) and Amine Pump (P-202) are provided to collect
amine in the system during shutdown for any maintenance in the amine system
equipment.
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4.0 PROCESS FLOW DIAGRAMS
(Preliminary)
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5.0 CATALYST AND ADSORBENTS
5.1 CATALYST
Initial catalyst charge for the plant is supplied by Praxair. The preliminary catalyst data
are given below:
PSA adsorbents are supplied by Linde. Under normal operating conditions, the
adsorbent is expected to last through the life of the plant.
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5.3 BOILER CHEMICALS
The chemicals for normal operation are usually recommended by the water treatment
vendor and are supplied by the Purchaser.
The chemicals used for steam system boilout during startup, which include calgonite or
soda ash, caustic soda and wetting agent (commercial detergent), are supplied by the
Purchaser.
5.4 LUBRICANTS
Initial charge of lubricants for the compressors, fans, and pumps is supplied by Hydro-
Chem.
5.5.1 Carbon
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6.0 DESIGN FEATURES
Hydro-Chem plant design is conservative, with emphasis on the flexibility of operation and
efficiency. Some of the key features in our design are summarized below.
PSA Recovery, % 86
Steam to Carbon Ratio 3.0
Heat Losses, C
Desulfurizer 28
Reformer Feed 28
Reformer Exit 28
Convection Section 28
Combustion Air 28
6.2 Our design is based on 466C reformer inlet temperature. The inlet system is
mechanically designed for 522C. The inlet header system and trombones are stainless
steel.
6.3 The reformer outlet composition is based on 11C approach to reforming equilibrium.
With a conservative design flux, we have more than adequate catalyst to achieve a
much lower (as low as 5C at the end of catalyst life) approach to equilibrium. Hence,
the reformer outlet can be operated at a lower temperature for the same performance,
thus increasing the tube life.
6.4 We have designed the plant for a conservative steam to carbon ratio of 3.0. in the
primary reformer and the pre-reformer.
6.5 The Reformer Effluent Steam Generator is designed to have about 150% of the
required heat transfer surface. This additional surface provides the flexibility for proper
outlet temperature control, using the internal by-pass. This added surface also results in
lower heat flux, which decreases the potential for vapor blanketing of the tube surface.
The design of this unit is the best in the industry.
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6.6 The Flue Gas Steam Generator is also designed to have about 120% of the required
heat transfer surface. This additional surface provides the flexibility for proper outlet
temperature control. This added surface also results in lower heat flux, which decreases
the potential for vapor blanketing of the tube surface.
6.7 The Shift Effluent Steam Generator is also designed to have about 120% of the
required heat transfer surface. This additional surface provides the flexibility for proper
outlet temperature control. This added surface also results in lower heat flux, which
decreases the potential for vapor blanketing of the tube surface.
6.8 Hydro-Chems in-house design of the steam system provides over 10 minutes of
residence time for normal liquid level in the steam drum. This ensures flexibility in
operation and control. The sizing of the boiler and the internals result in proper quality of
steam for the process.
6.10 Hydro-Chems design uses only the fiber blanket insulation in the reformer firebox and
ductwork. The design does not use any firebrick or castable refractory. The fiber blanket
insulation has the following advantages:
Easy to maintain.
.
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7.0 EQUIPMENT DESCRIPTION
Reformer
R-101 A/B Reformers
Steam Generators
WH-102 Flue Gas Steam Generator
WH-104 Reformer Effluent Steam Generator
WH-105 Shift Effluent Steam Generator
Vessels
V-100 Hydrotreater
V-101 A/B Desulfurizers
V-102 Shift Converter
V-103 Hot Condensate Separator
V-104 Cold Condensate Separator
V-105 Vent Drum (By Linde)
V-106 Deaerator
V-107A/B Steam Drums
V-108 Blowdown Drum
V-110 Naphtha Buffer Vessel
V-111 CO2 Absorber
V-112 Absorber Overhead KO Drum
V-113 CO2 Stripper
V-114 Reflux Drum
V-115 Amine Carbon Filter
V-117 Amine Storage Tank
V-123 Feed K.O. Drum
V-130 Flare K.O. Drum
V-201 Naphtha K.O. Drum (Hydrocarbon Collection Tank)
V-202 Amine Collection Tank
X-101 PSA System (By Linde)
R-100 Pre-Reformer
F-113 Lean Amine Filter
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Heat Exchangers
HX-100 Naphtha Feed Vaporizer
HX-101 Feed Heater
HX-102 Boiler Feed Water Exchanger
HX-103 DA Exchanger
HX-104 Process Cooler
HX-108 Compressor Spillback Cooler
HX-109 HDS Start-up Cooler
HX-111 Lean/Rich Exchanger
HX-112 Lean Amine Cooler
HX-113 Stripper Overhead Condenser
HX-114 A/B Amine Reboilers
HX-118 Blowdown Cooler
HX-119 Naphtha Slop Cooler (Air Cooler)
HX-135 Nitrogen Heater (Electric)
Miscellaneous
X-102 Boiler Chemical Injection
STK-100 Flue Gas Stack
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7.2 REFORMERS R-101 A/B
The reformers are cylindrical up-fired, up-flow design. The shells are constructed
of ASTM A-36 carbon steel with an inner lining of high temperature blanket
insulation. The reformers are designed to prevent air from entering the radiant
and convection section.
A platform is provided at the top of the reformer cell. The platform is built to
OSHA standards with the following features:
Ladders are provided for access to the top of the furnace. Ladders are built in
accordance with OSHA standards.
The tubes are cast from a majority of (at least 90%) virgin materials. Only
in-house generated remelt material may be used for the balance.
Internal and external surface of castings are free from excessive wrinkled
dross and sags and are essentially smooth.
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Tube assembly conforms to the following:
Welds between tube sections and from the tube ends to the inlet stub end
and the outlet flange conforms to the manufacturer's standard, as
approved by the Purchaser.
For welds joining similar metals, root passes are made using the gas
tungsten arc welding process with an argon gas backing purge and no
filler metal. The remainder of the weld is made using the gas metal arc or
shielded metal arc welding process that will deposit metal essentially
identical in chemistry to the base metal.
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The manufacturer would supply the purchaser a certificate of conformance to
these specifications and written reports of the following tests:
The exterior surface of the tubes would be visually inspected for evidence
of flaws and porosity. Any suspect areas should be x-rayed.
