Installation Manual Urea Flare Stack

5/14/2018 Installation Manual Urea Flare Stack

1/23

J.. !!!rI'D~S~'!"! DAEWOO E&C"II FOR CONSTRUCT ION I

INSTALLATION AND ERECTIONINSTRUCTION MANUAL

UR01/02-25-U-101zU102zU201FLARE STACK

\ A V Y I~~\-\ ~~~ J..


2/23

OWNER: PAGE 1 OF 23I JOHN ZINK EI-Djazairia EI-OmaniaL il Asmida Spa S.O. 9096357JOHN ZINK COMPANY LLC PROJECT CUSTOMER: MHIAlgeria Oman Fertiliser Project (AOFP) REV. 3

. , J . . . . ~"'"!Y.!'R~l"'! DAEWOO E&C

INSTALLATION & ERECTION MANUALFOR

UT-01!02-25-U-101,102,201FLARE STACK

3 10/13/2010 CUSTOMER APPROVAL REVISED JF TR HB2 9/ 17120 10 DOCUMENT RE-EOITED JF HB HBERECTION PROCEDURE FORFRONT END AMMONIA FLARE

1 5/18/2010 STACK HB HB HBERECTION PROCEDURE FORFRONT END AMMONIA FLARE0 3/312010 STACK HB HB HB 9096357-91

Nr. DATE DESCRIPTION BY CHK APP DOCUMENT Nr.


3/23

JOHN ZINKJO HN ZINK CO MPANY LLC

ERECTION PROCEDURE FORFRONT END AMMONIA FLARE STACKSUTOll02 -25-U-I01l102 Train 1& 2 & U-201S.0.9096357 Doc # 9096357-91

MHI DOC # 6423MU350-00-10910-00Rev. 3

Installation and Erection InstructionsFor

ALGERIA OMAN FERTILIZER

PROJECT AMMONIA FLARE STACKS

U-tOl/U-t02 &U-20t

Note: Document re-edited on each page no revision triangles provided.

R ev Dare Page Description Prpd Chkd Appd0 01110/10 All I ss ued fo r A pp ro va l JF. T R . HBT .I 05/17/10 AS NOTED C U S T O MER C OMMEN T S ADDED JF . T R . HBT .2 09116/10 All Document re-edited JF HBT HBT3 10/11/10 As noted C ustomer C omments added JF HB BBT

Page 2 of22


4/23

JOHN ZINKJOHN ZINK CO MPANY LLC

ERECTION PROCEDURE FORFRONT END AMMONIA FLARE STACKSUTOI/02 -25-U-IOllI02 Train 1 & 2 & V-201S.O. 9096357 Doc # 9096357-91MHI DOC # 6423MV350-00-10910-00Rev. 3

WARNINGThe following is a general sequence of events designed for the erection of the flare stack UT01l02-25-U-I01 Train 1 & 2. This procedure outlines the major operations that must be performed in order toerect the flare stack, as well as make recommendations on the order of those sequences. Thisprocedure must be reviewed by an experienced and qualified construction company prior to theerection and construction of the flare stack. Use experience and judgment at your own discretionwith caution to safety of personnel and equipment

NOTEBefore proceeding with any erection activities make sure that all items have observed the storage

guidelines as outlined on this document. In case of damage please notify MHI inspector immediately.

WARNINGHigh voltage capable of causing death is used with this equipment. Use extreme caution whenservicing control cabinets and electrically actuated components

WARNINGDo not enter a furnace or fired vessel until an adequate cool-off period has been observed and thefacilities confined space entry procedures have been completed. Enter heater or furnace only in thepresence of individuals who are capable of rendering aid.

WARNINGDo not enter this equipment unless guides, shields are in place for moving components, rotatingequipment, mechanically automated devices, electrically, and pneumatically operated controlcomponents.

