PIP VESBI002 Design and Fabrication of Bulk Solids Product Containers

Transcription

1 May 2017 Vessel PIP VESBI002 Design and Fabrication of Bulk Solids Product Containers

2 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major industrial users, contractors, or standards organizations. By harmonizing these technical requirements into a single set of Practices, administrative, application, and engineering costs to both the purchaser and the manufacturer should be reduced. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on information contained in these materials. The use of trade names from time to time should not be viewed as an expression of preference but rather recognized as normal usage in the trade. Other brands having the same specifications are equally correct and may be substituted for those named. All Practices or guidelines are intended to be consistent with applicable laws and regulations including OSHA requirements. To the extent these Practices or guidelines should conflict with OSHA or other applicable laws or regulations, such laws or regulations must be followed. Consult an appropriate professional before applying or acting on any material contained in or suggested by the Practice. This Practice is subject to revision at any time. Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 3925 West Braker Lane (R4500), Austin, Texas PIP Member Companies and Subscribers may copy this Practice for their internal use. Changes or modifications of any kind are not permitted within any PIP Practice without the express written authorization of PIP. Authorized Users may attach addenda or overlays to clearly indicate modifications or exceptions to specific sections of PIP Practices. Authorized Users may provide their clients, suppliers and contractors with copies of the Practice solely for Authorized Users purposes. These purposes include but are not limited to the procurement process (e.g., as attachments to requests for quotation/ purchase orders or requests for proposals/contracts) and preparation and issue of design engineering deliverables for use on a specific project by Authorized User s client. PIP s copyright notices must be clearly indicated and unequivocally incorporated in documents where an Authorized User desires to provide any third party with copies of the Practice. PUBLISHING HISTORY July 2001 June 2009 May 2017 Issued Complete Revision Technical Revision Not printed with State funds

3 May 2017 Vessel PIP VESBI002 Design and Fabrication of Bulk Solids Product Containers Table of Contents 1. Scope References Process Industry Practices Industry Codes and Standards Other References Government Regulations Definitions Requirements General Overall Responsibilities Jurisdictional Compliance Documentation Responsibilities Process Design Effects on Components of Bulk Solids Product Container Types of Flow Container Inserts Internals Design Methods for Determining Wall Loads Mechanical Design Geometric Configurations Design Pressure and Temperature Maximum Design Temperature Coincident With Design Pressure Minimum Design Metal Temperature (MDMT) and Coincident Pressure Design Loads and Load Combinations Solids Product Container Support Systems Top Head Shell Bottom Shell-to-Bottom Joint (Skirt Ring) Container Connections Gaskets Internal Components Corrosion Allowance Compartmented Solids Product Containers Minimum Thickness Anchor Bolting Lifting Lugs Structural Materials General Allowable Stress Values Carbon Steel Stainless Steel Clad Material Fabrication General Welding Flanges Process Industry Practices Page 1 of 42

4 4.5.4 Prohibited Connection Details Tolerances Linings Examination Inspection and Testing Inspection Testing Shipping General Cleaning Painting Preparation for Shipping Side-Entry Instrumentation Nameplate and Stampings Nameplate Stampings Appendices Appendix A Manufacturer s Drawing Information Appendix B Design Calculations Information Appendix C Manufacturer s Data Package Documentation Appendix D Equivalent Pressure Formulas for Bending Moment and Axial Tensile Load Appendix E Flanged Pressure Boundary Joint Assembly Process Industry Practices Page 2 of 42

5 1. Scope This Practice provides requirements for the construction of cylindrical atmospheric and lowpressure, welded, shop- and field-fabricated dry bulk solids containers (e.g., bins, hoppers, silos, and gravity blenders). This Practice describes requirements for design, materials, fabrication, examination, testing, and shipping for cylindrical shell, single-wall containers for dry bulk solids (i.e., bins, hoppers, silos, and gravity blenders) having internal design pressures not exceeding 15 psig (103 kpa) and/or full vacuum external pressure at the top of the container in its normal operating position. Containers may be welded, shop- and field-fabricated, and shall generally be designed in accordance with the philosophy and requirements of the ASME Boiler and Pressure Vessel Code, Section VIII, Division 1, henceforth referred to as the Code. Code inspections and stamping are not required for these containers. The following are not covered by this Practice: a. Containers with nominal diameters 2 ft (0.6 m) or less b. Containers with volumes less than 100 ft 3 (2.8 m 3 ) c. Bolted containers operating at atmospheric conditions d. Mechanically fastened shell or head courses with or without seal welding e. Non-metallic material f. Fluidized beds g. Non-cylindrical shells h. Containers requirements associated with mechanical agitation by motor-driven blade impellers i. Portable transport containers j. Containers containing lethal substances defined as poisonous gases, liquids, or solids of such nature that a very small amount of the gas, liquid, or solid mixed or unmixed with air is dangerous to life if inhaled or if contacting skin. See Code paragraph UW References Applicable parts of the following Practices, industry codes and standards, and references shall be considered an integral part of this Practice. The edition in effect on the date of contract award shall be used, except as otherwise noted. Short titles are used herein where appropriate. 2.1 Process Industry Practices (PIP) PIP CTSE1000 Application of External Coatings PIP VEDBI003 Documentation Requirements for Bulk Solids Product Containers PIP VEFV1100 Vessel/S&T Heat Exchanger Details (Applicable details are as follows:) PIP VEFV1101 Vessel Nameplate Bracket Process Industry Practices Page 3 of 42

