Ei Aker Project: Site: Bayer Project Number: APG Project Number: EPRO Project Bayer Vapi Private Limited AOOKM-000158 506111-1905 STRESS DESIGN BASIS Project Phase: FEL3 (Basic Engineering) Document: File Name: - Restricted - 3 Document Number: ‘Stress Design Basis. 1905-403-00-0102-A4-001 ‘Author: Name: EMail ‘Shweta Desai 022 6641 6236 ‘Shweta desai@akersolutions.com Document Revision: + _ | sorot7 [97'S0 33 = — eo 2woseo17 | SD 82 Approval Gas AAP Date sy | PEM Status Revision Tite Checked Approved Industrial Complex Process Plant Plant section Building Division VAP. ‘EPRO- (CropScience (© Bayer Engineering & Technology ‘Aker Powergas Pvt. Ltd Powergas House, Think Techno Campus, Kanjurmarg (E). Mumbai - 400042 Tel: +91 22 6691 5901] Fax: +91 22 6691 5934 | wn akersolutions.com Confidential © 2017 Aker Solutions Pc1805009_RoDivision: CROPSCIENCE Bayer Project No: AOOKM-000158 APG Project No:_06111-1905 GDL Chapter No: 11.03.01 # VAPI, INDIA Doc No: 1905-403-00-0102-A4-001 L Plant: EPRO Doe Title: Stress Design Basis AkerSoluti Date 1110077 | RevNo 07 PAGENO 2 of 16 SIGNATURES: Author Name Title Date / Signature Shweta Desai Stress and Support Coordinator PF ror017 Contributor Name Title Date / Signature Checked Name Title Date / Signature comtswan | rinnsransrastsiet | OME sar Approved Name Title _ Date / Signature Abhijeet Patsule ‘Supervisor Fiitor2017 ‘© Bayer Engineering & Technology P1905008_R0 Confidential © 2017 Aker SolutionsIE AkerSolutions Division: CROPSCIENCE Location: VAPI, INDIA Plant: EPRO Bayer Project No: A0OKM-000158 APG Project No:_5061 11-1905 GDL Chapter No: 17.03.01 Doc No: 1905-403-00-0102-A4-001 Doc Title: Stress Design Basis Date 17702017] — Revo. OF PAGENO_3 at 15 REVISION HISTORY: Rev./ | a D: vos. ate Change Description 0 | 210812017 | Original Issue 1 | 111072017 | Revised As Marked Ri” “ebayer Engineering & Technology Pc1905009_RO Confidential © 2017 Aker SolutionsBayor Project No: AOOKI-000158 JAPG Project No:_506111-1905 |GDL Chapter No: 11.03.01 Division: CROPSCIENCE Location: VAPI, INDIA Doc No: 1905-403-00-0102-A4-001 ~ brant: EPRO Doe Tile Sess Design Basis IE AkerSolutions Sa ART [a ae DOCUMENT REFERENCES: Current Rev. / Vers. of this Document | 0 Referenced Documents Document Booument Revision / Version Name number ‘@ Bayar Enginesring & Technolopy Confidential © 2017 Akar Solutions Pc1908009_R0[Bayer Project No: AOOKM-000158 lon: CROPSCIENCE APG Project No:_506111-1905 GDL Chapter No: 11.03.01 Doc No: 1905-403-00-0102-A4-001 Verts | EPRO Doe Tie: Stress Design Basis Ei AkerSolutions aes TOT Rare meee TABLE OF CONTENTS. Location: VAPI, INDIA 1 General... . 2. Stress Analysis. 24 Stress analysis design criteria, 244 Design Codes....... 242 Stress Critical Line List Basis.. 2.1.3 Conditions Considerations... 21.4 Load Case Consideration... 21.5 Nozzle Loading 12 22 TOI nnn . 13, 221 Software And Version ... 13, 222 Geometrical Database... 13, 2.3 Caesar-il modelling for critical Piping components:- nee 2.3.1 Modelling of Elbows to Include Stiffening Effects of Flanges ... 14 2.3.2 Integration of SIF in Caesar-Il for unconventional pipe intersections. 14 2.3.3. Use And Modelling of Expansion Joints (EJs): M4 23.4 Use and modelling of Flexible Hoses:- 15 ‘© Bayar Engineering & Technology Confidential © 2017 Aker Solutions PC1805009_RO8 eden) Division: CROPSCIENCE _ [APG Project No:_506111-1905 (PAXER) GDL Chapter Nor 17.03.01 RA Location: VAPI, INDIA IE AkerSoluiions |r" EPRO Doe Title: Stress Design Basis, Bayer Project No: AOOKM-000158 Doc No: 1905-403-00-0102-A4-001 Date 107017 _] Row No.1 PAGENO 6 of 15 1. General 1.4. Client Bayer Vapi Private Limited 1.2 Project EPRO Project, 1.3 Process Licensor Bayer Crop Science 1.4 Site Location Vapi 2. Stress Analysis The stress critical line selection criteria below are only applicable to lines which have significantly changed from the original design. 