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Engineering Design Basis – Static

Equipment [Security Level2]
TOYO Project Doc. No.: Page 1 of 26
Work No.: 6447 6447-D8-E0-MS-SPC-0001-A4 Date: 27-Jul-23

Asian Paints (Polymers) Private Limited

Dahej Project

Green field
Vinyl Acetate Ethylene Emulsion (VAE),
Vinyl Acetate Monomer (VAM) and Offsite & Utilities
In Dahej, Gujarat, India

Engineering Design Basis – Static

Equipment.

Digitally signed
2 by Umair
Haidery
Digitally signed by
abhijit
Date: 2023.07.28
16:50:57+05'30'
Digitally signed by
Mr. Mangesh
Lokhande
AM Batte
1 27-Jul-23 For Approval UMH AKG MYL AMB

0 27-Apr-23 For Approval UMH AKG MYL AMB

ISSUE
REV DATE ISSUED PREPARED CHECKED APPROVED AUTHORIZED
PURPOSE

THIS VOLUME EMBODIES PROPRIETARY INFORMATION OF TOYO ENGINEERING INDIA PRIVATE LIMITED. THIS VOLUME OF THE
MATERIAL DESCRIBEDTHEREON MAY NOT BE COPIED OR DISCLOSED IN ANYFORM OR MEDIUM TO THIRD PARTIES, OR USED FOR
OTHER THAN THE PURPOSE FOR WHICH IT HAS BEEN PROVIDED, IN WHOLE OR IN PART IN ANY MANNER EXCEPT AS EXPRESSLY
PERMITTED BY TOYO ENGINEERING INDIA PRIVATE LIMITED.
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Revision History

Rev. Remarks

0 First Issue

1 • Owner Logo has been added.

• Clause 2.6.b revised as per APPPL comment.
1
• Clause 2.9 revised as per APPPL comment.
1
• Clause 2.19 revised as per APPPL comment.
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Table of Contents

1.0 GENERAL: ........................................................................................................................................ 5

1.1 SCOPE:................................................................................................................................................................ 5
1.2 REFERENCES: ...................................................................................................................................................... 5
1.3 ABBREVIATIONS: .................................................................................................................................................. 5
1.4 ORDER OF PRECEDENCE: ..................................................................................................................................... 5
1.5 STATUTORY REQUIREMENTS, LOCAL REGULATIONS AND LAWS: ............................................................................. 6
1.6 CODES & STANDARDS / PUBLICATIONS:................................................................................................................. 6
1.7 UNITS OF MEASUREMENT: .................................................................................................................................... 8

2.0 DESIGN CONDITIONS: ..................................................................................................................... 9

2.1 MINIMUM SHELL / HEAD THICKNESS: ..................................................................................................................... 9

2.2 STANDARD TUBE THICKNESS: ............................................................................................................................. 10
2.3 EQUIPMENT END CLOSURES: .............................................................................................................................. 10
2.4 DESIGN PRESSURE: ........................................................................................................................................... 10
2.5 TEST PRESSURE: ............................................................................................................................................... 11
2.6 DESIGN TEMPERATURE: ..................................................................................................................................... 11
2.7 CORROSION ALLOWANCE: .................................................................................................................................. 11
2.8 WIND CONSIDERATION: ...................................................................................................................................... 12
2.9 SEISMIC / EARTHQUAKE CONSIDERATION: ........................................................................................................... 13
2.10 SUPPORTS: ........................................................................................................................................................ 14
2.11 MANHOLES: ....................................................................................................................................................... 14
2.12 NOZZLE AND NOZZLE FLANGES: .......................................................................................................................... 15
2.13 GIRTH FLANGE DESIGN: ..................................................................................................................................... 15
2.14 ALLOWABLE NOZZLE LOADS: .............................................................................................................................. 15
2.15 INTERNALS: ........................................................................................................................................................ 18
2.16 VENT / DRAIN NOZZLE CONNECTIONS: ................................................................................................................ 18
2.17 PLATFORM & LADDER: ........................................................................................................................................ 18
2.18 STORAGE TANKS: ............................................................................................................................................... 19
2.19 IMPORTANT CONSIDERATIONS:............................................................................................................................ 20
F) ALLOWABLE TENSILE STRESS OF FOUNDATION BOLTS OF SA307 GR. B SHALL BE 100 N/MM2. ALLOWABLE SHEAR
STRESS OF FOUNDATION BOLTS OF SA307 GR. B SHALL BE 80 N/MM2 ............................................................................. 20

G) ALL FOUNDATION BOLTS SHALL BE HOT DIP GALVANIZED. .................................................................................... 20

3.0 SPARE PARTS:............................................................................................................................... 21

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3.1 MANDATORY SPARES: ........................................................................................................................................ 21

3.2 ERECTION AND COMMISSIONING SPARES: ........................................................................................................... 23
3.3 2 YEARS OPERATION SPARES (TO BE QUOTED SEPARATELY AND NOT TO BE INCLUDED IN BASE COST): .................. 25
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1.0 General:

1.1 Scope:
This Specification covers the design criteria for the purpose of carrying out Engineering for
procurement of various static equipment required including requirement with regards to spare
parts & special tools.
Also, this design basis defines the design philosophy to be adopted for this project.
Electrical items, Instrumentation and Controls, Piping, Rotating equipment etc. associated with
Static Equipment shall comply with the design requirements specified in respective discipline
Engineering Design Basis.