A 1 (25 mm) long ring would be cut from each tenth tube section with a
minimum of one per heat at the opposite end of the pouring. The ring
would be etched and examined for the presence of inclusions and
porosity. The ring samples would then be labeled with the tube and heat
designations.
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7.2.4 Catalyst Tube Inlets and Header
Each tube inlet is connected to the carbon steel inlet header by a stainless steel
trombone. The design temperature for the inlet header and trombones are
566C.
The tube outlet is connected to an incoloy 800HT (ASTM B407-800H) pig tail
loop designed and fabricated in accordance with Hydro-Chem's standard. The
loop is connected at the other end to an 800HT (ASTM B407-800H) outlet
header. The outlet header is connected to a stainless steel down comer.
Wall thicknesses for the pig tails, header and downcomer are computed using
the vendors published stress to rupture in 100,000 hours at the EOR reformer
exit temperature plus a 20C (36F) safety factor. The system is designed for the
following cases:
1. The design temperature (as specified above) and the operating pressure.
2. The operating temperature and the design pressure (based on the
downstream relief pressure plus losses through intervening equipment).
3. The average of design and operating temperatures and the average of
design and operating pressures.
Air tight bottom access peep doors are provided in the reformer for viewing the
catalyst tubes. Quantity provided is dependent on the number of catalyst tubes.
An access door (with peep door) is provided on the lower section of the reformer.
7.2.8 Burners
The burners supplied are designed to burn the low calorific value vent gas from
the PSA system as the primary fuel and the natural gas or refinery fuel gas as
makeup fuel. The burners are forced-draft design and are provided with an
electric ignition for the pilot and safety monitoring system per IRI standards. Fuel
for the burner pilot is natural gas or RFG.
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7.3 WASTE HEAT RECOVERY
This unit consists of a coil box type superheater placed in the internally insulated
reformer Flue Gas section. The coil is designed and fabricated in accordance
with ASME code section B31.3. The coil is Inconel 800HT.
The fin-tube heat exchanger performs heating of the boiler feed water using
waste heat in the reformer flue gas. The unit will be of carbon steel construction.
The unit will be designed and fabricated in accordance with ASME Code, Section
VIII, Division I per ASME Code requirements. The tubes are SA-179 seamless
carbon steel.
The export steam superheater is a helical coil type. The coil is placed in the
internally insulated reformer Flue Gas section. The coil is designed and
fabricated in accordance with ASME code section B31.3. The coil is Inconel
800HT.
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7.4 STEAM GENERATORS
This fire tube type steam generator is designed and fabricated from the inlet code
division point in accordance with the ASME Code, Section VIII, Division 1. The
inlet and outlet plenums would be internally insulated with eight pound density
refractory blanket. The shell is externally insulated with calcium silicate and
wrapped with an aluminum jacket.
A manway and/or inspection openings are provided as required per the ASME
Code. Incorporating flanged end closures provides access to the tubes.
Materials of Construction:
Shell SA516 Gr 70 CS
Tubesheets SA516 Gr 70 CS
Tubes SA178 GR A CS
Plenums SA36 CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts SA193-B7
Design Conditions:
Shell side temperature 254C
Shell side pressure 42 barg
Inlet Plenum 829C
Outlet Plenum 482C
Tube side Pressure Neg. 500 mm H2O
Tube wall temperature TBD
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7.4.2 Reformer Effluent Steam Generator WH-104
This shell and tube steam generator is designed and fabricated from the inlet
code division point in accordance with the ASME Code, Section VIII, Division 1.
The channels are internally insulated with fiber blanket and protected by a
stainless steel metal liner. The inlet tube sheet is protected by the block
insulation and inlet ferrules. The inlet and outlet heads are internally insulated
with ceramic fiber blanket protected with a SA240 TP304 H metal liner. The
outlet temperature is controlled using an internal by-pass and two dampers in the
outlet bonnet.
Materials of Construction:
Shell SA516 Grade 70 CS
Inlet Bonnet SA240 TP304H SS and
Incoloy 800HT
Outlet Bonnet SA516 Grade 70 CS with
Internal insulation
Front Tubesheet SA516 Grade 70 CS with
4 High temp vacuum formed board
Ferrules TP304 SS
Tubes SA178 Grade A CS
Bypass tube SA106 Grade B CS
SA240 TP304H SS
Rear Tubesheet SA516 Grade 70 CS
Gasket Spiral Wound 304 SS/
Flexicarb Filler
Bolts SA193-B7
Design Conditions:
Shell side temperature 254C
Shell side pressure 42 barg
Inlet plenum 843C
Outlet plenum 460C
Tube side pressure 31 barg
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January 7, 2014
7.4.3 Shift Effluent Steam Generator WH-105
This shell and tube heat exchanger is designed and fabricated in accordance with
ASME Code, Section VIII, Division 1. This steam generator is post-weld heat
treated in accordance with ASME Code requirements. The shell is externally
insulated with calcium silicate and wrapped with an aluminum jacket.
Materials of Construction:
Shell SA516 Gr 70 CS
Tubes SA178 Gr A CS
Tubesheets SA516 Gr 70 CS
Inlet Bonnet SA-240-304 SS
Outlet Bonnet SA516 Gr 70 CS
Gasket Spiral Wound 304 SS/
Flexicarb Filler
Bolts SA193-B7
Design Conditions:
Shell side temperature 254C
Shell side pressure 42 barg
Inlet Plenum 432C
Outlet Plenum 288C
Tube side pressure 31 barg
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January 7, 2014
7.5 VESSELS
Materials of Construction:
Shell SA516 Gr 70 CS or SA106 Gr CS
Heads SA516 Gr 70 CS
Nozzles SA106-B CS
Skirt SA36 CS or SA106 Gr B CS
Support screen 304 Stainless Steel
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts SA193-B7
Design Conditions:
Temperature 427C
Pressure 37 barg
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7.5.2 Desulfurizers V-101 A/B
Materials of Construction:
Shell SA516 Gr 70 CS or SA106 Gr CS
Heads SA516 Gr 70 CS
Nozzles SA106-B CS
Skirt SA36 CS or SA106 Gr B CS
Support screen 304 Stainless Steel
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts SA193-B7
Design Conditions:
Temperature 427C
Pressure 37 barg
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January 7, 2014
7.5.3 Shift Converter V-102
Materials of Construction:
Shell 304 SS or SA 387-11 Cl 1 1.25 Cr
Heads 304 SS or SA 387-11 Cl 1 1.25 Cr
Nozzles 304 SS or SA 387-11 Cl 1 1.25 Cr
Skirt SA36 CS or SA106 Gr B CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts SA193-B7
Design Conditions:
Temperature 441C
Pressure 31 barg
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January 7, 2014
7.5.4 Hot Condensate Separator V-103
This vertical vessel is designed and fabricated in accordance with ASME Section
VIII, Division 1. This vessel is supported by a skirt, with an inspection port and
vents.