21 Stress analysis design criteria 24.4 Design Codes Chemical Plant Piping Steam Piping Power plant piping (Applicable code and edition as per contract Instruction shall be used). ASME B 31.3, ‘ASME 8 31.3 / Indian Boiler Regulations (for Indian project) or ASME B 31.1 if used for power generation. ASME B 31.1 24.2 Stress Critical Line List Basis, Piping connected with centrifugal pumps having size 65 mm (2%) NB and above with maximum operating temperature of 120° C and above and 150mm (6") NB and above size with maximum operating temperature af 60° C and above(use solar black body temperature). All other lines as below : * 4° to 6%: design/analysis temp. above 300°C + 8"to 14”: design/analysis temp. above 150°C ‘+ 46" and above: design/analysis temp. 80°C. ‘+ Jacketed Lines - All sizes ‘+ Any line for which formal calculations are specified, either by client or focal authorities. For example, for Indian project IBR-370 calls for flexibility analysis of IBR controlled piping. However same temperature criteria shall be followed as stated above. «For open PSV discharge systems, lines connected to PSV's 2° & above having set pressure 5.0 Kg/cm? ‘+ For close PSV discharge system, all lines 6" and above inlet line size shall be analysed. + Lines connected to Vessels fabricated from fragile Construction such as graphite, glass, etc. ‘© Bayar Enginearing & Technolooy P190G009_RO Confidentia!© 2017 Aker SolutionsI AkerSo! Dates T0017 Bayer Project No: AOOKIM-000158 ision: CROPSCIENCE APG Project No:_506111-1905 GDL Chapter No: 11.03.01 Location: VAPI, INDIA Doc No: 1905-403-00-0102-A4-001 Plant: EPRO PAGENO 7 of 15 size shall be analysed, Lines meeting Wind analysis criteria ‘+ Lines meeting Seismic analysis criteria + Lines meeting Steam-out criteria ‘+ Any other lines that the Piping Engineer andi or Lead Stress Engineer consider Critical + Lines connected to Column Top, Bottom. + All3" and above lines with wall thickness in excess of 10% of outer diameter. * All 20" and above fines with wail thickness less than 1% of outer diameter. + All the lines with Category ‘M’ fluids shall be analysed. + Stress analysis of PP FRP lines for all the sizes shall be in vendor's scope. + For Lines with bursting disc, 6” and above inlet line (Below criteria is for preiminary/visual Stress analysis only. No documentation shall be done + Lines 65 mm (2%") NB to 80 mm (3°) NB from temperature 260° C to above. * Lines 100 mm (4") NB to 150 mm (6") NB from temperature 120° C to 300°C + Lines 200 mm (8°) NB to 350 mm (14") NB from temperature 120° C to 150°C. * Lines 650 mm, (26") NB and above in between temperature 60° C to 80° C (use solar black body temperature). For subzero lines: + Lines 65 mm (2%) NB to 125 mm (5*) NB at temperature (-) 200° C or below. + Lines 150 mm (6") NB to 600 mm (24") NB at temperature (-) 100° C or below. + Lines 650 mm (26") at temperature (-) 40° C or below. ‘@ Bayer Enginooring & Technology Pc1905009_Ro Confisental © 2017 Aker Solutions (Rn) OD)B Bayer Project No: AOOKM-000158 Sen) Division: GROPSCIENCE APG Project No: _506111-1905 E ) | GDL Chapter No: 17.03.01 al Location: VAPI, INDIA Doc No: 1905-403-00-0102-A4-001 Doc Title: Stress Design Basis, Ii AkerSolutions [Pe Date 11702017 [| Rew No. 01 EPRO PAGENO 8 of 15 2.4.3 Conditions Considerations Max. op.) Pressure (Design/ operating! ‘* Design pressure shall be used for analysis. + For occasional cases: operating Pressure, & for