6 PIP VEFV1102 Vessel Tolerances PIP VEFV1103 Vessel Grounding Lug PIP VEFV1116 Vessel Manway Hinges PIP VEFV1117 Vessel Manway Vertical Davit PIP VEFV1118 Vessel Manway Horizontal Davit PIP VEFV1128 Skirt Attachment PIP VEFV1130 Solids Product Container Blend Tube and Shell Interface PIP VEFV1131 Solids Product Container Flush-Mounted Side-Entry Manway PIP VESV1003 Special Fabrication Requirements for Welded Vessels and Tanks to Be Lined PIP STF05501 Fixed Ladders and Cages Details PIP STF05520 Pipe Railing for Walking and Working Surfaces Details PIP STF05521 Details for Angle Railing for Walking and Working Surfaces PIP STF05535 Vessel Circular Platform Details 2.2 Industry Codes and Standards American Institute of Steel Construction (AISC) AISC Allowable Stress Design (ASD) Manual of Steel Construction American Petroleum Institute (API) API 650 Welded Steel Tanks for Oil Storage American Society of Mechanical Engineers (ASME) ASME Boiler and Pressure Vessel Code Section II Materials, Parts A SA-193 Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications SA-194 Specification for Carbon and Alloy Steel Nuts for Bolts for High- Pressure or High-Temperature Service, or Both SA-263 Specification for Stainless Chromium Steel-Clad Plate SA-264 Specification for Stainless Chromium-Nickel Steel-Clad Plate SA-265 Specification for Nickel and Nickel-Base Alloy-Clad Steel Plate SA-480 Specification for General Requirements for Flat-Rolled Stainless and Heat-Resisting Steel Plate, Sheet, and Strip SA-578 Specification for Straight-Beam Ultrasonic Examination of Plain and Clad Steel Plates for Special Applications Section VIII Pressure Vessels, Division 1 (hereinafter noted as Code) Section IX Welding and Brazing Qualifications ASME B16.5 Pipe Flanges and Flanged Fittings ASME B16.9 Factory-Made Wrought Steel Buttwelding Fittings ASME B16.21 Nonmetallic Flat Gaskets for Pipe Flanges Process Industry Practices Page 4 of 42

7 ASME B Large Diameter Steel Flanges (NPS 26 NPS 60) ASME B46.1 Surface Texture, Surface Roughness, Waviness and Lay ASME PCC-2 Repair of Pressure Equipment and Piping American Welding Society (AWS) AWS A2.4 Standard Symbols for Welding, Brazing, and Non-Destructive Examination American Society of Civil Engineers (ASCE) ASCE 7 Minimum Design Loads for Buildings and Other Structures Standard Association of Australia AS 3774 and Supplements 1 and 2 Loads on Bulk Solids Containers British Standards Institute and the British Materials Handling Board Draft Design Code for Silos, Bins, Bunkers, and Hoppers Deutsches Institut fur Normung (DIN) DIN 1055, Part 6 Design Loads for Buildings, Loads in Silo Bins [German Standard] International Conference of Building Officials (ICBO) Uniform Building Code (UBC) Manufacturer s Standardization Society (MSS) MSS SP-6 Standard Finishes for Contact Faces of Pipe Flanges and Connecting End Flanges of Valves and Fittings National Association of Corrosion Engineers (NACE) NACE SP0178 Standard Recommended Practice - Fabrication Details, Surface Finish Requirements and Proper Design Considerations for Tanks and Vessels to Be Lined for Immersion Service Welding Research Council (WRC) WRC Bulletin 537 Precision Equations and Enhanced Diagrams for Local Stresses in Spherical and Cylindrical Shells Due to External Loadings for Implementation of WRC Bulletin Other References ASCE Task Committee on Wind-Induced Forces, Wind Loads and Anchor Bolt Design for Petrochemical Facilities [ISBN ] Buzek, J. R., Useful Information on the Design of Steel Bins and Silos, American Iron and Steel Institute and Steel Plate Fabricators Association, Inc., 1989 Galletly, G. D., Design Equations for Preventing Buckling in Fabricated Torispherical Shells Subjected to Internal Pressure, Proceedings, Institution of Mechanical Engineers, London, Vol. 200, No A2, pp , 1986 Process Equipment Design, Brownell and Young, Wiley and Sons Publishers, 1959 Process Industry Practices Page 5 of 42