Materials of Construction:
Shell SA312 TP304 SS
Heads SA403 WP304 SS
Nozzles SA312 TP304L SS
Skirt SA36 CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts SA193-B7
Demister SS 304L
Design Conditions:
Temperature 288C
Pressure 31 barg
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7.5.5 Cold Condensate Separator V-104
This vertical vessel is designed and fabricated in accordance with ASME Section
VIII, Division 1. This vessel is supported by a skirt, with an inspection port and
vents.
Materials of Construction:
Shell SA312 TP304 SS
Heads SA403 WP304 SS
Nozzles SA312 TP304L SS
Skirt SA36 CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts SA193-B7
Demister SS 304L
Design Conditions:
Temperature 288C
Pressure 31 barg
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7.5.6 Vent Drum V-105 (Linde)
Vent Gas Drum is made of Carbon Steel (A516 Gr-70 or equivalent) and is
complete with
Vessel skirt
Internals
Clips for fire-proof insulation on skirt
Process safety valve
Earthing lugs
Tailing lug and lifting trunnions
1 Vessel template
Davit for manhole cover
Anchor bolts
Design conditions:
Temperature 66C
Pressure 2.1 barg
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7.5.7 Deaerator V-106
This unit consists of a horizontal vessel with a vertical stripping column supported
by 2 saddles. The vessel is designed and fabricated in accordance with ASME
Section VIII, Division 1. The stripping column contains either a packing distributor
or a spray nozzle and a support plate. The internals are accessible through the
flanged top. The vessel is insulated with calcium silicate and wrapped with
aluminum jacket. Manways and/or inspection openings are provided as required
per the ASME Code.
Materials of Construction:
Shell SA516 Gr 70 CS or SA106 Gr B CS
Heads SA516 Gr 70 CS
Nozzles SA106 Gr B CS
Saddles SA36 CS
Stripping column SA240 TP304 SS or SA312 TP304 SS
Stripping column nozzles SA312 TP304L SS
Stripping column internals SA240 TP304L SS
Gaskets Blue Guard 3200
Bolts SA193-B7
Design Conditions:
Temperature 150C
Pressure 3.4 barg / Full Vacuum
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7.5.8 Steam Drums V-107A/B
The horizontal pressure vessels are designed and fabricated in accordance with
ASME Section VIII, Division 1. Internal mechanical baffling and an outlet demister
are provided. An 18 (600mm) manway will be provided as a minimum. These
vessels are externally insulated with perlite and wrapped with an aluminum
jacket.
Materials of Construction:
Shell SA516 Gr 70 CS
Heads SA516 Gr 70 CS
Nozzles SA106 Gr B CS
Support Saddles SA36 CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts A193-B7
Design Conditions:
Temperature 254C
Pressure 42 barg / Full Vacuum
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7.5.9 Blowdown Drum V-108
This vertical separator is designed to separate flashed vapor from steam system
blowdown. The vessel is designed and fabricated in accordance with ASME
Code, Section VIII, Division 1. This vessel is supported by a skirt, with an
inspection port and vents. The vapor outlet nozzle has an exhaust head to
ensure that any entrained liquid does not vent with the vapor. The liquid flows out
by gravity through an external seal loop. The vessel is insulated with calcium
silicate and wrapped with an aluminum jacket.
Materials of Construction:
Shell SA106 Gr B CS
Heads SA234 WPB CS
Nozzles SA106-B CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Skirt SA36 CS
Bolts SA193-B7
Design Conditions:
Temperature 221C
Pressure 3.4 barg / Full Vacuum
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7.5.10 Naphtha Buffer Vessel V-110
The vessel will have 20 mins holdup from normal liquid level to empty.
Materials of Construction:
Shell SA516 Gr 70 CS
Heads SA516 Gr 70 CS
Nozzles SA106-B CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Skirt SA36 CS
Bolts A193-B7
Design Conditions:
Temperature 66C
Pressure 3.5 barg
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7.5.11 CO2 Absorber V-111
This is a packed column complete with the internals such as packing, packing
support, and liquid distributors.
Materials of Construction:
Shell, Heads, & Nozzles CS
Internals 304 SS
Skirt CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts CS
Design Conditions:
Temperature 100C
Pressure 31 barg
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7.5.12 Absorber Overhead KO Drum V-112
Materials of Construction:
Shell, Heads, & Nozzles CS
Internals 304 SS
Skirt CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts CS
Design Conditions:
Temperature 100C
Pressure 31 barg
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7.5.13 CO2 Stripper V-113
This is a packed column complete with the internals such as packing, packing
support, and liquid distributors.
Material of Construction:
Shell, Heads, & Nozzles CS/Top 10 Ft 304 SS
Internals 304 SS
Skirt CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts CS
Design Conditions:
Temperature 150C
Pressure 3.5 barg
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7.5.14 Reflux Drum V-114
This vessel contains a demister pad to minimize carryover of liquid in the gas
stream.
Material of Construction:
Shell, Heads, & Nozzles 304 SS
Internals 304 SS
Skirt CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts CS
Design Conditions:
Temperature 66C
Pressure 3.5 barg
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7.5.15 Amine Filter V-115
The vessel is equipped with 1 loading nozzle and 1 cleanout nozzle. A bucket
screen is attached to the outlet to prevent carbon from entering the piping
system.
Materials of Construction:
Shell, Heads, & Nozzles CS
Support screen 304 SS
Skirt CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts CS
Design Conditions:
Temperature 71C
Pressure 35 barg
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7.5.16 Amine Storage Tank (V-117)
Materials of Construction:
Shell, Heads, & Nozzles CS
Skirt CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts CS
Design Conditions:
Temperature 66C
Pressure 3.4 barg
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7.5.17 Feed K.O. Drum V-123
This vertical vessel contains a demister pad to minimize carryover of liquid in the
gas stream.