Upset cases: respective conditions, shall be used, © Allworst cases will be ensured + For design of expansion joint max. operating pressure will be used, Operating) For line analysis, Temperature (Design/ Max. op./ Design temperature and operating / analysis, temperature will be used for stress analysis. + For occasional cases: operating condition, & for upset cases: respective conditions, shall be used. All worst cases will be ensured ReferenceInstallation temperature for analysis As per site condition /21°C. Wind pressure/ velocity Seismic Wind loading conditions as per ITB document or IS 875_Part_3. Wind analysis selection criteria, + Lines viz. column overhead lines, transfer lines. Lines running other than shielded structure & pipe-rack with diameter 20" (including insulation) & above and at elevation 10 m & above. Seismic analysis will be performed when piping satisties any one of the following criteria, + All emergency service pipe line above ground with mass equal to or greater 111kg/m (corresponds to 10" STD schedule water filled pipe line) * All two phase vibration prone slug lines with mass equal to or greater 148kg/m (corresponds to 12° STD schedule water filled pipe line) +All lines with flange rating 900 # & above higher pressure class with a mass greater than the 210kg/m (corresponds to 16” STD schedule water filled pipe line) + For all other lines which do not come under any of above three types following criteria shall be considered - All piping systems above ground with a mass greater than the 420kg/m (corresponds to 24" STD schedule water filed pipe line) © Bayer Engineering & Technology Pc1905009_R0 Confidential © 2017 Aker Solutions (R)Plant: Ie AkerSo Date 117107017 vision: CROPSCIENCE, Location: VAPI, INDIA Bayer Project No: AOOKM-000158 APG Project No:_506111-1905 GDL Chapter No: 11.03.01 Doc No: 1905-403-00-0102-A4-001 Doc Title: Stress Design Basis EPRO PAGENO. 9 of 15 + All piping systems above ground with any part routed at or greater than 25m and with a mass. greater than the 210kg/m (corresponds to 16" STD schedule water filled pipe line) Site spectrum & multiplication factor as per site Information criteria or 1S1893-Partt. ‘Two Phase Flow subject to - Oynamic Analysis for natural frequency checks to be Slug Plug Flow done. Natural frequency of piping system to be 4 Hz and higher. Piping system to be checked for manually calculated slug forces in static analysis. Solar expansion 60°C (Use black body solar radiation.) ‘Steam out condition For all hydrocarbon lines or lines specified in Line list Lines considered to be connected to equipment. Refer Stress ciitcal fine list for lines where this criteria és governing Friction factors for various Steel to steel 03 suriaces Steel to Graphite 045 (Friction to be used for vertical pn : loads only. No friction willbe | Steel to PTFE oa used for horizontal loads) 1~ Roller bearing 0.05 Finished $.S to S.S 0.15 Mill Tolerance 12.5% or as specified for exotic materials. Insulation Thickness & Density Insulation Thickness As per Line list. Density — Mineral woot- 150Kg/m* Puff- 160Kg/m? Usage of cold pull Generally Not allowed, Usage of expansion bellows if yes, specify probable vendor Permitted where identified in P&I0's. Use Senior Flexonics / Pathway for preliminary vendor data, or actual past project data 2.1.4 Load Case Consideration Sustained Load Case + Design Pressure as specified in the line list for individual lines shall be used within the piping system weight analysis. + Design Pressure as specified in the piping specification index shall be used for pipe and pipe component pressure calculation. ‘© Bayer Engineering & Technology