Expansion Joint Data Sheet and Technical Specification for FCC Units

Transcription

1 Expansion Joint Data Sheet and Technical Specification for FCC Units Colaboração de Medeiros e Nunes da Petrobras 1. PURPOSE This specification establishes the minimum conditions required for design and fabrication of a packed metallic bellows universal expansion joint for the flue gas system of the FCCU-Fluid Catalytic Cracking Unit. The corresponding expansion joint data sheet follows in continuation to this specification. 2. GENERAL CONDITIONS 2.1. All deviations and exceptions from the specification shall be clearly identified in the proposal and submitted for approval. Otherwise the proposal will be considered as full acceptance of the specification, and no work regarding such non-conformities shall be performed The bidder shall submit information about the size, and thickness of the bellows, the material of all parts, the design movements, the bellows spring rates, and overall dimensions of the expansion joint. Constructional details specified in this technical specification, as well as on the data sheet shall also be submitted Compliance with this specification does not exempt vendor from the responsibility of supplying any accessories suitable for the intended service Vendor shall guarantee that the expansion joint is free from defects of workmanship, materials and design for a period of one year from the unit start-up or two years after shipment, whichever occurs first The manufacturer shall provide a supply list of similar applications in FCC units for petroleum industry, with, at least, five years of operation The manufacturer shall provide a recommended spare parts list with the proposal The schematic drawing shown on the last sheet of this specification is to be used as a reference only. Vendor shall provide all the features considered necessary to achieve the minimum requirements established herein All work shall conform to acceptable practice for refinery and process plant installations as well as comply with required codes and standards mentioned in item 3 below. Any conflict between specifications, recommended practices, and codes or standards shall be brought to the attention of and resolved with the OWNER before proceeding with the fabrication of the affected parts. 3. CODES AND STANDARDS The following codes and standards shall apply: 3.1 ASME Code Se II Materials 3.2 ASME Boiler and Pressure Vessel Sec.VIII Div.1; 3.2. ASME Code Section IX Welding ; 3.3. ASME B16.5 Pipe Flanges and Flanged Fittings NPS ½ through 24; 3.4. ASME B31.3 Process Piping; 3.5. ASTM C795 Standard Specification for Thermal Insulation for Use in Contact with Austenitic Stainless Steel; 3.6. ASTM E94 Standard Guide for Radiographic Examination; 3.7. EJMA Standards; 3.8. PETROBRAS Standard N-2 Anticorrosive Coating of Industrial Equipment; 3.9. PETROBRAS Standard N-133 Welding; PETROBRAS Standard N-1617 Application of Refractory Castable; PETROBRAS Standard N-1728 Concreto Refratário ; PETROBRAS Standard N-1910 Castable Lining Design. 4. REFERENCE DOCUMENTS 4.1. Expansion Joint Data Sheet. petroblog-santini Fl. 1/9