Materials of Construction:
Shell, Heads, & Nozzles CS
Skirt CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts CS
Design Conditions:
Temperature 66C
Pressure 28 barg
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7.5.18 Flare K.O. Drum V-130
Materials of Construction:
Shell, Heads, & Nozzles CS
Skirt CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts CS
Design Conditions:
Temperature 427C
Pressure 3.5 barg
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7.5.19 Naphtha K.O. Drum (Hydrocarbon Collection Tank) V-201
Materials of Construction:
Shell, Heads, & Nozzles CS
Skirt CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts CS
Design Conditions:
Temperature 66C
Pressure 3.5 barg
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7.5.20 Amine Collection Tank V-202
Materials of Construction:
Shell, Heads, & Nozzles CS
Skirt CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts CS
Design Conditions:
Temperature 66C
Pressure 3.4 barg
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7.5.21 PSA System (Linde) X-101
The PSA system is made of Carbon Steel (A516 Gr-70 or equivalent) and is
complete with:
Vessel skirt
Adsorbent bed support
Inlet / Outlet nozzle screens
Clips for fire-proof insulation on skirt
Earthing lugs
Tailing lug and lifting trunnions
Anchor bolts
One common lifting device for all adsorbers for erection at site
One common vessel template for all adsorbers
Design Conditions:
Temperature 66C
Pressure 31 barg
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7.5.22 Pre-Reformer R-100
The vessel is equipped with 1 loading nozzle and 1 cleanout nozzle. A bucket
screen is attached to the outlet to prevent catalyst form entering the piping
system. The vessel is insulated with calcium silicate and wrapped with an
aluminum jacket. Loading and cleanout nozzles will be in insulated with blanket
covers.
Materials of Construction:
Shell SA387 Gr 11, Cl. 1, 1.25 Cr
or 304SS
Heads SA387 Gr 11, Cl. 1, 1.25 Cr
or 304SS
Nozzles SA387 Gr 11, Cl. 1, 1.25 Cr
or 304SS
Skirt SA36 CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts A193-B7
Design Conditions:
Temperature 566C
Pressure 37 barg
Cartridge type, 5-10 micron, filters to remove any suspended solids from the
circulating amine.
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7.6 HEAT EXCHANGERS
This shell and tube, BKU type exchanger is designed in accordance with TEMA
class C, and ASME Section VIII, Division 1, as applicable. The shell and bonnets
are insulated with calcium silicate and wrapped with an aluminum jacket.
Materials of Construction:
Shell SA 106 CS
Tubesheets SA 516-70 CS
Bonnet SA 234-WPB CS
Tubes SA 178A CS
Tie Rods SA 36 CS
Baffles SA 36 CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts SA193-B7
Impingment plate 304 Stainless Steel
Design Conditions:
Shell side temperature 260C
Shell side pressure 37 barg
Tube side temperature 254C
Tube side pressure 42 barg
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7.6.2 Feed Heater HX-101
This shell and tube, BEM, or multi-tube double pipe exchanger is designed in
accordance with TEMA Class C and ASME Code, Section VIII, Division 1, as
applicable. The shell and bonnets are insulated with calcium silicate and
wrapped with an aluminum jacket.
Materials of Construction:
Shell SA 312 TP 304 SS
Tubesheets SA 240 304 SS
Bonnet SA 312 TP 304W SS
Tubes SA 249 TP 304W SS
Tie Rods SA 479 304 SS
Baffles SA 240 304 SS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts SA193-B7
Design Conditions:
Shell side temperature 441C
Shell side pressure 31 barg
Tube side temperature 427C
Tube side pressure 37 barg
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7.6.3 Boiler Feed Water Exchanger HX-102
This shell and tube, BEM or multi-tube double pipe, exchanger is designed in
accordance with TEMA class C and ASME Section VIII, Division 1, as applicable.
The shell and bonnets are insulated with calcium silicate and wrapped with an
aluminum jacket.
Materials of Construction:
Shell SA53 B CS
Tubesheets SA240-304 SS
Bonnet SA312 TP304-W SS
Tubes SA249 TP304-W SS
Tie Rods SA36 CS
Baffles SA36 CS
Gaskets Spiral Wound 304 SS/Flexicarb Filler
Bolts A193-B7
Impingement plate 304 Stainless Steel
Design Conditions:
Shell side temperature 260C
Shell side pressure 45 barg
Tube side temperature 288C
Tube side pressure 31 barg
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7.6.4 DA Exchanger HX-103
This shell and tube type BEU exchanger is designed in accordance with TEMA
class C standards. The unit shall also be designed and fabricated to the
requirements of ASME Section VIII, Division 1, as applicable. The shell and
bonnets are insulated with calcium silicate and wrapped with an aluminum jacket.
Materials of Construction:
Shell SA312 TP304 SS
Tubesheets SA240 TP304 SS
Bonnet SA312 TP304-W SS
Tubes SA249 TP304-W SS
Tie Rods SA 479 304 SS
Baffles SA 240 304 SS
Gaskets Spiral Wound 304 SS/Flexicarb Filler
Bolts A193-B7
Impingement plate 304 Stainless Steel
Design Conditions:
Shell side temperature 288C
Shell side pressure 21 barg
Tube side temperature 160C
Tube side pressure 31 barg
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7.6.5 Process Cooler HX-104
This shell and tube, BEM exchanger is designed in accordance with TEMA Class
C and ASME Code, Section VIII, Division 1, as applicable. The shell is insulated
with calcium silicate and wrapped with an aluminum jacket.
Materials of Construction:
Shell SA312 TP304 SS
Tubesheets SA240-304 SS
Bonnets SA 234-WPB CS
Tubes SA249 TP 304 SS
Tie Rods SA479-304 SS
Baffles SA240-304 SS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts SA193-B7
Impingement plate 304 Stainless Steel
Design Conditions:
Shell side temperature 288C
Shell side pressure 31 barg
Tube side temperature 71C
Tube side pressure 21 barg
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7.6.6 Compressor Spillback Cooler HX-108
This shell and tube, BEM exchanger is designed in accordance with TEMA Class
C and ASME Code, Section VIII, Division 1, as applicable. The shell is insulated
with calcium silicate and wrapped with an aluminum jacket.
