A 30.11.2013 ISSUED FOR INFORMATION O.Y O.Y E.D

Rev.No. Date Description

Prepared Checked Contr. By Approved ------------

ORIGINATOR Published by

EDOPEC ENERJİ PETROL MÜHENDİSLİK SANAYİİ VE TİCARET LİMİTED ŞİRKETİ

Contractor

Document Title

DOUBLE WALL AMMONIA STORAGE TANK DESIGN

Office :

Palmiye Mah. Adnan menderes Bulv. Oktay Sitesi No: 9/8 PK = 33100 Yenişehir/Mersin –TURKEYP:+90 324 3260595 F:+90 324 3260596Ankara Office :UĞUR MUMCU CAD(köroğlu cad) ERDİL APT 87/13 Gop-Çankaya -Ankara-TURKİYEP: +90 312 447 17 18 / 20F:+90 312 447 17 21İstanbul Office: Burhanıye Mahallesı Çamlıca Caddesi İhlamur villaları no 28 / 6^ŞRD3K Villa ^ Beylerbeyi –Üsküdar İstanbul / TURKEYP : +90 216 4220414 PBXF: +90 216 4220415www.edopec.com. info@edopec.com

Document No.

EDO PPP ME GNR INT XXX 013 107 108 Rev ACo. Org.

CodDoc Type

Disc. Code

Unit Code

Prj. type

Prj.NO

Prıj.Year

Pro.Doc.Seq.No

DCC Seq.NoPage Scale

33

DESIGN,SUPPLY AND CONSTRUCTION OF AMMONIA STORAGE TANK

TANK DETAIL

SERVICE = Refrigerated Liquid Ammonia ProductTANK TYPE = Double Containment DESIGN CODE ‘S = API 620 ,

ANSI K61.1.,Standarts for The Storage and Handling of Anhydrous AmmoniaAPI 2000API 2550ASCE 97-1

AMMONIA STORAGE TANK DESCRIPTION

BASIC DESIGN PARAMETER Capacity = …. tonnes Inner tank Volume = …. m3 (Inner Tank ) Tank Diameter = … meter (Inner Tank) Tank Height = … meter(Inner Tank) Outer tank Volume = ……. m3 (Outer Tank ) Tank Diameter = … meter (Outer Tank) Tank Height = … meter(Outer Tank) Materials

ASTM A 516 GR 60 , or ASTM A 537 Cl1, DIN EN 10025-P275 NL1 NL2

PROJECT EXECUTION PLANE

TANK SHELL CALCULATIONS

DOME ROOF CALCULATIONS

SPRAY DETAIL

SOIL AND EARTHQUAKE INVESTIGATION

INTERNAL CATHODIC PROTECTION CALCULATIONS IF REQURED

EXTERNAL CATHODIC PROTECTION CALCULATIONS IF REQURED

EARTHING CALCULATIONS

LIGHTING CALCULATIONS IF REQURED

WELD MAP

INSPECTION TEST PLAN

WPS

PQR

LİST OF MATERIAL (STEEL PLATE,BOLT,PIPE)

Cathodic Protection and LIGHTING EARTHING MATERIALS

PAINTING

MECHANICAL INSTALLATION MANUAL

ELECTRICAL INSTALLATION MANUAL

INSTALLATION AND COMMISSIONING MANUAL

MONTHLY PROGRESS REPORT

WEEKLY PROGRESS REPORT

REFRİGİRATİON SYSTEM CALCULATION

TANK BOTTOM PLATE ERECTION DETAIL

-

TANK SHELL PLATE GENERAL LAYOUT

TANK SHELL STAIRS AND BALUSTRADE DETAIL

ROOF STAIR SHELL DETAIL

ROOF STAIR SLEDGE DETAIL

NOZZLE ORIENTATION

ROOF DRAIN NOZZLES DETAIL

SHELL MANHOLE DETAIL

DOME ACCESSORIES DETAIL

COOLING SYSTEM DETAIL

INTERNAL CATHODIC PROTECTION SYSTEM GENERAL LAYOUT DETAIL

EXTERNAL EARTHING DETAILS

TANK BOTTOM EXTERNAL CATHODIC PROTECTION SYSTEM LAYOUT DETAIL

VENTING CALCULATION

HSE DOCUMENTS

QAC CONTROL DOCUMENTS

GAS DETECTION –TEMPERATUR AND PRESSURE TEMP. SYSTEM DETAIL

ALL INSULATION SYSTEM DESIGN AND CALCULATION

ENGINERING AND PROJECT CONTROL DOCUMENT SCOPE

The scope of the project will cover the below mentioned engineering work. Preparation of the production quality plan. Calculations to be made according to the standards & detailed drawings for storage tank.Determination the material quantity, thickness, dimensions etc.To prepare the welding projectsPreparation of the WPSPreparing Pipe Isometrics for the all tank connection -Detailing all connections regarding the Electric & instrumentation Preparation of the numbering systemPreparing of the packaging plansPreparation of the quality files for all productionPreparing hand book for ErectionPreparing hand book for maintenance & operation All other kind of works mentioned for the technical list of conditions.

