080036-CC-SG-004_Rev.0 (Spec. for Tower Trays & Other Internals)

Specification for

Tower Trays and Other Internals

AL-JUBAIL K.S.A

CONTRACTOR ID CODE 080036-CC-SG-004 OWNER ID CODE 080036-CC-SG-004 Sheet 1 of 10

Issue 0

ARABIAN CHLOR VINYL PROJECT

SPECIFICATION FOR

TOWER TRAYS AND OTHER INTERNALS

EPC CONTRACTOR:

0 A

Issue For Construction Issue For Approval

S.H.Joo S.H.Joo

S.B.Ahn D.S.Kim C.W.Yang 09-Jun-2010S.B.Ahn D.S.Kim C.W.Yang 16-Apr-2010

Issue DESCRIPTION PREP’D CHK’D APPR’D APPR’D Date

This Document is the property of ACVC and is lent without consideration other than the Borrower’s agreement that it shall not be reproduced,

copied, lent, or disposed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by patents.

Specification for

Tower Trays and Other Internals

AL-JUBAIL K.S.A

CONTRACTOR ID CODE 080036-CC-SG-004 OWNER ID CODE 080036-CC-SG-004 Sheet 2 of 10

Issue 0

ARABIAN CHLOR VINYL PROJECT

TABLE OF CONTENTS

1.0 SCOPE

2.0 DESIGN

3.0 MATERIALS

4.0 TOLERANCES

5.0 CONSTRUCTION REQUIREMENTS

6.0 MARKING

7.0 DRAWINGS

8.0 CONSTRUCTION SPARES 8.1 General 8.2 8.3 8.4 8.5

9.0 SHIPMENT

10.0 INSTALLATION INSTRUCTIONS 11.0

RING TYPE TRAY SUPPORTS

9 9 10

Spare parts for field-installed trays Spare parts for other internals Spare parts for internal packing Spare Parts for 2 Years Operation 8 8 8 9 9 9 8 8 6 5 4 3 3 This Document is the property of ACVC and is lent without consideration other than the Borrower’s agreement that it shall not be reproduced, copied, lent, or disposed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by patents.

Specification for

Tower Trays and Other Internals

AL-JUBAIL K.S.A

CONTRACTOR ID CODE 080036-CC-SG-004 OWNER ID CODE 080036-CC-SG-004 Sheet 3 of 10

Issue 0

ARABIAN CHLOR VINYL PROJECT

1.0 SCOPE

This specification contains project specific requirements related to the design and supply of Tower Internals for the Arabian Chlor Vinyl Project to which all the “Parties involved” shall ensure compliance. This document should be read in conjunction with specifications 080036-GP-SG-0002 “General Requirements Specification for Mechanical Equipment” and 080036-CD-SG-0001 “Specification for Pressure Vessel”.

It is not the intent of this specification to define all technical requirements or to set forth the requirements adequately covered by applicable codes and standards. It is for the DIC to draw out detailed specifications based on the ACVC documents. Details of design not included in this Standard or the drawings shall be by the tray fabricator.

2.0 DESIGN

Internals shall be designed for the design temperature specified on the data sheets / drawings using maximum allowable stresses in accordance with the ASME Boiler and Pressure Vessel Code, Section VIII, Division 1, latest revision, and its addenda, which shall be referred to herein as the \"Code\". The minimum thickness of materials used for internals shall be as follows:

For Carbon Steel Internals:

Separate Beams and Supports

Decks, Down comers and Integral Trusses

Sumps, Seal Pans, Accumulator Pans, Draw-off BoxesCaps (or Valves) and Risers Tray Support Rings

For Alloy Steel Internals:

Separate Trusses and Supports

Decks, down comers and Integral Trusses

Sumps, Seal Pans, Accumulator Pans, Draw-off BoxesCaps (or Valves) and Risers Tray Support Rings

Deflections shall be limited to 1/1000 of tower I.D. with the trays filled with water 50 mm above the tops of the weirs. Special attention shall be paid to this requirement in cases of lightweight trays with integral trusses in large diameter (over 2150 mm) towers.

This Document is the property of ACVC and is lent without consideration other than the Borrower’s agreement that it shall not be reproduced, copied, lent, or disposed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by patents.