Materials of Construction:
Shell SA106 B CS
Tubesheets SA516 Gr 70 CS
Bonnets SA 178 Gr A CS
Tubes SA106 B CS
Tie Rods SA36 CS
Baffles SA36 CS
Gaskets Spiral Wound 304 SS/
Flexicarb Filler
Bolts SA193-B7
Design Conditions:
Shell side temperature 160C
Shell side pressure 37 barg
Tube side temperature 66C
Tube side pressure 25 barg
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7.6.7 HDS Start-up Cooler HX-109
This shell and tube, BEM, exchanger is designed in accordance with TEMA
Class C and ASME Section VIII, Division 1, as applicable.
Materials of Construction:
Shell SA106-B CS
Tubesheets SA516 Gr 70 CS
Tubes SA178 Gr A CS
Bonnets SA106-B CS
Baffles SA36 CS
Bonnet Gaskets Blue Guard 3200
Bolts A193-B7
Design Conditions:
Shell side temperature 427C
Shell side pressure 37 barg
Tube side temperature 66C
Tube side pressure 25 barg
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7.6.8 Amine Lean/Rich Exchanger HX-111
Materials of Construction:
Plates 316 SS
Gaskets EPDM with peroxide cured
Nozzles SA106 Gr B
Design Conditions:
Hot side temperature 150C
Hot side pressure 3.5 barg
Cold side temperature 130C
Cold side pressure 31 barg
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7.6.9 Lean Amine Cooler HX-112
This shell and tube, BEM, exchanger is designed in accordance with TEMA,
Class C, and ASME Section VIII, Division 1, as applicable.
Materials of Construction:
Shell 304SS
Tubesheets 304SS
Tubes 304SS
Bonnets CS
Tie Rods & Baffles 304SS
Gaskets Blue-Guard 3200
Bolts CS
Impingement Plate 304SS
Design Conditions:
Hot side temperature 105C
Hot side pressure 3.5 barg
Cold side temperature 66C
Cold side pressure 7 barg
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7.6.10 Stripper Overhead Condenser HX-113
This shell and tube, BEM, exchanger is designed in accordance with TEMA,
Class C, and ASME Section VIII, Division 1, as applicable.
Materials of Construction:
Shell 304SS
Tubesheets 304SS
Tubes 304SS
Bonnets CS
Tie Rods & Baffles 304SS
Gaskets Blue-Guard 3200
Bolts CS
Impingement Plate 304SS
Design Conditions:
Shell side temperature 130C
Shell side pressure 3.5 barg
Tube side temperature 66C
Tube side pressure 7 barg
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7.6.11 Amine Reboilers HX-114 A/B
The shell and tube, BKU type, exchanger is designed in accordance with TEMA
Class C, and ASME Section VIII, Division 1, as applicable. This exchanger has
two tube bundles one for process gas and the other one for steam. The shell is
insulated with calcium silicate and wrapped with an aluminum jacket.
Materials of Construction:
Shell CS
Tubesheets CS/SS
Tubes CS/SS
Bonnets CS/SS
Tie Rods & Baffles CS
Gaskets Blue-Guard 3200
Bolts CS
Design Conditions:
Shell side temperature 150C
Shell side pressure 3.5 barg
Tube side temperature 204C/160C
Tube side pressure 31 barg/5 barg
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7.6.12 Blowdown Cooler HX-118
This exchanger is not designed according to ASME Code due its small size. If
required, the shell is insulated with calcium silicate and wrapped with an
aluminum jacket. Blowdown discharge from this exchanger will be below 38C.
Shell CS
Tubes CS
Design Conditions:
Shell side temperature 221C
Shell side pressure 3.4 barg
Tube side temperature 66C
Tube side pressure 7 barg
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7.6.13 Naphtha Slop Cooler HX-119
This forced draft fin-fan air cooler is designed in accordance with ASME Section
VIII.
Headers CS
Tubes CS
Fins By Vendor
Design Conditions:
Process side temperature 427C
Process side pressure 3.4 barg
The design is based on cooling the naphtha vapor discharge from PSV's on
desulfurizers.
This unit heats the nitrogen required for startup of the pre-reformer. The heater
will be an electric flange type heater designed for use in a hazardous area.
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7.7 COMPRESSORS, PUMPS AND FANS
Two 100% compressors are provided; one operating and one 100% standby.
The unit is a screw compressor complete with a TEFC electric motor.
Two compressors are provided. One operating and one 100% standby. The
machines are single stage, oil-free, reciprocating type, driven by an TEFC
electric motor. The motor terminals will be suitable for connecting aluminum
cables. Each compressor is supplied with a distance piece, a suction block valve,
suction strainer, discharge check valve, discharge block valve and local stop-
start push button station.
Two pumps are provided. One operating and one 100% standby. The pumps are
single stage, centrifugal type, driven by a TEFC electric motor. The motor
terminals will be suitable for connecting aluminum cables. Pumps are furnished
with mechanical seals. Each pump is supplied with a suction block valve, suction
strainer, discharge check valve, discharge block valve and local stop-start push
button station. Pumps are supplied will meet API standards and specifications.
Materials of Construction:
Casing Carbon Steel
Seal Housing Cast Iron
Impeller/Inducer Carbon Steel
Shaft AISI 8620
Shaft Sleeve 316 SS
Mechanical Seal Vendor Standard
Bearings Ball
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7.7.4 Boiler Feed Water Pumps P-101 A&B
Two pumps are provided for this service: one operating and one 100% standby.
The pumps are single stage, centrifugal type, driven by a non-overloading, TEFC
electric motor. Pumps are furnished with mechanical seals. Each pump is
supplied with a suction block valve, suction strainer, discharge pressure
indicator, discharge check valve, discharge block valve and local stop-start push
button station.
Materials of Construction:
Casing CS
Seal Housing Cast Iron
Impeller/Inducer 316 SS
Shaft 316 SS
Shaft Sleeve 316 SS
Mechanical Seal Vendor Standard
Bearings Ball (if applicable)
Two pumps are provided for this service: one operating and one 100% standby.