8 Jenike, A. W., Johanson, J. R., and Carson, J. W., Journal of Engineering for Industry, Transaction ASME, Series B Vol. 95, No. 1, Feb. 1973, pp Vellozzi, Joseph, Dynamic Response to Wind Loading, U.S. Dept. of Standards 2.4 Government Regulations 3. Definitions U.S. Environmental Protection Agency (EPA) Clean Air Act Amendments of 1990 U.S. Department of Labor, Occupational Safety and Health Administration (OSHA) OSHA 29 CFR (b)(5)(ii) Flammable and Combustible Liquids OSHA 29 CFR Process Safety Management of Highly Hazardous Chemicals OSHA 29 CFR , (K)(3)(ii) Permit-Required Confined Spaces for General Industry angle of repose (poured): The slope of the surface of bulk solids when formed as a pile by pouring solids onto a horizontal plane. The angle is measured from the horizontal plane. This angle is not a flow property. angle of repose (drained): The slope of the top surface of bulk solids when formed by discharging a container that holds the bulk solid. This angle is not a flow property. arching: A no-flow condition in which the bulk solid forms a stable arch across a solids product container. Typically, this arch forms at the bottom outlet opening, but may form at a higher location in the hopper or bin. At a sufficiently large discharge opening, a stable arch cannot be sustained. The terms bridge and dome are also used to describe this condition. bulk density: Weight per unit volume of a material including voids within the particle structure and also including voids between individual particle masses. The bulk density of a material can vary, depending on over-pressurization, vibration, time consolidation, etc. Code: The ASME Boiler and Pressure Vessel Code, Section VIII, Division 1 construction: An all-inclusive term comprising materials, design, fabrication, examination, and testing fabrication: The actual making and assembling of the container and container components from specified materials fluidization: The use of gas flow to permeate the interstitial spaces in bulk solids, making bulk solids act more like a liquid Manufacturer: The party responsible for the construction of a solids product container in accordance with the requirements in this Practice owner: The party who owns the facility wherein the solids product container will be installed and used Process Industry Practices Page 6 of 42

9 Purchaser: The party responsible for establishing construction criteria (e.g., selection of the geometry, loads, etc.) consistent with the philosophy and service hazards, for defining and specifying the mechanical design requirements, and for contracting with the Manufacturer for the fabrication of the container or container components. The Purchaser is also required to assure that all owner requirements are fulfilled. solids product container (or container): Bin, hopper, silo, or blender used to store bulk solids 4. Requirements 4.1 General Overall Responsibilities A solids product container and associated chutes, supports, and internal/external assemblies as specified in the contract documents shall be provided in accordance with this Practice and the following if applicable: a. PIP VEDBI003 including Purchaser s PIP VEDBI003-D Data Sheet b. The Code c. PIP VEFV1100 details: VEFV1101, VEFV1102, VEFV1103, VEFV1116, VEFV1117, VEFV1118, VEFV1128, VEFV1130, VEFV1131 d. PIP STF05501, PIP STF05520, PIP STF05521, and PIP STF05535 e. Other codes and standards referenced in this Practice f. Local requirements g. Other contract documents furnished by the Purchaser If a conflict is identified between this Practice, the design drawings, data sheets, referenced codes and standards, or any supplementary specification, written clarification shall be obtained from the Purchaser before proceeding with any work If this Practice and any datasheets and Purchaser s specifications do not provide enough information to design and construct a complete solids product container, requirements necessary to make the container complete shall be provided by the Manufacturer Licensing and licensing fees associated with the design, fabrication, and/or use of the container shall be provided Before any welding or preparation for welding is subcontracted to another shop or fabricator, approval for subcontracted fabrication work shall be obtained from Purchaser. The Manufacturer shall be responsible for assuring that subcontracted fabrication work is in accordance with this Practice and the contract documents Solids product container and associated chutes, supports, and internal assemblies shall be identified and labeled, e.g., for item numbers or Process Industry Practices Page 7 of 42

10 nameplate content, in accordance with designations furnished by the Purchaser Jurisdictional Compliance The requirements in this Practice and the Code may be substituted by other requirements only by written agreement with the Purchaser All aspects of the work shall be in accordance with the applicable local, county, state, and federal rules and regulations, including but not limited to the rules and standards established by EPA and OSHA, if applicable. See Purchaser s PIP VEDBI003-D Data Sheet Laws, rules, and regulations specific to the site where the solids product container is to be installed shall be considered for all criteria and shall be noted on data sheets, in engineering notes, or in specific site specifications All references to EPA and OSHA may be replaced with national equivalent references that apply at the solids product container installation site Documentation Responsibilities Solids product container documentation shall be provided in accordance with Purchaser s PIP VEDBI003-R Documentation Requirements Sheet Fabrication drawings shall be prepared in accordance with Appendix A Design calculations shall include information in accordance with Appendix B Manufacturer s Data Package shall include the information shown in Appendix C. 4.2 Process Design Effects on Components of Bulk Solids Product Container Types of Flow The type of flow required for the bulk solids container shall be as specified on Purchaser s PIP VEDBI003-D Data Sheet This Practice provides requirements for solids product containers that have only symmetrical flow of solids. Symmetrical flow is the flow pattern that results from a center discharge nozzle with no obstructions that can cause preferential flow from one side of the outlet or from one side of the container Graphical representations of the four major symmetrical flow types are shown in Figure 1. Process Industry Practices Page 8 of 42

11 Type 1 Mass Flow Type 2 Funnel Flow Flow Zone Primary Flow Zone Flow Along Walls Secondary Flow Zones Type 3 Rathole (Pipe Flow) Type 4 Expanded Flow Flow Region Secondary Flow Zones Stagnant Regions Figure 1 Types of Flow Process Industry Practices Page 9 of 42