1.2 References:

Sr. No. Description Document Number

1 Engineering Specification for Pressure Vessels 6447-D8-E0-MS-SPC-0002-A4
2 Engineering Specification for Fractionating 6447-D8-E0-MS-SPC-0003-A4
Trays.
3 Engineering Specification for General Welding 6447-D8-E0-MS-SPC-0004-A4
Requirements for Pressure Containing
Equipment.
4 Engineering Specification for Heat 6447-D8-E0-MS-SPC-0005-A4
Exchangers.
5 Engineering Specification for Double Pipe and 6447-D8-E0-MS-SPC-0006-A4
Multi-tube Heat Exchangers.
6 Welded Atmospheric Storage Tanks 6447-D8-E0-MS-SPC-0007-A4

1.3 Abbreviations:
API – American Petroleum Institute.
ASME – The American Society of Mechanical Engineers.
IS – Indian Standard
TEMA – The Tubular Exchanger Manufacturers Association.
WRC – Welding Research Council.
MAWP – Maximum Allowable Working Pressure.
MDMT – Minimum Design Metal Temperature.
IBR – Indian Boiler Regulation

1.4 Order of Precedence:

In the event of conflict following order of precedence shall be followed.
1. Applicable Statutory Requirements, Local Regulations and Laws.
2. Engineering drawings or Mechanical Datasheets of equipment.
3. Process Datasheets of equipment.
4. Engineering Design Basis - Static Equipment.
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5. Engineering Specifications and Standard drawings.

6. Equipment design codes and standards.
7. Vendor’s specifications, documents and information.
In the event of conflict, it shall be the duty of the bidder to bring it to Owner’s attention for
resolution and get it resolved before proceeding with the fabrication. Owner comments shall be
final and binding on bidder without any time and cost implications.

1.5 Statutory Requirements, Local Regulations and Laws:

Following statutory requirements, local regulations and laws shall be complied as per
applicability.
• Indian Boiler Regulations (IBR).
• Petroleum and Explosives Safety Organization (PESO).
1.6 Codes & Standards / Publications:

Sr. Design codes and

Title Purpose Edition
No. Standards
For Pressure
Rules for Construction of
1. ASME Sec VIII Div. 1 Vessels, Heat 2021
Pressure Vessels
Exchangers
For Pressure Vessels
Rules for Construction of and Heat Exchangers
2. ASME Sec VIII Div. 2 Pressure Vessels (Selectively for high 2021
(Alternative Rules) pressure/high
thickness)
13th Edition, March
Welded Tanks for Oil For Atmospheric
3. API 650 2020 Errata 1,
Storage Storage Tanks
January 2021
Ferrous material
For material
4. ASME Sec II Part A specifications 2021
specification

Nonferrous material
For material
5. ASME Sec II Part B specifications 2021
specification

Specifications for welding

rods, electrodes, and filler For material
6. ASME Sec II Part C 2021
Metals specification

Properties-material For material

7. ASME Sec II Part D 2021
properties
2015.
Design Loads (Other than For Wind load
8. IS: 875 (Part 3) Amendment No. 1 –
Earthquake) for Buildings consideration
April 2016.
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Sr. Design codes and

Title Purpose Edition
No. Standards
and Structures - Code of Amendment No. 2 –
Practice. June 2020.
Part 3 – Wind Loads.
(Third Revision)
Criteria for Earthquake
2016.
Resistant Design of
Amendment No. 1 –
Structures For Seismic Design
9. IS 1893 (Part 1) September 2017.
Part 1 – General Provisions consideration
Amendment No. 2 –
and Buildings (Sixth
November 2020.
Revision).
Criteria for Earthquake
resistant design of
2014
Structures For Seismic Design
10. IS: 1893 (Part 2) Amendment No. 1 –
Part 2 – Liquid Retaining consideration
March 2022.
Tanks (Fifth Revision)

Criteria for Earthquake

2015
resistant design of
Amendment No. 1 –
Structures
For Seismic Design September 2017.
11. IS: 1893 (Part 4) Part 4 – Industrial
consideration Amendment No. 2 –
Structures including Stack
July 2018.
Like Structures (First
Amendment
Revision).
Qualification Standard for
Welding, Brazing, and
Fusing Procedures;
12. ASME Sec IX For welding 2021
Welders; Brazers; and
Welding, Brazing, And
Fusing Operators
Pipe Flanges and Flanged
Fittings
13. ASME B 16.5 For Flanges 2017
NPS 1/2 Through NPS 24
Metric/Inch Standard
Large Diameter Steel
Flanges, NPS 26 through For large diameter
14. ASME B 16.47 2017
NPS 60 metric/inch Flanges
standard
ASME B 16.20 / Metallic Gaskets for Pipe
15. For Gaskets 2017
B 16.21 Flanges
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Sr. Design codes and

Title Purpose Edition
No. Standards
Standards of the Tubular
For Shell and Tube
16. TEMA Exchanger Manufacturers 10th Edition
Exchanger
Association.
Precision Equations and
Enhanced Diagrams for
Local Stresses in
Local Stresses in Spherical
WRC Bulletin Spherical &
17. and Cylindrical Shells Due 2020
#107/537 Cylindrical Shells due
to External Loadings for
to External Loadings.
Implementation of WRC
Bulletin 107 - 2nd Edition
WRC Bulletin 297 - Local Local Stresses in
Stresses in Cylindrical Cylindrical Shells due
18. WRC Bulletin #297 1987
Shells due to External to External Loadings
Loadings on Nozzles on Nozzles.