C1905009_RO Confidential © 2017 Aker SolutionsFe Bayer Project No: ADOKM-000158 (ea8er) Division: CROPSCIENCE | APG Project No:_506111-1905 \ Ek y | GDL Chapter No: 11.03.01 RS Location: VAPI, INDIA Doc No: 1905-403-00-0102-A4.001 ve [Plant: ERO Doe Title: Stress Design Basis EE AkerSolutions Ba TOOT [Rev We PAGENO_10 aE Weight of the piping system shall be taken from software library. Operating load case Displacement Stress Range ‘Thermal loads (for hot lines) may be calculated using elastic modulus at max. operating temperature, or, conservatively at 21.°C Solar radiation effect shall be considered if tong line is exposed to sun-light for a long time with stagnant fluid or empty. No. of thermal cycles 7000 Sustained + displacement Expansion loads + Equipment ‘Temp. Load + Equipment displacement Highest stress value within allowable stress value of code Liberal allowable stress may be used, Thermal stress shall be calculated using elastic modulus at 21°C Steam out case Steam out case shall be considered for the lines indicated in the Line list. Steam out temperature will be max operating Temp & Low Pressure Steam. Pressure wil be 0.5 kg/cm’g. Equipment & piping to be considered at same temperature. Considered as occasional load case. In case line temperature is above steam out temperature, this case will not be analysed. Steam out case will be done with lines connected to equipment and checked for stress and nozzle loading but not flange leakage Occasional Load case Wind Load case Sustained load + Wind load for Code Stress Check Operating load + Wind load case only for support. Two occasional cases shall not be considered together. Line connected to tall equipment, the equipment sway due to wind shall be considered for line wind design in terms of nozzle & Support as per Site wind conditions, “© Bayer Engineering & Technology PC1605009_RO Confidential © 2017 Aker SolutionsB & \ (Baver}) Ye J R EE AkerSolutions Date 11102017] _RevNo.07 Location: VAPI, INDIA Plant: jon: CROPSCIENCE Bayer Project No: ADOKM-000158. APG Project No: _506111-1905 GDL Chapter No: 11.03.01 Doc No: 1905-403-00-0102-A4-001 EPRO PAGENO_11_of 16 + Equipment shall be modelled as actual diameter and thickness, ‘+ Nozzle loads shall not be qualified for wind load cases. Seismic Load Case ‘= Sustained + Seismic load - Code stress check * Operating + seismic load only for nozzle & support loading. + Line connected to tall equipment, the equipment sway due to seismic shall be considered + Equipment shail be modelled as actual diameter and thickness, and contents + internals modelled with adjusted contents S.G. ‘+ Nozzle toads shall not be qualified for seismic cases. Start-up & Shut down foad case Consider this case for 1. Column connected lines 2. Continuous Reactor connected lines 3. Intermittent operation lines. (Process group to be referred) 4. Lines connecting to equipment with large Thermal mass. Pump suction & discharge lines ‘The following conditions shall be considered * Operating condition Pump A and Pump 6 hot. + Operating condition Pump A is operating and Pump B, Standby. ‘+ Operating condition Pump B is operating and Pump A, Standby. Hydrostatic test case As identified in line list for pressure & Test Medium. All lines assumed hydro tested Unless noted otherwise. Calculations required for Lines 12°NB and above only. Analysis Option * Pressure Stress = PD/ at 2 Vertical direction = Y ‘* Include axial force in stress calculation. ‘* Use liberal allowable stress. * Bourdon effect on thin walled lines 24” & above on ‘compressor only. ‘© Bayer Engineering & Technology Pc1908009_Ro Confidential © 2017 Aker Solutionsa (opBen (Bayer) Ve J