12 4.2.2 Container Inserts If a container insert (i.e., internal cone or other flow aid) is specified on the Purchaser s PIP VEDBI003-D Data Sheet, the container insert shall be designed for the loads caused by the solids product expected for both static and discharging modes The container and connection members to a container insert (e.g., bolts, flanges, welds, etc.) shall be designed for the dead load of the container insert and any live loads or fatigue loads created by use of the insert (e.g., vibrating bottoms) Internals Design Design shall account for the following forces that may act on supports, blend tubes, etc.: a. Increased radial forces from solids product flow (i.e., increased circumferential stresses) produced by changes in cross-sectional area, such as the presence of internal cones, blend tubes, and shellto-bottom transitions b. Lateral forces from solids product flow within a solids product container area caused by the presence of a gravity blend tube system. These lateral forces impact both the system and the system-toshell/cone intersection. Providing additional reinforcement at the tube-to-wall intersection and blend tube support areas shall be considered. c. Shear forces from solids product flow caused by eccentric outlets. If internal members exist within a solids product container having one or more eccentric outlets, the internal members and member supports shall be designed for the additional shear forces from solids product flow through the outlets For areas where blend tubes, if specified, penetrate a solids product container cone wall, PIP VEFV1130 shall be used to design sloped deflectors on the upstream side between the tube and the cone Methods for Determining Wall Loads For determining unit load values for the design of solids product containers, the methods provided by the following sources can be used with the agreement of the Purchaser for determining load profiles along solids product container walls: a. DIN 1055, AS 3774, A.W. Jenike, et al. (ASME Engineering Journal for Industry) b. Draft Design Code for Silos, Bins, Bunkers, and Hoppers (British Standards Institute and the British Materials Handling Board) Comment: A comparison of these methods can be found in Buzek (1989). An ASME standard is currently under development for design of solids containers but the standards listed in a and b above are the recommended standards for the design. Process Industry Practices Page 10 of 42

13 4.3 Mechanical Design Geometric Configurations The operating capacity, maximum product level, and equipment dimensions shall be in accordance with Purchaser s PIP VEDBI003-D Data Sheet Design Pressure and Temperature The maximum and minimum operating/design pressures and temperatures shall be in accordance with the Purchaser s PIP VEDBI003-D Data Sheet Purchaser-specified design pressures (internal and external) shall be considered minimums The solids product container shall be designed to withstand the specified design pressures and any additional loads (e.g., wind and seismic loads) at both the maximum and minimum design metal temperatures The solids product container shall be designed so that any component in a corroded condition will withstand the test conditions defined in Section without exceeding the allowable stress levels defined in the Code Maximum Design Temperature Coincident With Design Pressure Code paragraph UG-20(a) rules shall be used to determine the coincident maximum design temperature to be stamped on the nameplate A suitable margin consistent with the uncertainties with which the true maximum mean metal temperature can be determined shall be included The maximum design temperature rating shall be increased to the highest temperature possible without affecting the thickness of the shell or heads and without changing the pressure class for the nozzle flanges The maximum design temperature shall not be less than 150 F (65 C) Minimum Design Metal Temperature (MDMT) and Coincident Pressure The minimum design metal temperature (MDMT) shall be shown on the PIP VEDBI003-D Data Sheet The mean metal temperature during shop and future field pressure testing shall also be considered during the solids product container design stage. During the pressure test, the pressure-resisting components and attachments that are welded to pressure-retaining components and judged to be essential to the structural integrity of the container, (e.g., supports), shall have a temperature not less than the MDMT shown on the container drawings and [to be] stamped on the nameplate. Process Industry Practices Page 11 of 42

14 4.3.5 Design Loads and Load Combinations General The solids product container and container supports shall be structurally designed for the loads caused by internal and external factors described in Section without exceeding the allowable stress values and without deforming the container walls Dead and Live Loads (L1) Dead load is the installed weight of the container, including internals, platforms, insulation, fireproofing, piping, and other permanent attachments. This also includes snow load and live load on the roof where applicable Operating Load (L2) 1. Operating load is the weight of the bulk solid at the maximum operating level, including bulk solid on or in container internal structures. 2. The maximum weight of the contained bulk solid product shall be calculated on the basis of the equipment dimensions, the angle of repose of the contained product, and the maximum bulk density of the contained product. 3. If a collapse of arching bulk solid product can impact the container hopper and supporting structure, the container shall be designed for the impact loads as follows: a. Impact loads resulting from collapse of arching shall be considered separately from the operating load. b. Impact loads shall be additive to the equipment dead load. c. Impact loads shall not be considered to act concurrently with wind and seismic loads Pressure Load (L3) 1. Pressure load is the design pressure (internal or external at the coincident temperature), including the pressure drop through the solids product container. 2. For containers with more than one independent chamber, pressure load shall be determined in accordance with Code paragraph UG- 19(a). 3. If fluidization is specified on Purchaser s PIP VEDBI003-D Data Sheet, the container shall be designed for the hydrostatic pressures caused by the contained solids product. The computation of pressures shall be based on the effective hydrostatic head of the product. 4. Overpressure scenarios other than deflagration (e.g., relief pressure, pressure testing, etc.) shall be accounted for in the container design. Process Industry Practices Page 12 of 42