1.7 Units of Measurement:

Unless otherwise specified, Metric measurement system will be used for this Project. Unit of
measurement for some important parameters is mentioned below.

Sr. No. Description Unit of Measurement

1. Pressure bar(g), mmH2O

2. Temperature °C

3. Length, Width, Height Meter or millimeter

4. Volume m3

5. Capacity Liters or kilo-Liters

6. Weight kgf

7. Mass kg

8. Moment kg-m

9. Time sec

10. Density kg/m3

11. Velocity m/sec

12. Area m2

13. Power kW

14. Heat Duty kW or MW

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Sr. No. Description Unit of Measurement

15. Nozzle Sizes Inch

16. Flowrates kg/hr

2.0 Design Conditions:

Equipment shall be designed in compliance with the latest design code requirements and applicable
standards/ specifications. All design calculations shall be performed considering all applicable loads
for erection, operating and hydro test conditions.

2.1 Minimum Shell / Head Thickness:

a) The minimum nominal shell thickness for vessels and columns including corrosion
allowance shall be as follows:

Carbon Steel and Low High Alloy Steel and

Shell Inside Diameter
Alloy Steel Non-Ferrous Material
[mm]
[mm] [mm]
up to 1,500, incl. 6 4
over 1,500 to 3,000, incl. 8 6
over 3,000 to 4,500, incl. 10 8
over 4,500 to 6,000, incl. 12 10
over 6,000 to 7,500, incl. 14 12
over 7,500 16 14

b) For Shell & Tube Heat Exchangers, the minimum nominal shell thickness including
corrosion allowance shall be in accordance with TEMA including RECOMMENDED
GOOD PRACTICE.
c) For Shell & Tube Heat Exchangers, when the specified shell-side corrosion allowance
exceeds 3 mm, the minimum baffle and support plate thickness specified in the TEMA
standard shall be increased by the shell-side corrosion allowance in excess of 3 mm.
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2.2 Standard Tube thickness:

a) Standard tube thickness shall be as follows:
Unit: mm
Tube thickness
Tube C.S. & Low Copper &
High Alloys
Outside Alloys Copper Alloys
(Average Wall)
Diameter (Minimum Wall) (Average Wall)
19.05 2.11 1.65 1.65
25.4 2.77 1.65 1.65
31.8 2.77 2.11 2.11
38.1 2.77 2.11 2.11

b) For Heat Exchangers in IBR service, minimum tube thickness shall be in accordance
with Indian Boiler Regulations Act.
2.3 Equipment End Closures:
a) The shape of formed head shall be as specified in Engineering Drawing or mechanical
datasheet.
b) The nominal thickness of head shall be selected to assure that the minimum thickness
after forming shall not be less than the minimum required thickness of head. Also, the
nominal thickness shall not be less than the minimum required thickness of connecting
cylindrical shell except for Hemispherical Head.
2.4 Design Pressure:
a) Design pressure shall be as specified on Purchaser’s engineering drawing or
mechanical data sheet.
b) Vessels operating under vacuum condition shall be designed for an external design
pressure of 1.013 bar and designated as full vacuum. Only when a safety device is
installed to the pressure vessel, the difference between the absolute internal and the
atmospheric pressure may be taken as the external design pressure.
c) Design pressure shall mean the gauge pressure at the top of a completed vessel in its
operating position. Unless otherwise agreed in advance, internal static head shall be
added to the design pressure to determine the thickness of any specific part of the
vessel.
d) Unless otherwise specified, vessels normally subject to internal pressure only shall be
designed to withstand a minimum external pressure of 0.172 bar at the ambient
temperature (20 °C).
e) Vessel parts subject to different internal pressure on both sides shall be designed to
withstand the most severe combination of the pressures.
f) MAWP may be assumed to be same as Design pressure.
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2.5 Test Pressure:

Hydrotest pressure for shop and site location shall be as follows.
Sr.
Design code Hydrotest Pressure
no.
1. ASME Sec. VIII Div. 1 As per UG-99(b)(Note 35)
2. ASME Sec. VIII Div. 2 As per 8.2.1(a)
3. API 650 As per the code

2.6 Design Temperature:

a) Design temperature shall be as specified on Purchaser’s engineering drawing or
mechanical data sheet. Two kinds of design temperature, one for maximum design
temperature (called as “Design Temperature”) and the other for minimum design
temperature (called as “Minimum Design Metal Temperature” = MDMT) are specified.
b) Design temperature (maximum), which is the basis of the pressure vessel design, shall
normally be the maximum anticipated operating temperature, but shall not be less than
65 °C.
c) The minimum design metal temperature (MDMT) shall be determined for each pressure 1
vessel in accordance with UG-20(b) of the ASME Boiler and Pressure Vessel Code 1
Section VIII, Division 1. MDMT shall be 5°C, unless otherwise specified on the
engineering drawing or the mechanical data sheet.
d) When design temperature or MDMT cannot coincide with the maximum pressure, the
corresponding design pressure shall be designated together with the design
temperature and MDMT.
e) Vessel parts in contact with two fluids having different temperatures shall be designed
for both higher and lower design temperatures.
f) When the vessel inside is insulated from high temperature fluid, the design temperature
may be determined by heat transfer calculations.