The pumps are single stage, centrifugal type, driven by a non-overloading, TEFC
electric motor. Pumps are furnished with mechanical seals. Each pump is
supplied with a suction block valve, suction strainer, discharge pressure
indicator, discharge check valve, discharge block valve and local stop-start push
button station.
Materials of Construction:
Casing SS
Seal Housing SS
Impeller/Inducer 316 SS
Shaft 316 SS
Shaft Sleeve 316 SS
Mechanical Seal Vendor Standard
Bearings Ball (if applicable)
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7.7.6 Reflux Pumps P-114 A&B
For each service, two pumps are provided: one operating and one 100% standby.
The pumps are single-stage, centrifugal-type, driven by a non-overloading TEFC
electric motor. Pumps are furnished with mechanical seals. Each pump is
supplied with a suction block valve, suction strainer, discharge pressure indicator,
discharge check valve, discharge block valve and local stop-start pushbutton
station.
Materials of Construction:
Casing 316 SS
Seal Housing Cast Iron
Impeller/Inducer 316 SS
Shaft AISI 8620
Shaft Sleeve 316 SS
Mechanical Seal Vendor Standard
Bearings Ball
Two pumps are provided for this service: one operating and one 100% standby.
The pumps are single stage, centrifugal type, driven by a non-overloading, TEFC
electric motor. Pumps are furnished with mechanical seals. Each pump is
supplied with a suction block valve, suction strainer, discharge pressure
indicator, discharge check valve, discharge block valve and local stop-start push
button station.
Materials of Construction:
Casing SS
Seal Housing SS
Impeller/Inducer 316 SS
Shaft 316 SS
Shaft Sleeve 316 SS
Mechanical Seal Vendor Standard
Bearings Ball (if applicable)
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7.7.8 Amine Charge Pump P-117
One pump is provided for each service. The pump is a single stage, centrifugal
type, driven by a non-overloading, TEFC electric motor. The Pump is furnished
with mechanical seals. The pump is supplied with a suction block valve, suction
strainer, discharge pressure indicator, discharge check valve, discharge block
valve and local stop-start push button station.
Materials of Construction CS
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7.7.12 Induced Draft Fan F-101
This induced draft fan is single width, single inlet designed and constructed in
accordance with vendor standard. The fan is all welded heavy gauge steel
constructed, designed for 250C max operating temperature. The fan is supplied
with:
(a) Balanced wheel
(b) Housing side braces
(c) Low point drain
(d) Clean out door with gasket
(e) Two pillow block ball bearings
(f) Shaft and bearing guard with extended lubrication limits
(g) Shaft cooler with guard
(h) Motor heat shield
(i) Direct drive
(j) TEFC electric motor
(k) Motor slide base with jack screws
(l) VFD control (by Purchaser)
This forced draft fan is single inlet designed and constructed in accordance with
Vendor Standard. The fan is all welded heavy gauge steel constructed, designed
for 66C max operating temperature, and supplied with:
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7.8 MISCELLANEOUS
The package includes the equipment needed for the chemical treatment of boiler
water. These chemicals maintain the pH of the boiler water, prevent fouling in
the boiler, and remove dissolve oxygen. The chemical injection equipment
includes:
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8.0 MECHANICAL DESCRIPTION
8.1 INSTRUMENTATION
8.1.1 General
Hydro-Chem will provide the control system and instrumentation to operate the
Hydrogen plant. The instrumentation design and supply is per Hydro-Chem
standards / Praxair standards.
All electric wiring is general purpose. Instrument air tubing is stainless steel.
Control valves, flow and pressure transmitters, and other instrumentation are
supplied by the vendors specified in the Vendor List.
Local start/stop switches and remote stop function in the PLC are provided for
the rotating equipment.
Units of measure for the PLC and plant mounted instrumentation is as follows:
Pressure barg
Differential Pressure mm H2O
Temperature C
Flow, Gas Nm3/h
Flow, Steam kg/hr
Flow, Boiler Water m3/hr
Flow, Cooling Water m3/hr
Heat kcal
Dimension m / mm
Weight kgs
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8.1.1 CONTROL SYSTEM ARCHITECTURE DRAWING
(Attached)
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8.1.2 Major Control Instruments
Plant safety shutdowns are designed to prevent costly damage to catalyst and
reformer furnace. The shutdown logic is as follows:
1. If the burner pilot goes out and if the firebox temperature is below 1,400F
(760C), plant automatically shuts down except steam to reformer.
2. High and low fuel pressure to burners will automatically shut plant down,
except steam to reformer.
3. In case of steam failure, plant shuts down and burner goes to low fire.
4. In case of high reformer temperature, burner goes to low fire, feed gas to
reformer shuts down and steam flow continues.
5. In case of high shift converter temperature, plant shuts down, burner goes to
low fire.
6. Failure of fan shuts plant down.
All flame failure relays, ignition transformers, indicating lights and push buttons
are mounted in a free standing NEMA 4 enclosure, which is mounted in the
reformer area.
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8.1.5 Analyzers
1. One MSA Orion Multi-Gas Analyzer that measures both LEL and Oxygen
2. One MSA portable Pump Analyzer with twenty detector tubes for each of the
following:
(a) Carbon Monoxide 2-300 ppm
(b) Hydrogen Sulfide 0.5-25 ppm
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8.2 CIVIL AND STRUCTURAL
Structural items for the plant are designed and supplied in accordance with applicable
Hydro-Chem specifications and AICS codes for civil/structural.
Structural design is based on the wind velocity and earth quake zone listed in Section
2.6.
Structural skids are designed to be filled with concrete in the field. No grating is provided
on the base level of the modules.
Hydro-Chem shall do design of the grounding requirements within skids and equipment.
Grounding connections will be supplied on the equipment/skids. Praxair shall perform
underground design and site installation.
Hydro-Chem will provide center of gravity locations for skids when drawings are issued.
8.3 PIPING
Piping for the plant is designed and supplied in accordance with applicable Hydro-Chem
specifications.
Interconnecting piping between skid, reformer and other off-skid equipment is supplied.
Interconnecting piping 1 and smaller is provided as bulk for field fabrication and
installation. All valves within skid limits are supplied.
All bolts and gaskets for on-skid piping and ship-loose piping are supplied. Purchaser
supplies bolts and gaskets for customer tie-ins.
Hydro-Chem will design and supply the flare header upto the B/L based on Purchaser
spec and input during project execution.