5 mm 3,5mm 5 mm 1,5mm

Refer to section 11

Weirs 3,5mm 3 mm 2 mm 3,5mm 1,5mm

Refer to section 11

Weirs 2 mm

Specification for

Tower Trays and Other Internals

AL-JUBAIL K.S.A

CONTRACTOR ID CODE 080036-CC-SG-004 OWNER ID CODE 080036-CC-SG-004 Sheet 4 of 10

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ARABIAN CHLOR VINYL PROJECT

When calculating the supports required for trays, the total load shall include the following minimum liquid loads in addition to the dead weight of the tray:

DIAMETER

Up to and including 3650 mm Over 3650 mm

MINIMUM LIQUID LOAD 1000 N/m2 750 N/m2

As a separate requirement, the trays are to be checked for stress in the extreme fibre of the material at operating loads and temperature. The trays shall also be capable of supporting workmen at ambient temperature based on a concentrated load of 120 Kg at mid-span of each support member.

Unless otherwise specified, no corrosion allowance shall be provided on any tray parts including integral trusses, and beamletts (beamletts are separate beams with the same function of integral trusses and they must not be intended as minor beams) except that separate carbon steel support beam shall have 1.5mm corrosion allowance on all exposed surfaces.

Tray Manufacturer's standard equipment and design, differing from this Standard, may be offered where significant price, delivery or other advantage is obtainable. However, in offering any alternate design which will affect tower design, the tray Manufacturer must point out the required changes in tower internals, nozzles, etc.

Tray Manufacturer shall provide for differential thermal expansion between the internals and the vessel.

The tray Manufacturer is responsible for reviewing the location of nozzles and the arrangement of distributors to ensure compatibility with trays and other internals.

All internals that are not welded to the tower shell shall be designed and fabricated in sections to pass through the tower man ways.

3.0 MATERIALS

Unless otherwise specified, materials shall conform to, as the minimum, the latest revision of the following specifications:

For Carbon Steel Internals:

 ASTM A-283 Grade C for plate, or commercial quality carbon steel per ASTM A-569 for sheet (tray

decks, down comers, blanking strips, weirs, seal pans, beams and supports)

 ASTM A-36 for structural steel shapes

This Document is the property of ACVC and is lent without consideration other than the Borrower’s agreement that it shall not be reproduced, copied, lent, or disposed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by patents.

Specification for

Tower Trays and Other Internals

AL-JUBAIL K.S.A

CONTRACTOR ID CODE 080036-CC-SG-004 OWNER ID CODE 080036-CC-SG-004 Sheet 5 of 10

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ARABIAN CHLOR VINYL PROJECT

 ASTM A-53 Grades A or B, or ASTM A-106 Grades A or B for pipe

 Commercial quality carbon steel for bolting

 Bolting for man way shall be always 11-13% Cr type 410

For Alloy Steel Internals:

 11-13% Cr Type 410S or Type 405 for trays, decks, down comers, blanking strips, weirs, seal pans,

trusses and supports

 11-13% Cr Type 410 for bolting

Welding electrodes shall be selected to deposit weld metal equivalent in analysis to the base metal, except that for 11-13% Cr Type 410S material, Type 309L electrodes shall be used.

Tape and packing material shall be fiberglass (Amatex or equal), furnished and shipped with the trays. Asbestos is prohibited.

4.0 TOLERANCES

Tolerances and tray rings shall be in accordance with the following:

NOMINAL INT. VESSEL WIDTH OF TRAY NOMINAL TRAY DIAMETER DIAMETER SUPPORT RINGUnder 914 mm 915 mm to 1850 mm 1851 mm to 3400 mm 3401 mm to 5500 mm Over 5501 mm

The tolerance on parts bolted to clips or brackets welded to the vessel shall be plus or minus 3 mm.

Internals shall be level, so that when fully assembled, with the vessel in a vertical erected position, they shall not exceed the following tolerances taken over the full tray diameter:

This Document is the property of ACVC and is lent without consideration other than the Borrower’s agreement that it shall not be reproduced, copied, lent, or disposed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by patents.

TRAY DIAMETER TOLERANCE

40 mm 50 mm 60 mm 80 mm 90 mm

Vessel inside diameter minus + 0 mm 40 mm - 3 mm Vessel inside diameter minus + 0 mm 40 mm - 3 mm Vessel inside diameter minus + 0 mm 50 mm - 3 mm Vessel inside diameter minus + 0 mm 65 mm - 7 mm Vessel inside diameter minus + 0 mm 75 mm - 7 mm

Specification for

Tower Trays and Other Internals

AL-JUBAIL K.S.A

CONTRACTOR ID CODE 080036-CC-SG-004 OWNER ID CODE 080036-CC-SG-004 Sheet 6 of 10

Issue 0

ARABIAN CHLOR VINYL PROJECT

Less than 6100 mm diameter 　 ±3 mm From 6101 mm to 9150 mm diameter, inclusive ±5 mm Over 9151 mm diameter 　 ±7 mm

The tolerance on all like parts shall be such as to make the parts completely interchangeable.