SCOPE OF ENGINEERING

STORAGE PRODUCT DATA: Normal Operating Temperature : -35°C Normal Operating Pressure : 0.051 Kg/cm2g Liquid Density : 673 kg/m³ Vapour Density : 0.89kg/m³ Viscosity (vapour) : 0.007 cP Viscosity ( liquid) : 0.25 cP Molecular Weight : 17.03 PRIMARY TANK DESIGN CONDITIONS : Design Pressure - Inner Tank : 0.153 Kg/cm2g - Outer Tank : 0.00775 Kg/cm2g Vacuum Design Pressure (Inner & Outer) : 0.00612 Kg/cm2 * Design Temperature: Shell : –40 / +60°C Design Temperature: Roof : -27°C/ +60°C

BASIC DESIGN PARAMETER

ALGORITM FOR PREFABRICATION Material Selection Design and Calculation Materials Supply, procurement Additional Testing for plate Welder Qualifcation ASME IX( Welding and Brazing

Qualification WPS , PQR) Welding – (if necc.. Heat Treatment) NDT ( Xray , dye penetrant, ) 3.rd party Control Final Documentation Package and loading Transportation

VENDOR LISTMaterial Vendor Origin of the

ProductPressure Vacuum Vent Turkey

Cathodic Protection Instruments Turkey

Pipes Borusan, Mannesman TurkeySteel Plates Erdemir,Arcelor Turkey-ItalyPaint Jotun

İnternationalHempel

NorwayUSA

Flanges Gürgenler, Nişancı TurkeySteel Bolt Ar Conta Turkey3.Party Inspection TUV Turkey

NDT AÇI Turkey

Calibration AÇI Türkey

Engineering Türkey

SCOPENo” Work and Materials Unit

1 Basic design Each

2 Tank steel materials- For Inner Tank kg

3 Factory production, cutting ,Preparing plate edges for welding, plate bending, site erection - for Inner Tank kg

4 Tank steel materials- For Outer Tank KG

5 Factory production, cutting ,Preparing plate edges for welding, plate bending, site erection- for Outer Tank KG

6 Paint for Inner Tank İnternal and external m2

7 Paint for Outer Tank Internal and external m2

8 Blast and Painting m2

9 4" Nozzle 150 Class Each

10 2" Nozzle 150 Class Each

11 8" Nozzle 150 Class Each

12 10" Nozzle 150 Class Each

13 1 1/2" Nozzle 150 Class Each

14 3" Nozzle 150 Class Each

15 4" Nozzle 300 Class Each

16 6" Nozzle 300 Class Each

17 1 1/2" Nozzle 300 Class Each

18 10" Relief Valve Each

19 10" Vacuum Breaker Each

20 8" Relief Valve - For Annulus Each

21 8" Vacuum Breaker for annulus Each

22 Manhole 24" Each

23 CL Out Door 36x48" Each

24 Cathodic Protection Materials for Inner Each

25 All Spray Rings other equipment and pipe Lot

26 Cathodic Protection Materials for External Lot

27 Level Gauge Each

28 Pressure Transmitters Each

29 NDT and Other Service Lot

Gas Detection System Lot

30 Temperature Thermocouples Each

Scope Description Qty Unit1 Main Component2 Miscellaneous Items

PipingInstrumentation Lot 1

Electrical Lot 1Steel Structure Lot 1

InsulationPaint Lot 1

Lube Oil3 Spare Parts

Erection and Commisioning Spare Lot 1Two Years Operation Spare Lot 1

4 Inspectıon and Testing Lot 15 Exports Packing Lot 16 Ocean Transportation Lot 17 Vendors Services

Engineering Lot 1Documantation Lot 1Shop Training Lot 1

Erection Supervision Lot 1Commissioning Supervision including Test Run Lot 1

BREAK DOWN LIST

PIPING SYSTEMS FOR ANHYDROUS AMMONIA

Piping for anhydrous ammonia systems should be extra heavy (Schedule 80) carbon steel when threaded joints are used. Standard weight (Schedule 40) carbon steel may be used when joints are either welded or joined by welding type flanges. Teflon tape along with Gas-Oil Pipe Thread Sealer have been used successfully as a pipe thread lubricant and sealer and is highly recommended.

All piping should be well supported and provisions should be made to protect the piping against the effects of expansion, contraction, jarring, vibration, settling and external corrosion. All fittings should be forged steel; non-malleable metals must not be used. Unions should be of the ground joint type. Some unions have brass seats which must not be used.

PIPING SYSTEMS FOR ANHYDROUS AMMONIA

All piping should be tested for leaks after assembly by introducing ammonia vapor.

Do not introduce liquid ammonia initially because, if it is necessary to disassemble the piping to repair the leak, excessive bleed down time will be necessary. Refer to the section covering ammonia leaks. Wherever there is the possibility of liquid ammonia being trapped between two valves, provisions must be made to include a hydrostatic relief valve to protect the section of isolated pipe and valve. Rubber hoses should never be used in permanent installations. Use only all steel gauges and valves made for ammonia service.