Hydro-Chem will provide all the instruments and associated piping and valves ISBL even
if they are off-skid.
Hydro-Chem provides pipe or tube routing to BMS skid. Supports for electrical will be
supplied by the Purchaser.
Hydro-Chem will supply pipe racks in 40ft sections and piping with flanged ends.
Hydro-Chem will provide utility drops / stations for instrument air, nitrogen and water.
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8.4 PAINTING
Painting for the plant is specified and supplied in accordance with applicable Hydro-
Chem specifications.
8.5 INSULATION
Insulation for the equipment and piping is specified and supplied in accordance with
applicable Hydro-Chem specifications.
No winterization is provided.
Hydro-Chem will provide insulation and wiring for field installation. In the case that the
quantity of materials sent by Hydro-Chem is not enough to satisfy the field insulation
requirement, it will be the responsibility of the Purchaser to supply the remaining
material. Purchaser is responsible for providing and installing off-skid insulation.
Reformer and the ducting (on-skid and ship-loose) are insulated in Hydro-Chem shops.
Purchaser is responsible for providing and installing insulation for the pipe rack.
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8.6 ELECTRICAL
Electrical components are designed and supplied in accordance with applicable Hydro-
Chem specifications and American standards NEMA and ANSI.
Except the reformer area, all equipment and materials are suitable for installation in an
area classified as Class 1, Group B, Division 2, except the reformer area. The reformer
area is general purpose.
All the motors have TEFC enclosures and are furnished with local pushbuttons on both
the skids and on the remote control system operator interface. Selector switches are
provided for all the motors. For motors off-skid, Hydro-Chem will provide the selector
switches for field installation by the Purchaser.
Each skid has junction boxes for instrument and control wiring. Junction boxes for all
modules are pre-wired in the shop.
Field wiring consists of wiring from terminals in the motor control center to motors and
terminals in the control panel; wiring to terminals in the junction boxes of each module;
and wiring from control panel terminals to off skid instruments, controls and control
valves. The field control wiring is supplied and installed by the Purchaser. The field
power wiring is supplied and installed by the Purchaser. Wiring between thermocouples
and the control system is supplied and installed by the Purchaser.
The 4160 volt, 3-phase, 60-cycle power feeder from motors to the motor control center is
supplied and installed by the Purchaser. The motor control center is supplied and
installed by the Purchaser. Wire number adequately identifies all terminal points.
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9.0 INSTALLATION
Installation Scope
The Purchaser will provide the necessary materials, construction equipment, labor and
supervision to install the hydrogen plant and make it ready for operation. Purchasers work
items are summarized below:
Work Items
1. Provide all field excavations required and remove from job site any material not
designed to be kept.
3. Provide temporary construction office, telephone service and toilet facilities for
construction crew.
4. Furnish transportation for all equipment and skids from the point of manufacture to
the job site.
5. Unload and set skids and off-skid equipment on their foundations and grout (if
necessary).
6. Furnish and install pipe rack, piping, and supports, where required, to battery limits.
7. Install all field instruments. Supply and install all wiring from instruments to control
system.
8. Install all crossover piping between skid units and reformer, where required.
10. Supply and install control and instrumentation electrical wiring and cable tray to
control panel and between skids, reformer, and off skid wired devices.
11. Supply and install motor control center. Furnish and install conduit, wiring and
tagging between the motor control center, the skids and the reformer.
12. Fill skids with 8 of stone and cap top with 2 of concrete.
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13. Pressure test plant.
14. Calibrate and check all controls, instruments and safety devices.
15. Install all catalyst and adsorbents. Initial column intervals in absorber and stripper.
17. Remove all rust preventives, oils, bracing, etc., used to protect the equipment
during shipping and construction.
18. Conduct all flushing, blowing, purging and cleaning operations required.
22. Provide area lighting. Lighting level to be approximately 50-ft. candle at working
levels. Hydro-Chem will provide skid lights, wired to the junction box, but will ship
them loose.
23. For shop fabricated spools (with field fitup welds) and all field fabricated spools will
by hydrotested in the field by the Purchaser. Hydro-Chem will pressure test skid
piping and rack piping in the shop.
24. Provide inspection of the facility to assure erected plant conforms to flow diagrams,
construction drawings, vendor prints, specifications, etc.
25. Perform final punch list and correct all items required before and after startup.
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10.0 SCOPE OF SUPPLY
(See attached Excel sheet)
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11.0 PLANT LAYOUT
(Preliminary)
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12.0 PROJECT SCHEDULE
(Project deliverables are shown in the Schedule)
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13.0 EXCEPTIONS AND CLARIFICATIONS
The following exceptions and clarifications are based on the recent Praxair jobs which are
applicable to this project also. However, Hydro-Chem will have to review Praxair specifications
thoroughly and advise you about any other additional items.
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21. HC to takes exception to not having any connections less than 3/4". Many instrument
connections are 1/2". Hydro-Chem will provide minimum 3/4" process piping.
22. HC takes exception to painting SS piping. SS piping insulation material does not contain
chlorides.
23. Hydro-Chem takes exception to supply complete fire alarm system.
24. Hydro-Chem offer is based on Linde 5 bed PSA system.
25. Hydro-Chem offer is based on TEFC motors per NEC.
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14.0 VENDOR LIST
The underlined vendors are the basis for Hydro-Chems bid. Any Purchaser requested deviation
from these vendors will have to be evaluated for their cost impact. Hydro-Chem reserves the
right to use alternate suppliers listed with no impact.
Skid Assembly
Hydro-Chem, Multi, SOPC (Suzhou Oxygen Plant Company), Wonil, LPP, Baroda
Equipment and Vessels Pvt. Ltd.
Reformer Fabrication
Hydro-Chem, Castagna, SOPC (Suzhou Oxygen Plant Company), SC Uton SA, LPP,
ZBACH
Reformer Tubes
Manoir Electro-alloys, Kubota, Metaltek International (Wisconsin Centrifugal),
Paralloy, Duraloy Technologies, Centromet, Schmidt & Clemens Gmbh & Co.