R Plant: EE AkerSoliiions Date 11102017 [Rew No Of Division: Location: VAPI, INDIA Bayer Project No: AOOKM-000188 CROPSCIENCE APG Project No: _506111-1905 GDL Chapter No: 11.03.01 Doe No: 1905-403-00-0102-A4-001 Doe Title: Stress Design Basis EPRO PAGENO 12 of 15 2.1.5 Nozzle Loading Fabricated equipment Proprietary equipment Nozzle flexibility consideration Nozzle Loads to be qualified for Max. conditions and not for design conditions. Operating Allowable loading chart for Static Equipment as furnished by Vessel Group (APG Nozzle loading Std) or as agreed with equipment vendor. To be decided by case to case basis, not as default For ANSI pump, 0.8 times API 610/ Vendor allowable Centrifugal pumps Centrifugal Compressor Air Fin Cooler Turbine ‘Two times API 610 allowable as minimum, ‘Two times API 617 allowable as minimum, Two times API 661 allowable as minimum, Two times NEMA SM23 allowable as provided by vendor/Manufacturer. imum or as Lined equipment tank One times Table 1 of APG Nozzle loading Std. as minimum or as agreed with equipment vendor. Reaction Force Calculation Safety valve/ Control valve with open discharge: Calculated dynamic force to be fed as force at the outlet ofthe tailpipe to atmosphere. STD, API RP5S20/ASME B31.1/ CAESAR II PSV Module to be used for force calculation Safety valve or Bursting disk in liquid service with closed discharge into vent header /flare header. All forces are balanced in steady-flow condition. Unbalanced “pop” force is short duration. System to be restrained against vibration, Long pipe runs (>40D approx’) shall be restrained axially. Use Caesar Il PSV module for calculating force on restraint Settlement Case No settlement to be considered for piled foundation. No differential settlement between open foundations to ‘open foundation. For settlement condition identified for area like tank farm, first support to be taken from equipment foundation. Civil to inform accordingly. Springs * — % load variation for Critical lines shall be generally up to 25%. G Bayar Enginesring & Technology Pc905009_RO Confidential © 2017 Aker Solutions 0)Plant: Date. 11102017 | Revo. 01 Division: CROPSCIENCE Location: VAPI, INDIA EPRO Bayer Project No: AOOKM-000158 APG Project No:_506111-1905 GDL Chapter No: 11.03.01 Doc No: 1905-403-00-0102-A4-001 PAGENO 13 of 16 Normally Spring selection at operating temperature, But total range including design and upset conditions tobe ensured, ‘Spring located near pump and sensitive equipment nozzle will be designed to free the nozzle. ‘The % load variation shall be limited to plus or minus 6% of the calculated load for strain sensitive equipment such as compressors turbines which have a low range of allowable loading. Disptacements Generally the permitted displacements in horizontal directions to be limited to ‘Axial direction = 200mm Transverse deflection due to sustain loading = 25mm, max. Max. permitted sagging in vertical direction Vertical deflection in piping system in horizontal run between two adjacent support due to sustained loading shall be limited to 3mm max. for steam lines. % of gradient for stopping lines. 415 mm max. for all other lines. 