The tops of all risers, down comers and weirs shall be true and square with the tray. Additionally, regardless of tower diameter, weirs must not exceed 3 mm out-of-level. (This may be accomplished by using adjustable weirs).

5.0 CONSTRUCTION REQUIREMENTS

Unless otherwise specified on the drawings, tower internals shall be complete and include the following:

 Supports, including major and minor beams, trusses and bracing, all ring bars or angles, clips, bolting

bars and brackets required for the support of internals and welded to the tower shell shall be furnished by the vessel Fabricator. However, the tray Manufacturer shall design the tower attachments and submit detail drawings to EPC CONTRACTOR for the use of the vessel Fabricator. In addition, the tray Manufacturer shall furnish tray design loads for all attachments to the vessel

 Decks, sheds, seal pans, blanking strips, draw off pans and down comers

 Accumulator trays, risers and down comers

 Caps (or Valves) and risers

 Weirs

 Fasteners, including hold down bolts and clamps

 Gaskets and packing

 Riser and down pipes

 Feed piping and distributors (where indicated)

Trays shall be designed for metal-to-metal contact and to meet leakage tolerances as specified on drawings. If tolerances are not specified on drawings, the following applies:

 Bubble cap and similar type trays shall be designed so that with all drain holes plugged and the tray

loaded with water to the height of the weirs, the elapsed time for the water level to drop 25 mm shall be as follows:

This Document is the property of ACVC and is lent without consideration other than the Borrower’s agreement that it shall not be reproduced, copied, lent, or disposed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by patents.

Specification for

Tower Trays and Other Internals

AL-JUBAIL K.S.A

CONTRACTOR ID CODE 080036-CC-SG-004 OWNER ID CODE 080036-CC-SG-004 Sheet 7 of 10

Issue 0

ARABIAN CHLOR VINYL PROJECT

 For vacuum and atmospheric towers and other types of towers where 100% of liquid is removed

for pumping, circulating or process, use 10 minutes or more  Rerun and light end towers and all other, 5 minutes or more

 Valve type trays shall have leakage tolerances consistent with Manufacturer's standard designs.

 Sumps, draw-off boxes, seal pans and accumulator pans are to be designed to attain the tightest seal

possible, using packing and suitable sealing compounds. These items are to be tested by the tray Installer after installation in the vessel and adjusted as necessary to attain a water tight seal: the leakage tolerance specifications to be met in the test are same as specified for bubble cap trays.

 Packing if needed to meet the above requirements shall be used where necessary for proper

assembly.

 Trays for export shall be furnished with sufficient 1,5 mm thick tape gasketing material to allow the

field to completely gasket all contact surfaces of each tray, if this is found to be necessary, in the field, in order to meet the leakage requirements.

 Trays and draw off pans shall be constructed to the tray Manufacturer's standards so as to permit

easy installation or removal of plates, caps, or hold downs.

 Tray components which require drainage and which are not self-draining shall be provided with 10

mm diameter weep holes.

 All internals including deck plate sections with caps or valves assembled thereon and the support

beams, shall be sized so as to pass through the vessel man ways, except large lattice type major beams supporting two trays will be installed prior to attaching the top head of the vessel. The tray Manufacturer is to advise in his quotation when this latter condition exists.

 Field assembly joints shall be per the tray Manufacturer's standard, except that connections of the

major beams to the support clips shall be bolted using slotted holes. Field welding shall not be necessary to install internals, except where specifically indicated in the requisition.

 Trays over 915 mm diameter shall be provided with tray ways to permit access downward and upward

from tray to tray. For multi-pass trays, tray ways shall be provided to permit access downward, upward and across trays. (NOTE: This might be accomplished by a minimum of two (2) tray way. in two-pass trays, one permitting access from above on one side of centre down comer; the other from below on opposite side).

 If major beams are required (to support the minor beams) they shall be parallel to the flow across the

tray below. Beams shall not pass through down comer areas, excepting only major beams which are

This Document is the property of ACVC and is lent without consideration other than the Borrower’s agreement that it shall not be reproduced, copied, lent, or disposed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by patents.

Specification for

Tower Trays and Other Internals

AL-JUBAIL K.S.A

CONTRACTOR ID CODE 080036-CC-SG-004 OWNER ID CODE 080036-CC-SG-004 Sheet 8 of 10

Issue 0

ARABIAN CHLOR VINYL PROJECT

the main support for the tray.