15 5. Deflagration scenario criteria shall be an agreement between Purchaser and Manufacturer including whether permanent deformation is acceptable Thermal Load (L4) Thermal loads are forces caused by the restraint of thermal expansion/interaction of the solids product container and/or its supports Wind Load (L5) 1. The container, container supports, and anchor bolting shall be designed for wind load effects, as determined in accordance with criteria established by the Purchaser. See the PIP VESBI003 Data Sheet. 2. Wind load design requirements for U.S. locations shall be in accordance with ASCE 7. Unless otherwise specified, citations in this Section are to ASCE 7. Comment: Local codes or regulations can require compliance with UBC or other rules for wind load design. 3. A force coefficient (C f) shall be determined in accordance with Table 1. Comment: Force coefficients, formerly called shape factors, are needed to determine wind-induced forces acting on the container. Table 1. Recommended Force Coefficient (C f) Condition A. For all horizontal containers and for vertical containers having a h/d ratio not greater than 1 B. For vertical containers having a h/d ratio greater than 1 (applies to height of container without spoilers) C. For portion of height of vertical containers provided with spoilers C f 0.5 See ASCE 7 Table 6-7 for moderately smooth surfaces See ASCE 7 Table 6-7 for very rough surfaces 4. For determining the wind-induced forces, the projected area of the solids-product container and all appurtenances (e.g., ladders, platforms, handrails, piping, insulation, etc.) shall be accounted for in the projected area calculations. If such appurtenances are present, the wind-induced forces shall be determined in accordance with the Detailed Method described in the ASCE (ISBN ) report or other method as agreed to between Purchaser and Manufacturer. Process Industry Practices Page 13 of 42

16 5. The maximum allowable deflection in the corroded condition at the top tangent line of a vessel shall not exceed 6 inches per 100 feet (150 mm per 30 m) of vessel height. 6. Projected Area: When spoilers are added to a vessel, the column projected area normal to wind, and the corresponding force coefficient, (see Table 1) for the column height where spoilers have been added shall be used when designing the vessel and supporting structure to calculate the overturning load. The column projected area shall be calculated using the projected diameter taken at the outside edge of the spoilers multiplied by the height of the section under consideration. 7. Wind-Induced Vibration of Vertical Vessels: Vessels with an h/d ratio of 15 or greater shall be investigated for dynamic behavior due to wind excitation as described by Vellozzi (see Section 2.4). Other similar proven evaluation methodology may be used. 8. Vortex Shedding Ranges Vessels may vibrate in any of three vortex shedding ranges. a. Lower Periodic Vortex Shedding Range: When the Reynolds number is less than 300,000 and the Strouhal number is approximately 0.2, vibration due to periodic vortex shedding may occur with tall slender vessels that have very low fundamental frequencies. b. Random Vortex Shedding Range: When the Reynolds number is between 300,000 and 3,500,000, random vortex shedding occurs. When the Strouhal number is approximately 0.2, the random vortex oscillations may lock-in and become periodic, causing the vessel to vibrate. c. Upper Periodic Vortex Shedding Range: When the Reynolds number is above 3,500,000 and the Strouhal number is approximately 0.2, self-excited vibration will occur when the natural frequency of the vessel corresponds with the frequency of vortex shedding. 9. Corrective Action: When it has been determined that a vessel may vibrate and the attributes of the vessel (e.g., normal attachments) cannot be changed to put it in a range where vibration will not occur, wind spoilers in accordance with Sections a or b below shall be added to the top-third of the vessel. Such corrective actions shall be approved by the Purchaser. a. Helical Spoilers: Use a three-start system of spoilers in a helical pattern on the top third of the vessel. An optimum configuration consists of spoilers with an exposed width beyond insulation of 0.09D and a pitch of 5D, where D is the diameter of the top third of the vessel. The spoiler system may be interrupted to provide clearance at vessel appendages. Process Industry Practices Page 14 of 42

17 b. Short Vertical Spoilers: Use a three-start system of short vertical spoilers arranged in a helical pattern on the top-third of the vessel. The exposed width beyond insulation of the spoilers should be 0.09D and the pitch (height of one helical wrap) between 5D and 11D. There should be a minimum of eight (8) spoilers over the pitch distance (each complete helical wrap) and a minimum of 1.5 helical wraps, if possible, over the top-third of the vessel. The spoiler system may be interrupted to provide clearance at vessel appendages Seismic Loads (L6) Unless specified otherwise on Purchaser s PIP VEDBI003-D Data Sheet, the container shall be designed for seismic loads described in ASCE-7, and the Data Sheet. Comment: Local codes or regulations may require compliance with UBC or other rules for seismic design Test Load (L7) 1. Test load is the weight of the test medium. See Purchaser s PIP VEDBI003-D Data Sheet for the test medium. 2. Unless otherwise specified on Purchaser s PIP VEDBI003-D Data Sheet, the solids product container design shall be based on testing the container in its normal operating position Piping and Superimposed Equipment Loads (L8) Specified loads, and loads determined by Manufacturer, that are caused by piping (i.e., pneumatic conveying and other piping), and loads caused by superimposed equipment shall be accounted for in the design Dynamic Mechanical Loads (L9) Dynamic mechanical loads, if specified on Purchaser s PIP VEDBI003- D Data Sheet, are those caused by vibrators, air pulsation, agitators, flow aids, dischargers, etc Lift Condition 1. Unless otherwise specified on Purchaser s PIP VEDBI003-D Data Sheet, a minimum impact factor of 2.0 shall be applied to the lift weight for designing lifting attachments. 2. The basis for the lift weight shall be established during the design phase of the container so that the design of lifting attachments comprises all components to be included in the lift (e.g., trays, ladders/platforms, insulation, additional piping with insulation, etc.). 3. For containers having h/d ratios greater than 8 and weighing more than 25,000 lbs (11,340 kg), the following shall apply: a. Bending stresses from loads imposed during the lift from the horizontal to vertical position in the container shell/skirt shall be checked. Process Industry Practices Page 15 of 42