2.7 Corrosion Allowance:

a) Unless otherwise specified in Mechanical datasheet or Engineering drawing, corrosion
allowance for pressure retaining parts made of carbon steel and low alloy steel shall be
1.0 mm as minimum. Corrosion allowance is not required for high alloy and non-ferrous
metals.
b) Unless otherwise specified in engineering drawings, mechanical data sheets or other
applicable Engineering Specifications, the corrosion allowance for internal parts of
vessels shall be as follows:

(1) Parts directly welded to the shell or parts not removable from a manhole:

Add 1/2 of the specified corrosion allowance on each side.

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(2) Parts removable from a manhole:

Add 1/4 of the specified corrosion allowance on each side (min. 1.0 mm total
for both sides).

Notes:
1. In general, no corrosion allowance is added for high alloy and nonferrous
internals.

2. For the internal parts specified in Vessel Standard such as lugs and support
rings, corrosion allowance shall conform to the stipulations stated.

3. The specified corrosion allowance shall mean the corrosion allowance for the
shell.

4. Shell as used herein shall mean all pressure retaining parts of the vessel in
contact with the service fluid, including heads, nozzles, manholes and manhole
covers.

5. The corrosion allowance on tray shall be in accordance with Engineering

Specification ES-DZ103 “Fractionating Trays”.

c) No corrosion allowance is required for parts not in contact with the inside fluid such as
the outside surface of shell, skirt, anchor bolt and so on.
d) Unless otherwise specified, no corrosion allowance is added to tubes.
e) Corrosion allowance is not usually required for non-pressure parts such as tie-rods,
spacers, baffles and support plates.

2.8 Wind Consideration:

• Wind Design Code – IS 875 Part 3.
• Basic Wind Speed – 44 m/s as per Fig.1of IS 875 for terrain category 2 at 10 meter above
ground level based on 50 years mean return period.
• Probability Factor (k1) – 1.07 as per Table 1 of IS 875.
• Terrain roughness and height factor (k2) – As per Table 2 of IS 875. Factor shall be
considered for Terrain Category 2.
• Topography factor (k3) – 1.0
• Importance Factor for cyclonic region (k4) – 1.15 for Industrial Structures.
• Force Coefficient for equipment having circular shape in “Plan View”.
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Height / Breadth Ratio Force Coefficient (Cf)

Up to 2 0.7
Above 2 and up to 5 0.8
Above 5 and up to 10 0.9
Above 10 and up to 20 1.0
Above 20 1.2
• Force Coefficient for Platform and Ladders of Static equipment – 1.2.
• Dynamic Effects:
Flexible slender structures and structural elements shall be investigated to ascertain the
importance of wind induced oscillations or excitations in along wind and across wind
directions. In general, following guidelines may be used for examining the problems of wind
– induced oscillations.
a) Equipment with height to minimum lateral dimension ratio of more than about 5
or
b) Equipment whose natural frequency in the first mode is less than 1.0 Hz.
Any equipment which satisfies either of the above two criteria shall be
examined for dynamic effects of wind.

2.9 Seismic / Earthquake Consideration:

• Seismic Design Code –
o IS 1893 Part 4 for Pressure Vessels and Heat Exchangers.
o API 650 Annexure E for Liquid Retaining Tanks.
• Seismic Zone – III as per Fig. 1 of IS 1893 Part 1. 1
• Seismic Zone Factor – 0.16 1
• Equipment Category for Seismic Design – As per IS 1893 Part 4.
• For Category 1 equipment, Maximum Considered Earthquake (MCE) shall also be
performed in addition to Design Basis Earthquake (DBE).
• Importance Factor (I) –
o For Category 1 Equipment – 2.
o For Category 2 Equipment – 1.5.
• Response Reduction Factor (R) –
o For Pressure Vessels and Heat Exchangers – 2
o For Liquid Retaining Tanks –
a) Unanchored base – As per API 650 annexure E.
b) Anchored base – As per API 650 annexure E.
• Percentage Damping 1
o For Pressure Vessels and Heat Exchangers – 2% for DBE and 4% for MCE. 1
o For Tanks –
a) Percentage Damping in Convective Mode – 0.5%.
b) Percentage Damping in Impulsive Mode – 5%.

1
1
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• Design Vertical Seismic Coefficient – 2/3 of the Horizontal Acceleration Values.

• Design Spectrum – As per Annexure “B” of IS 1893 Part 4.
• Soil Type – Medium Soil.

2.10 Supports: 1

a) Vertical vessels shall generally be supported by skirts or lugs. Vessels may be 1

supported by legs made of steel angles, channels or pipes when satisfying all of the
following conditions;

(1) Shell diameter is not more than 1,000 mm.