2 5. GENERAL REQUIREMENTS 5.1. The expansion joint referred to in this specification shall be a universal type expansion joint with packed metallic bellows and provided with pantographic linkages The expansion joint shall be cold wall design, with a double layer refractory lining applied to its inside surface The refractory material shall be specified, supplied and installed according to PETROBRAS Standards and Specifications. A typical refractory-lined expansion joint detail is shown on the schematic drawing mentioned in item A typical packing detail for metallic bellows is also presented on the schematic drawing above mentioned. Packing requirements are defined in item All pressure containing and structural parts shall be in accordance with the Process Piping Code (ASME B31.3). Special items to be designed by analysis shall be in accordance with ASME Sec.VIII Div Supplier shall provide any necessary supporting device and lifting lugs to expansion joint. Supporting device shall be designed for minimum and easy maintenance Supplier shall supply electronic files of the following drawings and data reports for installation, maintenance and records purposes: a) Certified fabrication drawings of the equipment, showing complete longitudinal section and cross section, overall dimensions, bellows dimensions and details, bellows spring rates, cold clearances and construction materials of supplied expansion joint. When transportation bars or rods are supplied, the drawings shall contain instructions as to removal of such devices prior of plant operation. b) Calculation report, including: EJMA calculation, FEM Finite Element Analysis reports for thermal and structural analysis, whenever this calculation is performed The criteria to establish the design allowable stress shall consider the accumulated creep damage due to upset temperatures The expansion joint supplier shall provide all necessary data for mechanical assessment of the existing piping system, considering expansion joint reaction, such as: spring rate, expansion joint weight, bellows effective area or mean diameter of bellows corrugations, and geometrical data. The rated movements and other expansion joint limitations shall also be informed The specified axial, offset and rotation movements shall be available simultaneously, unless otherwise noted The design life of the expansion joint shall be at least 1,000 cycles at design condition Internal sleeves shall be installed to minimize catalyst volume trapped in, and the erosion action of catalyst impingement on bellows. These sleeves shall be designed so as to avoid interferences caused by lateral deflections and rotations, and shall not reduce the internal flow area. 6. PACKING AND SEALING REQUIREMENTS 6.1. The spaces between the internal sleeves and the metallic bellows shall be packed with ceramic fiber blanket insulation. The ceramic fiber insulation shall be installed in blanket form and shall be in accordance with ASTM Specification C795. The insulation dimensions shall be determined to avoid temperature above bellows material limits, and catalyst impingement 6.2. An external protection of woven wire mesh covered with a layer of aluminized fiberglass or silica cloth shall be provided with the ceramic fiber blanket, for mechanical sealing and easy handling. Alternative methods may be accepted, but shall be submitted for approval A heavy duty liner seal shall be provided in order to retain the ceramic fiber blanket and keep large particles out of the bellows/liner cavity. This liner seal shall be made of a 309 SS knitted wire hope, covered with a 309 SS hose braid. The petroblog-santini Fl. 2/9

3 liner seal shall be one-piece continuous circular section provided with only one splice The diameter of the liner seal shall be 1½ times the specified clearance in the radial direction for the expansion joint in the cold position before preset The liner seal shall be anchored by means of a seal rod, which is a U shaped clip, made of 309 SS, to be annealed after forming. As an alternative two retaining rings could be used The inner sleeve shall be connected to the shell by means of a conical transition with a 30 max. lateral angle Each sleeve shall be installed so that its free end is turned towards the expansion joint flow exit (downstream) end. 7. SPECIFIC REQUIREMENTS 7.1. The expansion joint shall be provided with double ply testable bellows, as follows: Each bellows ply shall be designed for the full design condition. The redundant ply shall guarantee the performance and sealing of the expansion joint in case of primary ply failure. Each expansion joint bellows shall be provided with a pressure sensor between the plies, for testing and detection of internal ply failure. The double ply assembly shall be configured to avoid galling or any obstruction that interfere on pressure reading. 7.2 Metallic bellows skin temperature shall range from 250 C to 450 C. Manufacturer shall provide proper external and internal blanket thermal insulation in order to achieve this range. This blanket shall be shop applied. 7.3 Supplier shall provide means of monitoring the bellows skin temperature. 7.4 Composite bellows plies are not allowed. 7.5 Bellows material shall be ASTM B433 alloy 625 LCF. 7.6 Bellows minimum thickness: 1.27 mm. 7.7 The number of convolutions per bellows shall be not less than three. 7.8 Bellows shall be protected by removable external covers with 6mm minimum thickness. 7.9 Whenever requested, equalizing or reinforcing rings shall be used, otherwise the manufacturer must justify why they are not used Besides equalizing the movement between the bellows, the pantographic linkage shall also be designed to withstand the total weight of the intermediate pipe spool Torsion loads (movements) shall not be transferred to metallic bellows Expansion joints shall be provided with movement indicators The expansion joint design shall be such as to allow easy access to any bellows, for inspection and maintenance purposes. 8. TAGGING 8.1. Expansion joint tag:???? 9. FABRICATION, EXAMINATION, INSPECTION AND TEST REQUIREMENTS 9.1. During the expansion joint fabrication and tests, inspection may be made by OWNER or by OWNER designated third part, to determine work in progress and check specification compliance Bellows shall be formed from longitudinally buttwelded cylinders. The maximum number of bellows longitudinal buttwelds for the expansion joint concerning this specification shall be 4. Adjacent longitudinal welds shall be no closer than 130 mm apart. The finished longitudinal welds are to be of the same thickness (-0% +10%) and same surface finish as the parent material. Circumferentially welded seams shall be prohibited All expansion joint welds shall be full penetration and smooth finished, with no undercut or lack of fusion. petroblog-santini Fl. 3/9