6.0 MARKING

To facilitate field installation of trays all parts shall have mark numbers painted or stenciled thereon. These mark numbers shall also be shown on the arrangement and detail drawings. Mark numbers shall be prominently located and of sufficient size to be clearly distinguishable.

Nuts and bolts shall be stamped with a suitable symbol, which will clearly identify material. All other components shall be identified as to material be reference to mark number on detail drawings.

7.0 DRAWINGS

Drawings shall be furnished as follows:

 Layout drawings  Assembly drawings

 Vessel attachment drawings.

Vessel attachment drawings are to be complete so that tower rings, angles, beam supports, bolting bars, etc. may be located correctly by the vessel fabricator. The drawing of these supports shall also contain values of all fabrication tolerances. The north arrow shall be included on orientations, where requested.

8.0 SPARE PARTS

8.1 General

The project spare parts philosophy is detailed in specification 080036-DZ-SG-001 “Spare Parts Requirements”.

8.2 Spare parts for field-installed trays

 Bolts and nuts: 15% surplus, with a minimum quantity of 2 sets for each type

 Washers (metallic and non-metallic): 20% surplus, with a minimum quantity of 2 sets for each type  Clamps: 10% surplus, with a minimum quantity of 2 sets for each type

 Gaskets (Rope and tape): 25% surplus, with a minimum quantity of 2 sets for each type  20% of tape packing seal materials

8.3 Spare parts for other internals

 Bolts, nuts, washers: 10% surplus with a minimum quantity of 2 sets for each type  Gaskets, any type ( except O-Rings ): 25% surplus  Ring Gaskets : 100%

This Document is the property of ACVC and is lent without consideration other than the Borrower’s agreement that it shall not be reproduced, copied, lent, or disposed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by patents.

8.4

Specification for

Tower Trays and Other Internals

AL-JUBAIL K.S.A

CONTRACTOR ID CODE 080036-CC-SG-004 OWNER ID CODE 080036-CC-SG-004 Sheet 9 of 10

Issue 0

ARABIAN CHLOR VINYL PROJECT

8.5

Spare parts for internal packing

 Inert balls : 15% surplus

 Rings, saddles, etc.: 15% surplus

 Filter elements : 1 set for each size / material

Spare Parts for 2 Years Operation

The selection of two years operation spare parts shall include minimum requirements stated in the following table:

Columns trays

Clamp bolts, for every type installed

Bolts, nuts and washers, for every type installed

Gaskets

Washer gaskets

2% (min. 5 pieces) 15% (min. 10 pieces) 25% (min. 3 metres) 20% (min. 3 metres)

9.0 SHIPMENT

10.0

Trays shall be shipped knocked down and decks, caps and miscellaneous items shall be tagged and shipped separately. There may be cases, however, for large field erected vessels where certain parts of the trays are required be boxed for each individual tray to facilitate field installation. When this requirement is necessary, this will consist of major tray items such as tray floors, down comers and weirs, but not including major beams, bolts, nuts and hardware items and when this requirement exists, it will be indicated in the inquiry and the purchase order. For shipping instructions, refer to the Purchase Order.

All hardware shall be individually stamped to indicate the material, or alternatively, bagged and clearly identified on tags securely attached to bags.

All materials shall be properly crated and protected to prevent damage during shipment. Overseas shipment requires stronger crating and more careful protection than rail or truck shipment.

One (1) complete set of shop detail drawings, including complete installation instructions shall be shipped simultaneously with the tray materials.

INSTALLATION INSTRUCTIONS

Complete installation instructions shall be furnished for field or shop assembly of trays and tray parts, shed rows, collector pans or other internal parts supplied. These instructions shall include means to prevent excessive leakage around internal peripheries and at the ends of beams, trusses, etc.

This Document is the property of ACVC and is lent without consideration other than the Borrower’s agreement that it shall not be reproduced, copied, lent, or disposed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by patents.

11.0

Specification for

Tower Trays and Other Internals

AL-JUBAIL K.S.A

CONTRACTOR ID CODE 080036-CC-SG-004 OWNER ID CODE 080036-CC-SG-004 Sheet 10 of 10

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ARABIAN CHLOR VINYL PROJECT

RING TYPE TRAY SUPPORTS

Tray supports shall be in accordance with Engineering Standard of Good Engineering Practice.

This Document is the property of ACVC and is lent without consideration other than the Borrower’s agreement that it shall not be reproduced, copied, lent, or disposed of directly or indirectly nor used for any purpose other than that for which it is specifically furnished. The apparatus shown in the document is covered by patents.