18 b. Calculated general primary membrane tensile stress shall not be greater than 80% of the material s specified minimum yield strength at 100ºF (38ºC). c. Calculated compressive stress shall not be greater than 1.2 times the B factor obtained from the Code. d. The design of the container for the lift condition shall be based on a wind speed no less than 33% of the basic wind speed. 4. For the imposed loads using an impact factor of 2.0, local stresses in the container shell/head/skirt/base rings from the lifting attachments (e.g., lugs, trunnions, etc.) shall be determined using local stress analysis procedures (e.g., WRC Bulletin 537) or other accepted local stress analysis procedures (e.g., finite element analysis). a. For the rigging condition, the allowable stresses shall be 1.5S for local primary membrane stress and 3S for primary membrane plus secondary bending stress. S shall be the Code-allowable stress at the design temperature. b. Shear stresses for fillet welds on the lifting attachments to the container shell/head shall not be greater than 0.55 times the Code-allowable stress at 100 F (38 C) for the material selected Load Combinations The container and its supports shall be designed to meet the most severe of the following load combinations: a. L1+L5 = Erected condition with full wind load b. L1+L2+L3+L4+L5+L8+L9 = Design condition with full wind load. Both full and zero pressure conditions [L3] shall be included for check of maximum longitudinal tensile and compressive stress. c. L1+L2+L3+L4+L6+L8+L9 = Design condition with full seismic load. Both full and zero pressure conditions [L3] shall be included for check of maximum longitudinal tensile and compressive stress. d. L1+ L3+(0.25) L5+L7 = Initial (i.e., new uncorroded) test condition and future (i.e., corroded) test condition with container in normal operating position and with 50% of basic wind speed (i.e., 25% of wind load) For this load combination, the general primary membrane tensile stress in the corroded condition, or if a corrosion allowance is not specified, shall not be greater than the following: 1) For carbon and low-alloy steels, 90% of the specified minimum yield strength at 100 F (38 C) 2) For austenitic stainless steels and aluminum, the specified minimum yield strength at 100 F (38 C) e. Lift Condition = See Section of this Practice. Process Industry Practices Page 16 of 42

19 4.3.6 Solids Product Container Support Systems See Purchaser s PIP VEDBI003-D Data Sheet, sketches, and/or drawings for type of solids product container support (e.g., skirt, legs, lugs, rings) Allowable design stresses for all container support components shall be in accordance with the Code for container pressure components For container supports outside the scope of the Code, either Codeallowable stresses or, for structural shapes, allowable stresses in accordance with AISC may be used For combinations of earthquake or wind loadings with other loadings listed in Code, paragraph UG-22, the following shall apply: a. The allowable stresses may be increased in accordance with Code, paragraph UG-23(c). b. See Section for load combinations to be considered. c. See Code Appendix G for guidelines on procedures for calculating stresses on attachments. d. For structural-shape support members in compression if slenderness ratio is a controlling design consideration, an increase in the allowable compressive stress shall not be permitted Stresses resulting from direct (through-thickness) bending in support and support ring base plates shall not be greater than 1.5 times the Codeallowable tensile stress values Compressive stresses in support rings and lug gussets and other compression members shall not be greater than 1.25 times the Codeallowable tensile stress values Support skirts attached to the bottom head shall have the skirt butted to the outer portion of the head such that the outer diameter of the shell and the outer diameter of the skirt coincide. The attachment shall be by a continuous weld, sized to accommodate the maximum imposed loads and in accordance with PIP VEFV Support skirts created by extending the shell below the bottom head to shell weld joint shall be in accordance with PIP VEFV For containers that are supported on load cells, see Purchaser s PIP VEDBI003-D Data Sheet for design requirements and any special details required Top Head Shallow conical heads and dished-only heads, including compression rings, identified within the scope of API 650 and with pressure ratings of 2.5 psig (17.2 kpa) maximum shall be designed in accordance with API 650 and API 650 allowable stress values Head designs other than those identified within the scope of API 650 and with pressure ratings greater than 2.5 psig (17.2 kpa) shall be in accordance with the Code and Code allowable stress values. Process Industry Practices Page 17 of 42

20 4.3.8 Shell Roofs without operator platforms shall be designed for a minimum live load of 20 psf (1.0 kpa) plus any snow load The contained solids product can exert upward forces on the top head of the container if overfilled and (1) the material is fluidized or (2) the top head has an angle with the horizontal plane that is greater than the minimum angle of repose for the product. If specified on the PIP VEDBI003-D Data Sheet, the top head shall be designed to withstand the forces exerted by the product. See Australian Code for force calculations Additional specified concentrated roof loads from top-mounted equipment (e.g., bin vents, cyclones, relief devices, etc.) shall be considered If a standard flanged and dished head is specified, the following apply: a. The inside crown radius shall not be greater than the outside diameter of the straight flange. b. The inside knuckle radius shall not be less than three times the minimum specified head thickness after forming. c. The minimum head thickness after forming shall be calculated in accordance with the Code For a formed torispherical head if specified, to prevent internal pressureinduced buckling of a head that is large diameter and thin (i.e., ratio of spherical or crown radius-to-required head thickness greater than 300), a design check of the Code-required thickness shall be performed. Comment: An acceptable design check method (among several that have been published) is listed by Galletly in Design Equations for Preventing Buckling in Fabricated Torispherical Shells Subjected to Internal Pressure. This check can reveal the need for a head thickness greater than the Code-required minimum thickness. The Code also has rules in 1-4(f) If approved by Purchaser, the diameter and straight side dimensions of the solids product container may be varied slightly to better utilize plate dimensions and available head diameters to provide more economical fabrication Shell design shall include the wall pressure induced by mass flow or funnel flow of solids on the basis of the flow test data specified. See Purchaser s PIP VEDBI003-D Data Sheet or paragraph if no loads are specified Shell design shall consider forces that can result from eccentric flow patterns created by flow through blend tubes, side discharge nozzles, etc. The method used to determine bulk loads for the purpose of the container design shall be agreed with Purchaser. Process Industry Practices Page 18 of 42