Reformer Burner
Lanemark, Callidus, Zeeco, Hamworthy, WS Wrmeprozesstechnik GmbH (Flox
burner)
Heat Exchangers
Hydro-Chem (ML, KGS, & PED), Brown Fintube, Heat Exchanger Design, Inc. (ML,
KGS, & PED), Hamco, Smithco, Industrial Heat Transfer, Inc. (PED), ITT Standard
(ML), ALCO, RW Holland, GEA Rainey, Cataract Steel Industries (ML), Southern Heat
Exchanger (ML), Aerofin (ML), Kreuger Engineering (ML), Funke, Thermotec, M. E.
Energy (IBR), Cataract (ML, KGS)
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Vessels
Hydro-Chem (ML, KGS, IBR, & PED), Arrow Tank & Engineering CO., Beaird
Industries (ML), Kreuger Engineering (ML), Suzhou Oxygen Plant Company (China),
Xebec, Linde, McAbee Construction, Budget Industries (Shiotook, OK), American
Fabrication Inc., SabaWerk GmbH, Wolf GmbH, M. E. Energy (IBR), Baroda Equipment
and Vessels Pvt. Ltd.
Fans
New York Blower, Twin City Fan & Blower Company, Chicago Blower, Robinson,
Buffalo Forge, Lampson, Reitz Ventilatoren, Woodcock & Wilson
Pumps
Sundyne/Sunflo, Corken, Goulds, Flowserve, Grundfos, Sulzer, MTH
Methanol Pumps
American Lewa Inc., Milton Roy, Grundfos
Coalescers / Filters
SW Filter, PALL, Perry Eq CO., Winston, Indufil
Recycle Compressor
Corken, Rix, Blackmer, Hycomp
Catalysts
Sud Chemie, Johnson Matthey, Haldor Topsoe, Unicat
PSA Adsorbents
Alumina = Coastal Chemicals, UOP, ZeoChem, Linde, Xebec
Carbon = Calgon (Barnabey & Sutcliff ), Norit, Linde, Xebec, Donau Carbon
Molecular Sieve = UOP, ZeoChem, Arkema, Linde (is required for LG projects), Xebec
Orifice Plates/Flanges/Annubar
Flow-Lin, Red Man, Aitken, Dieterich, Intra-Automation, Fluidic Techniques, Rosemount,
Air Monitor Corp.
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Vortex Flowmeters
Rosemount, Krohne
Control Valves
Globe Valves: Fisher, Metso-Jamesbury, Valtek / Kammer, Fisher / Baumann, Samson,
Valtek
PSA Valves
Valtek (piston actuated), Fisher, Samson
Relief Valves
Farris, Consolidated, Crosby / Tyco
Temperature Indicators
Ashcroft, Wika
Thermocouples
Pyromation, U.E., JMS, Moore, WIKA
Pressure Switches
United Electric, Barksdale, SOR, Ashcroft
Transmitters
General: Siemens, Honeywell, Rosemount, Yokogawa
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Pressure and Temperature Transmitters: Siemens, Honeywell, Rosemount, Yokogawa,
Moore
Level Switches
Bestobell-Mobrey, Magnetrol, Kayden, Endress & Hauser, Siemens
Level Gages
Jerguson, Inferno, Penberthy, Intra Automation
Actuators
El-O-Matic, Fisher
Solenoids/Shutdown
ASCO, Brkert, Samsomatic
Vibration Switch
Metrix, Assem-Tech Europe, Sensonics (ATEX)
Hand Valves
Apollo, Hills-Mccanna, Milwaukee, Metso-Jamesbury, Quartrol, Watts, Worcester,
Contromatics, KF, Marpac, Velan, WKM, Dezurik, Durco, Keystone, Norris, Posi-Seal,
Vanessa, Crane, Nibco, Powell, Walworth, ITT Grinnell, Eagle (KF), Mission, Stockham
Marlin, DSI, Kitz, Newco, Pacific, Prince, Aloyco, Cooper, Ladish, OIC, RP&C, Vogt,
Bonney, Smith, Anderson-Greenwood, Hex Valve, PGI, Dragon, Tufline, Mueller
Electrical Components
Crouse-Hinds, Cutler Hammer, Allen-Bradley, Siemens, Westinghouse,
Square D, Hoffman, GE
Positioners
PMV, Siemens, Fisher, Valtek, Samson (The manufacturer of the I/P Positioner will be
the same as the selected Valve manufacturer)
PLC
Allen-Bradley, Siemens
Motors
GE, Reliance, Siemens, Teco-Westinghouse, Baldor, ABB
CE Stamped: Siemens, Loher, Weg, ABB
Selector Valves
Anderson Greenwood, PGI, Dragon, Hex
Control Cabinets
STEP, PCS, T & G Controls, Pro-Panel, Siemens
Analyzers
O2 Servomex, Rosemount, Ametek
NOx California Analytical, Servomex, Siemens
CO Siemens, ABB, Horiba, Servomex
Portable Analyzers
MSA, Drager, General Monitors
Area Monitors
MSA, Sensidyne, Teledyne
Hydro-Chem, a division of Linde Engineering North America, Inc., and a member of Linde AG Engineering Division,
received the first order for a hydrogen plant in January 1976. Below is a list of installed and completed projects to
date. Ninety (90%) percent of the plants were fully constructed at our facilities, broken down into individual skids and
trucked to the jobsite, if domestic, or shipped overseas with a minimum of difficulty. As this list shows, many different
sizes of plants have been compartmentalized for easy shipment, giving Hydro-Chem exceptional experience in
module building..
HYDROGEN PLANTS
H2/CO PLANTS
CO2 PLANTS
N2 PLANTS (Cryogenic)
METHANOL PLANTS
Glidden-Durkee, Joliet, IL
Humko Products, Champaign, IL
Humko Products, Buena Park, CA
Central Soya, Fort Wayne, IN
Hunt Wesson, Fullerton, CA
SCM Corporation, Hammond, IN
PROCESS FABRICATION
PROPELLANT HYDROTREATERS
3
Esso, The Netherlands 2 M /HR Liquid Propane
4 M3/HR Liquid Butane
BIOGAS PLANTS
Hydro-Chem operates a 76,000-square-foot production facility on 17 acres of land, which is one of the most
modern and efficient of its kind. Our key personnel have extensive experience, which results in the highest
quality product and support service available worldwide. As a result, we proudly display our customer list
because we believe no one does a better job in the Skid Mounted Modular Plant field.
We would like the opportunity to meet with you to discuss, in detail, our qualifications and performance. We
also invite you to inspect our facilities so you can judge for yourself our workmanship and material quality.