(2) Weight of vessel operating does not exceed 3000 kg.
(3) Vessel height-to-diameter ratio is not more than 3
(4) Support height is not more than 1,500 mm.
(5) Vibration is not expected.

b) Vertical heat exchangers shall generally be supported by lugs.

c) Skirt shall be so designed that the both ends are continuously welded to the head and/or
shell and the base ring respectively.
d) The joint of the skirt to head and/or shell shall be designed and welded so as to prevent
excessive stress concentration.
e) Flanged connections shall not be provided inside the skirt unless otherwise specifically
required.
f) Skirt shall be provided with vents and access holes as indicated in engineering drawings
or in Vessel Standard.
g) Saddles, lugs or legs for pressure vessels shall be as per the tables in Vessel Standard.
h) Supports for low temperature horizontal vessels with the operating temperatures lower
than -20 °C shall be provided with wooden pillows according to Vessel Standard.

2.11 Manholes:
a) Manhole nominal diameters shall be as follows unless otherwise specified

Shell
Tray & Packing Drum
Diameter
Tower
[mm] [inch]
[inch]
up to 800, incl. Girth Flange Hand Holes (Note 1)
over 800 to 1,500, incl. 20” 20”
over 1,500 24” 24”
Note 1: Girth flanges shall also be provided if removable internals are installed.

b) For tray towers, manholes shall be provided at top and bottom of tower and for each 20
trays or 15 m elevation distance, whichever is less, as minimum.
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c) Bottom Manhole elevation from bottom tangent line of vertical vessel shall be
determined as follows.

Manhole size 18” 20” 24”

Distance from bottom TL (mm) 600 650 750

d) Hand hole shall be minimum 6-inch nominal size.

2.12 Nozzle and Nozzle Flanges:

a) Nozzle flanges 24 inch and smaller shall be as per ASME B16.5. Nozzle flanges larger
than 24-inch nominal shall be as per ASME B16.47 Series B. In case a nonstandard
flange is designed by Supplier, the companion flange with bolt, nut and gasket shall
be supplied by Supplier.
b) All nozzle flanges shall be weld neck type.
c) The nozzle neck thickness shall be selected in accordance with Vessel Standard based
on material, nominal size, flange rating and corrosion allowance. The pipe materials for
nozzle neck shall be seamless, unless otherwise approved by Purchaser.
d) When male and female (M&F) or tongue and groove (T&G) type flanges are specified,
the nozzle flange facing of the vessel shall be of female or groove type.
e) Minimum Nozzle sizes for clad or weld-overlaid equipment shall be 3”.

2.13 Girth Flange Design:

a) All girth flanges shall be weld neck type.
b) Girth flanges shall be designed as per applicable design code of equipment. Girth
flanges shall be designed as per Mandatory Appendix 2 if equipment design code is
ASME Section VIII Div.1.

2.14 Allowable Nozzle Loads:

a) Supplier shall perform local stress analysis for Pressure vessel (including Towers and
Reactors) related to external force and moment onto nozzles specified below:
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Table A1. Nozzle to Shell Loading

Flange Rating
Piping Loads Unit
150 lb. 300 lb. 600 lb. 900 lb. 1500 lb. 2500 lb.
Axial Tension /
Compression P kg 122 x D 142 x D 163 x D 366 x D 611 x D 672 x D
Force
Circumferential
VC kg 91 x D 107 x D 122 x D 275 x D 458 x D 504 x D
Force
Longitudinal
VL kg 122 x D 142 x D 163 x D 366 x D 611 x D 672 x D
Force
Circumferential
kg-
Bending MC 6.1 x D2 7.1 x D2 8.2 x D2 18.3 x D2 30.6 x D2 33.6 x D2
m
Moment
Longitudinal
kg-
Bending ML 8.0 x D2 9.3 x D2 10.6 x D2 23.9 x D2 39.8 x D2 43.7 x D2
m
Moment
Torsional kg-
MT 9.2 x D2 10.7 x D2 12.2 x D2 27.5 x D2 45.9 x D2 50.5 x D2
Moment m

Table A2. Nozzle to Head Loading

Flange Rating
Piping Loads Unit
150 lb. 300 lb. 600 lb. 900 lb. 1500 lb. 2500 lb.
Axial Tension
/
P kg 122 x D 142 x D 163 x D 366 x D 611 x D 672 x D
Compression
Force
Resultant
VR kg 152 x D 178 x D 203 x D 458 x D 764 x D 840 x D
Shear Force
Resultant
Bending MR kg-m 10 x D2 11.6 x D2 13.3 x D2 30 x D2 49.9 x D2 55.0 x D2
Moment
Torsional
MT kg-m 9.2 x D2 10.7 x D2 12.2 x D2 27.5 x D2 45.9 x D2 50.5 x D2
Moment
Where D = Nominal Diameter of Nozzle in inch
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TOYO Project Doc. No.: Page 17 of 26
Work No.: 6447 6447-D8-E0-MS-SPC-0001-A4 Date: 27-Jul-23

b) Supplier shall perform local stress analysis for heat exchanger related to external force
and moment onto nozzles specified below;