4 9.4. All retaining pressure welds shall be submitted to 100% radiographic examination or, alternatively, 100% ultrasonic examination, where the ASME B31.3 Code allows All internal welds, fillet and attachment welds shall be submitted to dye penetrant examination Bellows longitudinal welds referred to in item 9.2 shall be 100% radiographed and liquid-penetrant examined on outside and inside surfaces, prior to forming. Liquid penetrant examination on all surfaces shall be repeated after forming When the surface examined is of austenitic alloy steel or nickel-iron-chromium alloy materials having a design metal temperature above 400 C, the liquid penetrant material shall be tested for sulphur content and the surface shall be properly cleaned after completion of testing Welding procedure and qualification certificate shall be submitted for OWNER approval The fabricator shall scarf and otherwise prepare the welding ends that are to be welded by others All weld bevels on the ends of carbon or ferritic alloy steel piping components that are to be welded by others shall be coated on the inside and outside for a distance of 76 mm from the end of the component with a suitable protective product The welding process shall be according to ASME Section IX The fabricator shall provide heat treatment procedures, taking into account the risk of sensitization and sigmatization of the austenitic stainless steel parts Mill test reports shall be submitted for all materials and weld consumable Upon completion of all fabrication, the fabricator shall pressure test the expansion joint assembly. Before pressure testing, all internal surfaces of the expansion joint shall be cleaned so that it will be free of welding slag and flux, weld rod studs, loose scale, dirt and debris. Potable water with less than 5 ppm chlorine shall be used for hydrostatic testing. The expansion joint shall be drained and dried After pressure testing all openings shall be closed, sealed or covered to prevent access of water, dirt or corrosive dusts and vapors during shipment and site storage All defects requiring repair shall be corrected in accordance with the applicable code The expansion joint shall be painted according to OWNER Standard, up to 76 mm from each expansion joint end. Special high temperature indicating painting shall be used Refractory lining application shall be according to PETROBRAS standards N and N Inspection, examination and tests shall be according to ASME B31.3 Code and EJMA Standards. Expansion joint shall be tested at shop For 304 SS parts, the welds shall be with ER-308H electrodes 15/16 coating and ferrite control to be 3% to 8% FN Delong examination. 10. INSTALLATION REQUIREMENTS The expansion joint shall be delivered with shipping devices for transportation, temporary supports during installation, and field pressure test Spare parts shall be delivered clearly identified with name and part number The expansion joint shall have a name plate of corrosion resistant material informing: tag number, service, operating and design conditions, pressure test, manufacturer, purchase order number, year of fabrication and total weight Two flow direction indicators shall be placed on the external shell, 180 apart from each other. petroblog-santini Fl. 4/9

5 SCHEMATIC DRAWING REFRACTORY LINED PACKED MTALLIC BELLOWS EXPANSION JOINT MATERIAL LIST ITEM DESCRIPTION MATERIAL 1 Bellows ASTM B443 Alloy 625 LCF 2 Thermal insulation By manufacturer 3 Woven wire mesh AISI Removable cover Carbon steel 5 Pipe ASTM A672 Gr. C60 Cl mm thk. refractory lining Class A insulating refractory, according to PETROBRAS standard N Refractory anchor to be square head type studs, made of 304 SS. 7 Blanket insulation Ceramic fiber 8 Heavy duty liner Seal AISI U clip AISI Hexagonal mesh AISI mm thk refractory lining Class A antierosive refractory, according to PETROBRAS standard N-1728, similar to RESCO AA mm thk internal sleeve ASTM A240 TP Woven wire mesh AISI 304 petroblog-santini Fl. 5/9

6 EXPANSION JOINT DATA SHEET 1. PURPOSE This data sheet establishes the design data of an expansion joint for the flue gas system of the Fluid Catalytic Cracking Unit. 2. REFERENCE DOCUMENTS AND STANDARDS 3.1 EXPANSION JOINT TECHNICAL SPECIFICATION. petroblog-santini Fl. 6/9