22 Tools 2.2.4 Software And Version CAESAR II Version — 7.0 will be used. 22.2 Geometrical Database + Software library shall be used for piping ‘components, valves etc, including weight of the ‘components. In case not available, relevant vendor data to be used. Model need not be updated when final vendor data is received for valve weights except for control valves and other actuated valves. ‘+ Insulation thickness shall be entered from fine list + Specific gravity shall be as follows, Liquids = Actual Vapour! liquid mixture = 0.1 if actual not available Steam/ Vapour/Gas = nil ‘S Bayor Enginesring & Technology P1906009_RO Confidential® 2017 Aker Solutions(safer) Ee B o Division: R EE AkerSoiution: Plant: EPRO Date T0207 Rev No. OF CROPSCIENCE Location: VAPI, INDIA Bayer Project No: A00KM-000158 APG Project No:_06111-1905 GDL Chapter No: 11.03.01 Doe No: 1905-403-00-0102-A4-001 Doe Title: Stress Design Basis, PAGENO 14 of 15 2.3 Caesar-II modelling for critical Piping components: 2.3.4 2.3.2 Modelling of Elbows to Include Stiffening Effects of Flanges Integration of SIF in Caesar-iI_ for unconventional pipe intersections Caesar model for elbows / bends shall | include for the stiffening effects of flanges: (bend type-1 and type-2 in Caesar) This requirement is as per B31.3 Appendix D When the flange is welded to the pipe, close to the elbow / bend such that the weld-to- weld distance is one pipe diameter or less, then the flange shall be taken as welded direct to the elbow / bend, for the purpose of determining the bend type in Caesar, For large radius bends: The B31.3 correction factor applies only where factor h is < 1.0. Caesar does not check this, therefore do not use Caesar types 4 and 2 when the bend radius exceeds 1.5 Times D. For unconventional pipe intersectionyjoints such as lateral tee, Y-piece, Crosses etc. It is. recommended to consider 1.5 times SIF of C- WI calculated values, as C-ll does not calculate accurate SIF for unconventional pipe intersection geometry. This factor will provide on a conservative side. The same to be discussed with stress leadico-ordinator to implementation. 2.3.3 Use and Modelling of Expansion Joints (Eds) The use of EJs shall be minimised; however, due to the nature of Piping system there will be some locations where they cannot be avoided. The EJs shown on the first issue of the PID’S will require confirmation during basic design phase. Caesar Application Guide can be referred for EJ modelling, Common modelling errors are: Missing Cnodes on hinges, lateral EJs with free rotations, unrealistic spring rates, etc. Weights for preliminary models should be reasonably accurate, especially for large EUs. An estimated weight for a tied EJ shall be no less than ‘Two flanges + twice the empty weight of the same length of pipe + the weight of the ‘© Bayer Engineering & Technology P01905008_Ro Contidentia!® 2017 Aker Solutions(Ba A Location: VAPI, INDIA EE AkerSoiutions |r" Fe Date 117102017 | _RovNo.01 (am<>o) Bayer Project No: AOOKM-000158 ER) Division: CROPSCIENCE ‘APG Project No: _506111-1905 GDL Chapter No: 11.03.01 Doc No: 1905-403-00-0102-A4-001 Doc Title: Stress Design Basis, PAGENO15_of 15 ~ contents Weights for final models must be accurate where springs and/or sensitive equipment are part of the system. For tied lateral EJs, make sure the end rotation freedoms in the model match the number (2 or 3+) of tierods on the data sheet. Self-check the displacement results in detail All parts of the EJ must displace correctly, eg. rotation of start and finish node of a lateral EJ with 3 or more tierods must be identical 2.3.4 Use and modelling of Flexible Hoses- | « Hoses should not be oriented to absorb axial expansion, as this buckles the braiding and the equipment or piping is then subjected to the full pressure thrust, Modelling of hoses in Caesar should be avoided by locating a restraint adjacent to the hose and modelling a free end of the pipe. For a large (say >100NB) hose, if the lateral stifress “is available, the hose may be modelled using a smaltbore pipe of equivalent fateral stiffness. ‘© Bayer Engineering & Technology Pc1805009_RO CContdentia!© 2017 Aker Solutions