Table B1. Nozzle to Shell Loading

Flange Rating
Piping Loads Unit
150 lb. 300 lb. 600 lb. 900 lb. 1500 lb. 2500 lb.
Axial Tension /
Compression P kg 152 x D 152 x D 254 x D 611 x D 815 x D 1141 x D
Force
Circumferential
VC kg 114 x D 114 x D 190 x D 458 x D 611 x D 856 x D
Force
Longitudinal
VL kg 152 x D 152 x D 254 x D 611 x D 815 x D 1141 x D
Force
Circumferential
12.6 x 30.6 x 40.8 x 57.1 x
Bending MC kg-m 7.6 x D2 7.6 x D2
D2 D2 D2 D2
Moment
Longitudinal
16.5 x 39.8 x 53.0 x 73.4 x
Bending ML kg-m 9.9 x D2 9.9 x D2
D2 D2 D2 D2
Moment
Torsional 19.1 x 45.9 x 61.2 x 85.6 x
MT kg-m 11.4x D2 11.4 x D2
Moment D2 D2 D2 D2

Table B2. Nozzle to Head Loading

Flange Rating
Piping Loads Unit
150 lb. 300 lb. 600 lb. 900 lb. 1500 lb. 2500 lb.
Axial Tension /
Compression P kg 152 x D 152 x D 254 x D 611 x D 815 x D 1141 x D
Force
Resultant
VR kg 190 x D 190 x D 318 x D 764 x D 1019 x D 1427 x D
Shear Force
Resultant
20.7 x
Bending MR kg-m 12.4 x D2 12.4 x D2 49.9 x D2 66.6 x D2 93.2 x D2
D2
Moment
Torsional 19.1 x
MT kg-m 11.4 x D2 11.4 x D2 45.9 x D2 61.2 x D2 85.6 x D2
Moment D2
Where D = Nominal Diameter of Nozzle in inch
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TOYO Project Doc. No.: Page 18 of 26
Work No.: 6447 6447-D8-E0-MS-SPC-0001-A4 Date: 27-Jul-23

c) Nozzle loads specified in above Tables are applicable at the nozzle to shell or head
junction of equipment. These nozzle loads shall not be applied to flange face and also
shall not be used for flange rating selection. Nozzle flanges need not be checked for de-
rating as per ASME Sec VIII Div. 1 UG-44(b).

2.15 Internals:
a) Supplier shall design internals in accordance with the information indicated on
Purchaser’s engineering drawings.
b) Unless otherwise specified, removable internal parts shall be designed for installation /
removal from the vessel through the nearest upper manhole. Demister, however, may
be installed / removed through the nearest lower manhole or openings. The weight of
one block to be withdrawn shall not generally exceed 40kg with the exception on the
internal support beams.

2.16 Vent / Drain Nozzle Connections:

a) Exchangers shall be provided with vent and drain of 40 NB nozzle with blind flange etc.
Separate vent and drain will not be provided if vented / drained by process/other
nozzles. For clad exchangers, minimum size of vent and drain nozzle connection shall
be 50 NB LWN.

2.17 Platform & Ladder:

Unless and otherwise specified following information shall be considered for platform and
ladder arrangement during equipment design.
a) Platform type – Grating.
b) Dead Weight (Dead Load) –
i. Platform – 160 kg/m2
ii. Ladder – 30 kg / m
c) Platform and ladder arrangement for equipment design
i. Horizontal Drums – Platform shall be considered for drums having inside
diameter greater than 2000 mm.
ii. Vertical Columns and Drums –
Platform Platform Platform Platform H/D Ratio
Location Shape Width Angle
(mm) (Degree)
Top Platform Square 1.2 X Not Not Applicable
Shape Outside Applicable
Diameter of
Columns or
Drums
Fan Shape 1500 100 H/D > 20
1500 130 20 ≥ H/D > 10
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TOYO Project Doc. No.: Page 19 of 26
Work No.: 6447 6447-D8-E0-MS-SPC-0001-A4 Date: 27-Jul-23

Platform Platform Platform Platform H/D Ratio

Location Shape Width Angle
(mm) (Degree)
Side 1500 190 10 ≥ H/D
Platform at
Manholes
Side Fan Shape 1500 45 H/D > 20
Platforms for 1500 60 20 ≥ H/D > 10
Switchover 1500 90 10 ≥ H/D
of Ladders
Where H – Overall height of column and drums including skirt support.
D – Inside Diameter of columns and drums.
iii. Maximum ladder length – 6000 mm.

2.18 Storage Tanks:

a) All shell plates shall have a common inside diameter.
b) With respect to clause 5.1.5.9 e) of API 650 13th Edition, the outstanding leg of the top
angle shall extend outside the tank shell.
c) With respect to clause 5.3.2 of API 650 13th Edition, Corrosion allowance specified in
the Purchaser’s engineering drawing or mechanical data sheet shall apply to shell plates
and bottom plates. Unless otherwise specified, the corrosion allowance shall not apply
to roof plates and roof supporting structural members.
d) With respect to clause 5.5.1 of API 650 13th Edition, Annular bottom plates if required
shall be of the same material as the bottom shell course. Annular bottom plates shall be
butt-welded in all cases.
e) With respect to clause 5.6.1.1 of API 650 13th Edition, Nominal tank diameter shall be
the inside diameter of the shell course plates.
f) With respect to clause 5.6.3 and 5.6.4 of API 650 13th Edition, the minimum thickness of
the tank shell shall be calculated by 1-foot method for the tanks up to 60 m in diameter
and by variable-design-point method for tanks more than 60 m in diameter.
Nominal tank diameter D used for calculation shall be the inside diameter of the shell
course plates. Maximum design liquid level H used for shell thickness calculation for
both the design condition and the hydrostatic test condition shall be height to the top of
the shell including the top angle, if any or to the bottom of any overflow that limit the tank
filling height. Any other controlled level due to the restriction by an internal floating roof
or to allow for seismic wave action may be applied for calculation only when specially
agreed with Purchaser.
g) Low-type nozzles and threaded-type shell nozzles shall not be used.
h) Unless otherwise specified, flush-type cleanout fittings and flush-type shell connections
shall not be used.
i) With respect to clause 5.9.1 of API 650 13th Edition, stiffening rings shall be provided on
the outside of the tank shells.
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TOYO Project Doc. No.: Page 20 of 26
Work No.: 6447 6447-D8-E0-MS-SPC-0001-A4 Date: 27-Jul-23