21 The solids product container shall resist the axial load on the shell and hopper walls induced by vertical friction from the contained solids product. This internal dead load is additive to other dead loads (e.g., weight of the containing walls and roof above the support point), and to external live loads (e.g., wind and seismic loads) The total axial load shall be used to calculate the tensile and compressive stresses at the point of support, other critical points (e.g., bottom cone-toshell intersection), and all other discontinuities For mass flow designs, all internal longitudinal weld surfaces shall be provided with a ground smooth finish, and all circumferential weld surfaces shall be provided with a ground smooth finish having a maximum crown height the lesser of 1/8 inch (3 mm) or 25% of the wall thickness For mass flow designs, all internal weld surface finishes (i.e., ground smooth ) shall be in accordance with NACE SP0178, Appendix C If walls of the container are of different thickness, a constant inside diameter shall be maintained Code-required stiffening rings for shells under external pressure shall be placed on the outside of the container, have a thickness not less than 3/8 inch (19 mm), and have a ring width-to-thickness ratio not greater than 10. Stiffening rings shall be attached in accordance with the Code, paragraph UG Bottom Conical and toriconical head design shall be in accordance with the Code and Code allowable stress values For flat, chisel, and double cone bottoms, including geometric transition pieces, finite element modeling or another type of in-depth analysis shall be used to design these components as agreed with Purchaser The weld surface finishes (e.g., ground flush ) shall be in accordance with NACE SP0178, Appendix C, as specified on the Purchaser s PIP VEDBI003-D Data Sheet Shell-to-Bottom Joint (Skirt Ring) The shell-to-bottom joint shall be designed in accordance with the Code and Code allowable stress values Code paragraph 1-5 shall be used for the design of reinforcement for internal pressure Code paragraph 1-8 shall be used for the design of reinforcement for external pressure The shell-to-bottom joint can experience a large increase in stresses caused by the flow of the contained solids product. This peak stress shall be accounted for in the design of the joint and its reinforcement. The methods in paragraph or other advanced analysis techniques may be used to calculate these stresses. Process Industry Practices Page 19 of 42

22 Container Connections Flange configurations for nozzle and body sizes NPS 24 (DIN 600) and less shall be as follows: a. Flanges shall be in accordance with ASME B16.5. b. Permanent blind covers shall be in accordance with ASME B16.5 or designed in accordance with the Code, paragraph UG-34. c. Gaskets shall be in accordance with ASME B d. Flanges designed in accordance with the Code, Appendix 2, shall be permitted if the bolting dimensions and pattern are in accordance with ASME B Flanges for nozzle and body sizes greater than NPS 24 (DIN 600) shall be designed in accordance with the Code, Appendix 2, with bolting dimensions and pattern in accordance with ASME B16.47, Series B flanges or shall be B16.47 Series B flanges. Minimum design pressure shall be 50 psig (170 kpa) Lap joint flanges NPS 24 (DIN 600) and less shall be in accordance with ASME B16.5. The nominal outside diameter of laps shall be the same as the raised face diameter in ASME B16.5 standard flanges Flange configurations for manways shall be as follows: a. Flanges shall be designed in accordance with the Code, Appendix 2 or shall be in accordance with ASME B16.5 or B16.47 Series B. b. Manway covers shall be blinds designed in accordance with the Code, paragraph UG-34. c. Minimum design pressure for manway flanges and covers shall be 50 psig (170 kpa). d. Side-entry manways shall be provided with flush-plugs in accordance with PIP VEFV If nozzle loads are specified, see Section or PIP VEDBI003 for the method required to consider these loads Custom-designed flanges in accordance with Code, Appendix 2 shall be designed using the following bolting requirements: a. Bolts shall be SA-193, Gr. B7 stud bolts with SA-194 2H nuts. Minimum diameter is ¾ inch (M20) b. 1-inch and larger diameter bolts shall have 8 threads per inch. c. Bolts shall have rolled threads. d. The design of custom flanges shall include the effect of bolt spacing per the following: 1) Maximum bolt spacing = 2a + 6t/(m+0.5) Process Industry Practices Page 20 of 42