All piping shall be supported to prevent damage to the pipes. Provisions shall be made for expansion, contraction, jarring, vibration, and settling. All refrigeration system piping shall conform to the Refrigeration piping Code (ANSI B31.5) as it applies to anhydrous ammonia.

STANDART LIMITATIONS

The maximum design pressure of the tanks covered by this European Standard is limited to 500 mbarg. For higher pressures, reference can be made to EN 13445.

prEN 14620-2, Site built, vertical, cylindrical, flat-bottomed steel tanks for the storage of refrigerated,liquefied gases with operating temperatures between –5 °C and –165 °C — Part 2: Metalliccomponents

prEN 14620-3, Site built, vertical, cylindrical, flat-bottomed steel tanks for the storage of refrigerated,liquefied gases with operating temperatures between –5 °C and –165 °C — Part 3: Concretecomponents

prEN 14620-4, Site built, vertical, cylindrical, flat-bottomed steel tanks for the storage of refrigerated,liquefied gases with operating temperatures between –5 °C and –165 °C — Part 4: Insulationcomponents

STANDART’S• ANSI/IIAR 2-1992 - Equipment, Design, and Installation of Ammonia

Mechanical Refrigeration Systems Available from International Institute of Ammonia Refrigeration (IIAR)1200

• American National Standards Institutes (ANSI)K61.1, 1999 - Standards for the Storage and Handling of Anhydrous Ammonia Available from ANSI11

• NFPA 59A Standard for the Production, Storage, and Handling of Liquefied Natural Gas (LNG)

• API 0620 Design and Construction of Large, Welded, Low-PressureStorage Tanks

SAFETY RELIEF DEVICES Every container used in systems without permanent supply piping to

another source of excess pressure shall be protected from excess pressure by one or more pressure relief valves of the spring loaded type conforming with applicable requirements of ASME UG-125(c)(3); UL-132, “Standard on Safety Relief Valves for Anhydrous Ammonia and LP Gas”, or other equivalent pressure relief valve standard.

Pressure relief valves shall be in direct communication with the vapor space of the container. All pressure relief discharge openings shall have suitable rain caps that will allow free discharge of the vapor and prevent the entrance of water. Provision shall be made for draining condensate that may accumulate.

The discharge from pressure relief valves shall be vented away from the container, upward, and unobstructed to the atmosphere.

MATERIAL SELECTIONIn accordance with API 620 App.R For Double Containment with two metallic walls

Storage Tanks:

Materials for primary Components

For the design temperature of the inner shell as -40 0C SA 516 groups of the materials have enough

impactvalue

TENSILE PROPERTIES OF THE SA 516 AND IT MEETS THE YIELDSTRENGTH REQUIREMENTS OF MAX. 305 N/MM2

Materials for Secondary Components

PrEN14620 Material Requirements:

DESIGN AND CALCULATION

Tank will be designed in accordance with API 620 App.R for most severe condition which is defined by the user.

All load case will be considered in design calculations and combinations of the loadings will be clearly defined in the calculation.

Design calculations will be prepared by software.

Materials SupplyAll primary and secondary materials are supplied with

EN 10204 3.1 type material certificates. Also Material test results will be clearly defined and all materials will be purchased by specific purchase specifications.

ADDITIONAL TESTING FOR PLATESFor primary and secondary components, all materials

must be ordered as impact tested materials. And special carbon equivalent requirements must be considered (Ceq max 0.40).

Also yield strength of the materials must be limited as max.305 N/mm

WELDINGEach welding procedure specifications shall be qualified in accordance with ASME Sect. IX and additional requirements which outlined in project specifications are also considered. Test coupon shall be welded in horizontal and vertical pozition.

Welders and welding operators shall be qualified in accordance with ASME Sect. IX .

NDT-All of the exposed edges of the plates or pipes which contact with process fluids or vapour shall be checked by surface crack test

-All shell plates and annular plates shall be UT tested in accordance with BS 5996 grade L4

-All welds on pressure parts and temporary attachments shall be subject to MPT.

-All butt welding on tank including seal plate shall be subject to RT.

-All welding surface (bottom, corner and butt welding of shell) shall be checked by LPT before hydrostatic test.

-UT examinations which outlined in PS 26.4.16- All of the material and weld surfaces shall be subjected to visual

inspection

NDT PERSONNELNDT personnels shall have ASNT SNT-TC-1A LII for

interpretation results and LI if they are given written acceptance/ rejections criteria prepared by LII or LIII.

Personnel who has EN 473 LII or LI certificates can be employed if personnel has additional trainings on used NDT procedures.

ADDITIONAL TESTING ON WELD

When the welding completed below listed joints subjected to Vacuum box control for entire length

-All bottom annular plates welding.-All Roof plates welding.-All side wall linings-All suspended deck welding (if welded types)