7 1 TAG Identification To be informed latter 2 Quantity To be informed latter 3 Expansion Joint Type Universal type expansion joint with packed metallic bellows provided with pantographic linkages 4 Diameter (mm) To be informed latter 5a Fluid Description GAS AND CATALYST FINES 5b Density (kg/m 3 ) 5c Flow Rate (kg/s) To be informed latter 5d Flow Direction To be informed latter 6a Operating Conditions Pressure (kgf/cm²g) To be informed latter 6b Temperature ( C) To be informed latter 6c Room Temperature ( C) To be informed latter 7a Design Conditions Pressure (kgf/cm²g) To be informed latter 7b Temperature ( C) To be informed latter 7c Life Cycles a Emergency Conditions Pressure (kgf/cm²g) To be informed latter 8b Temperature ( C) To be informed latter 8c Duration 10 h/year 9 Test Pressure (kgf/cm²g) To be informed latter 10a Maximum Installation Axial Compression (mm) To be informed latter 10b Movements Axial Extension (mm) To be informed latter 10c Lateral (mm) To be informed latter 10d Angular (deg.) To be informed latter 11a Maximum Design Axial Compression (mm) To be informed latter 11b Movements Axial Extension (mm) To be informed latter 11c Lateral (mm) To be informed latter 11d Angular (deg.) To be informed latter 11e Number of Cycles a Operating Fluctuations Axial Compression (mm) To be informed latter 12b Axial Extension (mm) To be informed latter 12c Lateral (mm) To be informed latter 12d Angular (deg.) To be informed latter 12e Number of Cycles To be informed latter 13 Rods (Tie/Limit/Control) Yes see note 14 Pantographic Linkage Yes 15 Internal Sleeve Yes 16 External Cover Yes 17 Equalizing and Reinforcing Rings By manufacturer 18 Purge Connections No 19 Shipping Devices By manufacturer 20 Internal Lining Yes (See note) 21 External Insulation No 22 Ends (Welded / Flanged) Welded 23a Dimensional Limitations Overall Length (mm) To be informed latter 23b Outside Diameter (mm) To be informed latter 23c Inside Diameter (mm) To be informed latter 24a Spring Rate Limitations Axial (N/mm) By manufacturer 24b Lateral (N/mm) By manufacturer 24c Angular (N.m/deg.) By manufacturer petroblog-santini Fl. 7/9

8 25 Installation Position (Horiz or /Vert.) To be informed latter 26 Vibration Amplitude / Frequency of the piping To be informed latter 27a Materials of Bellows ASTM B-433 Alloy 625 LCF 27b Construction Material pipe specification As specified above 27c Flange Specification As specified above 27d Internal Sleeve ASTM A 240 Gr. 304H 27e Cover Carbon Steel 27f Rods By Manufacturer 27g Equalizing Rings By Manufacturer 27h Reinforcing Rings By Manufacturer 27i Internal Lining See note 28a Quality Assurance Code ASME B31.3 and EJMA 28b Requirements Additional Requirements To be informed latter 28c Technical Specification As specified above NOTES: 1. The manufacturer shall take into account dimension limitations inherent to the available room. 2. The expansion joint shall be cold wall, packed metallic bellows type, in accordance with the technical specification as specified above. 3. Tie rods shall be provide, to avoid that pressure thrust and spring loads be transferred to the adjacent equipments. 4. Final dimensions shall be established with the OWNER. 5. The diameter and arrangement of the tie rods will be checked by the OWNER to make sure that expansion joint will achieve its purpose. 6. The expansion joint shall be supplied with suitable allowance concerning the length, for field adjustment. 7. Manufacturer shall establish the expansion joint transverse dimensions taking into account the installation of tie rods. 8. The procedure for refractory lining application shall be submitted to OWNER for approval, and all application work shall be performed under supervision of OWNER technicians. 9. Duration of the emergency conditions: 10 h/year. 10. Pressure and temperature emergencies should not be considered as occurring simultaneously. 11. Manufacture shall inform the expansion joint spring rates. petroblog-santini Fl. 8/9

9 Schematic drawing of a Universal type expansion joint with packed metallic bellows provided with pantographic linkages petroblog-santini Fl. 9/9