23 2) If bolt spacing exceeds (2a + t), the design moment (Mo) acting on the flange shall be multiplied by Bolt space correction factor = (B s/(2a + t)) 0.5 where: M o, and m are as defined in Code Appendix 2, Paragraph 2-3; a = nominal bolt diameter, inches (mm) B s = actual bolt spacing, inches (mm) t = minimum finished flange thickness, exclusive of corrosion allowance, inches (mm) e. Unless otherwise approved by Purchaser, total number of bolts shall be divisible by 4 and shall straddle centerlines. f. See Appendix D for the method for considering significant mechanical loads other than pressure Minimum radial distance for wrench clearance for custom design flanges shall be as follows: a. 1-1/8 inch (28 mm) for 3/4 inch (M19) diameter bolts b. 1-1/4 inch (32 mm) for 7/8 inch (M22) diameter bolts c. 1-3/8 inch (35 mm) for 1 inch (M25) diameter bolts d. 1-1/2 inch (38 mm) for 1-1/8 inch (M28) diameter bolts e. 1-3/4 inch (44 mm) for 1-1/4 inch (M32) diameter bolts If lap joint flanges are specified, the following shall apply: Minimum finished thickness of custom-designed lap joint welding ring for flanged connections shall not be less than the following: 1) The T dimension shall be in accordance with ASME B16.9 for cylinder sizes less than NPS 24 (DIN 600). 2) The nominal thickness of the cylinder wall to which the welding ring is to be attached a required by Code. a. The cylinder wall shall be greater than 3/16 inch (4.8 mm) for cylinders NPS 24 (DIN 600) and greater. Comment: This thickness permits possible future re-machining of the lap and should be sufficient to permit the lap to be machined front and back, if necessary, to maintain parallel surfaces after repair Stub ends fabricated by the Manufacturer are not required to be marked in accordance with ASME B16.9 if the stub ends are in accordance with the Code For flanged connections NPS 24 (DIN 600) and less, the dimensional fitting requirements shall be in accordance with ASME B16.9 except the length may be changed to eliminate an additional weld. Process Industry Practices Page 21 of 42

24 Standard flanges and factory-made stub ends shall have a surface finish in accordance with ASME B16.5 or ASME B16.47, as applicable Unless otherwise specified on the Purchaser s PIP VEDBI003-D Data Sheet, standard flanges in service requiring special consideration, custom flanges, and shop-fabricated lap-joint stub ends shall have gasket-bearing surfaces finished as follows: a. Serrated concentric or serrated spiral surface finish of micro-inch (3.2 to 6.4 micro-meter) roughness average, in accordance with MSS SP-6 or as recommended by the gasket manufacturer b. Radial tool marks or scratches shall not be permitted. c. The finish shall be judged by visual comparison with Ra standards in accordance with ASME B46.1 and not by instruments having stylus tracers and electronic amplification If proposed, applied metallic linings for gasket-bearing surfaces shall be: a. Approved by Purchaser b. The design and welding details shall be submitted for approval by Purchaser. c. Finished thickness shall be 3/16 inch (5 mm) minimum Flange stops shall be provided below loose flanges on vertically oriented nozzles and container cylinders Studding pads (i.e., pad flanges) shall have bolting dimensions in accordance with the following standards: a. NPS 24 (DIN 600) and less: ASME B16.5 b. Greater than NPS 24 (DIN 600): ASME B16.47, Series B The flange assembly data for the following gasketed components shall be included on the Manufacturer drawings: a. Joints and nozzles NPS 16 (DIN 400) and greater b. Body joints NPS 10 (DIN 250) and greater c. The flange assembly procedure. See Appendix D for the required flange assembly bolt torque procedures Nozzles NPS 18 (DIN 450) and larger and man-ways NPS 24 (DIN 600) and larger with blind covers shall be equipped as follows with either a davit or hinge to facilitate handling of the blind flange: a. If the nozzle neck axis is oriented horizontally, a hinge shall be provided in accordance with PIP VEFV1116, or a davit shall be provided in accordance with PIP VEFV1117. For lap joint flanges, the davit socket bracket shall be attached to the nozzle neck. Process Industry Practices Page 22 of 42

25 b. For the top of a container with a nozzle neck axis oriented vertically, a davit shall be provided in accordance with PIP VEFV Nozzle projections shall be provided in accordance with the following: a. Minimum projection: 1) For NPS 6 (DIN 150) nozzles and less, 6 inches (150 mm) 2) For NPS 8 (DIN 200) nozzles and greater, 8 inches (200 mm) b. Nozzle projection dimensions shall be shown on the container drawings in accordance with the following: 1) Length of projection measured from container or container jacket outside diameter 2) Angle of projection referenced from the normal container centerlines to the face of the nozzle gasket-bearing surface c. If insulation is specified, a minimum wrench clearance of 2 inches (50 mm) shall be provided between the outside of the insulation and the end of the flange studs Analysis of nozzle loads shall be conducted as follows: a. For static nozzle loads, other than from agitators, analysis shall be in accordance with WRC Bulletin 537. The allowable stresses shall be 1.5S for local primary membrane stress and 3S for primary membrane plus secondary bending stress. S shall be the Code allowable stress at design temperature. b. For special nozzle loads (e.g., dynamic and thermal) specified by the Purchaser, a higher level of analysis shall be conducted as approved by Purchaser Minimum size connection shall be NPS 1.5 (DIN 40) Nozzle and manway openings shall not be made in weld seams The need for reinforcement shall be determined for all openings larger than NPS 2 (DIN 50) in accordance with the Code, paragraph UG All inside edges of nozzles, manways, and other connections shall be rounded to a minimum ¼ inch (6 mm) radius Gaskets For standard gaskets, gasket dimensions shall be in accordance with ASME B16.21 unless otherwise approved by Purchaser. Process Industry Practices Page 23 of 42