j) With respect to clause 5.7.6 of API 650 13th Edition, ASME B16.47 Series B shall be
applied, unless otherwise Series A is specified on Purchaser’s engineering drawing or
mechanical datasheet.
k) With respect to Table 5.3a, 5.3b, 5.5a & 5.5b and Figure 5.7a Shell Manhole of API 650
13th Edition, ASME B16.5, 150#, slip on and raised face flanges shall be applied for
shell manholes when liquid head exceeds 1 bar(g). Care should be taken especially for
the following storage tank;

1) Higher density stored fluids such as caustic make-up, spent caustic, sulfuric acid,
etc.
2) Large capacity storage tanks to store crude oil, diesel, gasoline, naphtha, pygas,
condensate, reformate, paraxylene. benzene, heavy aromatics, raffinate, etc.

2.19 Important Considerations:

a) IS 2062 Gr B material may be used wherever SA-283 Gr C is specified in the
Datasheets.
b) For tray towers or packed towers, the maximum shell deflection at the top of the shell
under the 2/3 of the design wind load shall be limited to 1/200 of the total height from the
base plate.
c) All vertical vessels, columns, horizontal vessels, heat exchangers and tanks shall be
designed so as to permit site testing of the equipment with water at the test pressure on
the top of the equipment considering 25% of design wind load. The design shall be
based on fully corroded condition.
d) Lifting lugs and tailing lugs shall be designed taking account of vessel weight and lifting
method, etc. Supplier shall decide location of lifting lug/tailing lugs in order to avoid
interferences between lifting wires and external attachments (such as platform, ladder,
and nozzles) during erection. Materials, procedures of welding them to the shell and
inspection method shall also be carefully checked. The following shock factor shall be
considered in the design of lugs and shell, unless otherwise specified;
1.50: for equipment lifting weight 100 ton and less
1.25: for equipment lifting weight exceeding 100 ton.
e) Minimum grade for concrete is M30. For M30 Concrete Grade, permissible stresses in
concrete shall be 10 N/mm2 in bending stress and 8 N/mm2 in direct stress.
f) Foundation bolts material shall be SA307 Gr. B or IS 2062 Gr. BR or IS 432 Gr.1.
Allowable tensile stress shall be 137 N/mm2 and allowable shear stress shall be 80 1

N/mm2 1

g) All foundation bolts shall be Hot Dip Galvanized.

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TOYO Project Doc. No.: Page 21 of 26
Work No.: 6447 6447-D8-E0-MS-SPC-0001-A4 Date: 27-Jul-23

3.0 Spare Parts:

3.1 Mandatory Spares:

a. For Pressure Vessels including Towers and Reactors.
Gaskets for Nozzles 100%
Gaskets for Girth Flanges / Main Body 100%
Flanges
Gasket for internal flanges 100%
Demister 20% (Min.4 Nos. of each size / Type) extra
Fasteners (bolts, nuts, clamps, spacers etc.)
as required for holding the demister.
Bolts and Nuts for Nozzles 10%. Minimum 2 sets.
Bolts and Nuts for Internals 10%. Minimum 2 sets.
Bolts and Nuts for Girth Flanges / Main Body 10%. Minimum 2 sets.
Flanges
b. For Heat Exchangers.
Gaskets for Nozzles 100%
Gaskets for Girth Flanges / Main Body 100%
Flanges
Bolts and Nuts for Nozzles 10%. Minimum 2 sets.
Bolts and Nuts for Internals 10%. Minimum 2 sets.
Bolts and Nuts for Girth Flanges / Main Body 10%. Minimum 2 sets.
Flanges
c. Pressure Vessel and Tower Internals.
Valves for tray 10% (each type, each size, each Material)
Bubble caps 10% (each type, each size, each Material)
Bolts, nuts 20 % (Each Type & Size Min. 10 Nos. of
each size)
Clamps assemblies 10 % (Each Type & Size Min. 10 Nos. of
each size)
Gaskets for Tray manways 100%
Gaskets or tape 100% (Each type & size)
Sealing foils / ropes for cartridge 200% (For each size)
Spray nozzles 25% (subject to minimum 5 nos. of each type
& size.)
Washer 20 % (Min. 3 piece)
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TOYO Project Doc. No.: Page 22 of 26
Work No.: 6447 6447-D8-E0-MS-SPC-0001-A4 Date: 27-Jul-23

Random Packing (Metallic) Refer Note 1 mentioned below the Table

Random Packing (Non-Metallic) Refer Note 1 mentioned below the Table
Note 1 – Random Packing spares shall be as follows:

D/d Spare packing

10 3 (7) %
20 3 (7) %
30 3 (7) %
40 5 (10) %
50 7 (12) %
60 and over 9 (14) %

Where D: Tower Inside Diameter (mm)

d: Packing Size (mm)
( ): Applied for ceramic packing only
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Equipment [Security Level2]
TOYO Project Doc. No.: Page 23 of 26
Work No.: 6447 6447-D8-E0-MS-SPC-0001-A4 Date: 27-Jul-23

3.2 Erection and Commissioning Spares:

a. For Pressure Vessels including Towers and Reactors.
Gaskets for Nozzles 100%
Gaskets for Girth Flanges / Main Body 100%
Flanges
Gasket for internal flanges 100%
Demister 20% (Min.4 Nos. of each size / Type) extra
Fasteners (bolts, nuts, clamps, spacers etc.)
as required for holding the demister.
Bolts and Nuts for Nozzles 10%. Minimum 2 sets.
Bolts and Nuts for Internals 10%. Minimum 2 sets.
Bolts and Nuts for Girth Flanges / Main Body 10%. Minimum 2 sets.
Flanges
b. For Heat Exchangers.
Gaskets for Nozzles 100%
Gaskets for Girth Flanges / Main Body 100%
Flanges
Bolts and Nuts for Nozzles 10%. Minimum 2 sets.
Bolts and Nuts for Internals 10%. Minimum 2 sets.
Bolts and Nuts for Girth Flanges / Main Body 10%. Minimum 2 sets.
Flanges
c. Pressure Vessel and Tower Internals.
Valves for tray 10% (each type, each size, each Material)
Bubble caps 10% (each type, each size, each Material)
Bolts, nuts 20 % (Each Type & Size Min. 10 Nos. of
each size)
Clamps assemblies 10 % (Each Type & Size Min. 10 Nos. of
each size)
Gaskets for Tray manways 100%
Gaskets or tape 100% (Each type & size)
Sealing foils / ropes for cartridge 200% (For each size)
Spray nozzles 25% (subject to minimum 5 nos. of each type
& size.)
Washer 20 % (Min. 3 piece)
Random Packing (Metallic) Refer Note 1 mentioned below the Table
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TOYO Project Doc. No.: Page 24 of 26
Work No.: 6447 6447-D8-E0-MS-SPC-0001-A4 Date: 27-Jul-23

Random Packing (Non-Metallic) Refer Note 1 mentioned below the Table

Note 1 – Random Packing spares shall be as follows:

D/d Spare packing

10 3 (7) %
20 3 (7) %
30 3 (7) %
40 5 (10) %
50 7 (12) %
60 and over 9 (14) %

Where D: Tower Inside Diameter (mm)

d: Packing Size (mm)
( ): Applied for ceramic packing only
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Equipment [Security Level2]
TOYO Project Doc. No.: Page 25 of 26
Work No.: 6447 6447-D8-E0-MS-SPC-0001-A4 Date: 27-Jul-23

3.3 2 Years Operation Spares (To be quoted separately and not to be included in base cost):
a. For Pressure Vessels including Towers and Reactors.
Gaskets for Nozzles 100%
Gaskets for Girth Flanges / Main Body 100%
Flanges
Gasket for internal flanges 100%
Demister 20% (Min.4 Nos. of each size / Type) extra
Fasteners (bolts, nuts, clamps, spacers etc.)
as required for holding the demister.
Demister 1 set of demister pad assembly.
Bolts and Nuts for Nozzles 10%. Minimum 2 sets.
Bolts and Nuts for Internals 10%. Minimum 2 sets.
Bolts and Nuts for Girth Flanges / Main Body 10%. Minimum 2 sets.
Flanges
b. For Heat Exchangers.
Gaskets for Nozzles 100%
Gaskets for Girth Flanges / Main Body 100%
Flanges
Bolts and Nuts for Nozzles 10%. Minimum 2 sets.
Bolts and Nuts for Internals 10%. Minimum 2 sets.
Bolts and Nuts for Girth Flanges / Main Body 10%. Minimum 2 sets.
Flanges
c. Pressure Vessel and Tower Internals.
Valves for tray 10% (each type, each size, each Material)
Bubble caps 10% (each type, each size, each Material)
Bolts, nuts 20 % (Each Type & Size Min. 10 Nos. of
each size)
Clamps assemblies 10 % (Each Type & Size Min. 10 Nos. of
each size)
Gaskets for Tray manways 100%
Gaskets or tape 100% (Each type & size)
Sealing foils / ropes for cartridge 200% (For each size)
Spray nozzles 25% (subject to minimum 5 nos. of each type
& size.)
Washer 20 % (Min. 3 piece)
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Equipment [Security Level2]
TOYO Project Doc. No.: Page 26 of 26
Work No.: 6447 6447-D8-E0-MS-SPC-0001-A4 Date: 27-Jul-23

Random Packing (Metallic) Refer Note 1 mentioned below the Table

Random Packing (Non-Metallic) Refer Note 1 mentioned below the Table
Note 1 – Random Packing spares shall be as follows:

D/d Spare packing

10 3 (7) %
20 3 (7) %
30 3 (7) %
40 5 (10) %
50 7 (12) %
60 and over 9 (14) %

Where D: Tower Inside Diameter (mm)

d: Packing Size (mm)
( ): Applied for ceramic packing only