WARNINGThe FLARE TIPS utilize fuel, which is flammable and potentially explosive. Familiarize yourselfwith the specific welding, hot work guidelines, torque, draining, venting, purging, bleed-downprocedures, leak checks, and line-entry instructions for the component worked on before startingwork on the fuel system.Rev Date Page Description Prpd Chkd Appd0 01110/10 All Issued for Approval JF. TR. HBT.I 05/17/l 0 AS NOTED CUSTOMER COMMENTS ADDED JF. TR. HBT.2 09116110 All Document re-edited JF HBT HBT3 1 0 / 1 1 / 1 0 As noted Customer Comments added JF HB HBT

Page 3 of22


5/23

JOHN ZINKJOHN ZINK C OM PANY LLC

ERECTION PROCEDURE FORFRONT END AMMONIA FLARE STACKSUTOll02 -2S-U-I01l102 Train 1 & 2 & U-201

S.0.9096357 Doc # 9096357-91MHI DOC # 6423MU350-00-10910-00Rev. 3

NOTEAt least the following personal protection equipment will be necessary when operating this equipment fireretardant/resistant clothing, ear protection, gloves, eye protection. When installing the equipment,additional safety equipment, such as steel-toed shoes, hard hat and respiratory protective equipment will benecessary. Refer to the personal protection equipment requirements of the operator and owner and theregulatory authorities (such as OSHA) to determine the personnel protection equipment appropriate for thework being performed.

Rev Date Page Description Prpd Chkd Appda 01/10/10 All Issued for Approval JF. TR. HBT.I 05/17/10 A S N O T ED CUSTOMER COMMENTS ADDED JF . TR. HBT.2 09/16/10 All Document re-edited JF HBT HBT3 10/11110 As noted Customer Comments added JF HB HBT

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6/23

JOHN ZINKJO HN ZIN K C OM PA NY LLC

ERECTION PROCEDURE FORFRONT END AMMONIA FLARE STACKSUTOllOZ-Z5-U-I01lI0Z Train 1 & Z & U-ZOI

S.O. 9096357 Doc # 9096357-91MHI DOC # 64Z3MU350-00-10910-00

Rev. 3

1. STORAGE INSTRUCTIONSDISCLAIMER NOTICE

THE FOLLOWING ARE GENERAL INSTALLATION INSTRUCTIONS ARRANGED INTHE LOGICAL SEQUENCE THAT WE CONSIDER SHOULD BE FOLLOWED.SPECIALIZED DETAILED PROCEDURES MA Y NEED TO BE PREPARED FOR

INDIVIDUAL ACTIVITIES BY THE RELEVANT PERSONNEL AND COMPANIES INCHARGE OF THE lNST ALLA TION AND ERECTION.

Do not attempt to install or erect Flare systems without first familiarizing yourselfthoroughly with these instructions and the equipment they cover. Loss of life anddamage to equipment may result if instructions are not strictly adhered to.Verify weight of equipment to assure the machinery used for moving and lifting isproperly rated, capable to safely handle the weight of the equipment.Consult John Zink drawings listed in this procdure before attempting to erect or installany equipment.

CLOSURE OF OPEN CONNECTIONS1 . F lan ge fa ci[lg s sh all b e co ate d w ith an ap pro ve d c orro sio n in hib ito r2. Th e m in im um th ickn ess of m eta l b lan k/nu mbe r of bo lts is :

F lange S ize Me ta l B lank Th ickness No. o f Bo lts 10mmDia .L es s th an 6 " 6mm 48 " to 1 2" 10 m m 4

Rev Datc Page Description Prpd Chkd Appd0 01110/10 All Issued for Approval JF. TR. HBT.1 05117/[0 AS NOTED CUSTOMER COMMENTS ADDED JF. TR. HBT.2 09/16/[0 All Document re-edited JF HBT HBT3 ID/l[/IO As noted Customer Comments added JF HB HBT

Page 5 of22


7/23

JOHNZINKJO HN ZINK CO MPANY LLC

ERECTION PROCEDURE FORFRONT END AMMONIA FLARE STACKSUTOl/02 -25-U-I01ll02 Train 1& 2 & U-20l

S.O. 9096357 Doc # 9096357-91MHI DOC # 6423MU350-00-l09l0-00Rev. 3

I Grea te r t ha n 14 " 13 mm 8A ll s u ch connecti on s shall b e t aped a round t he b la n klfla nge c ir cum fe rence a s anadded p re cau ti on a gain s t th e in g re s s o f mo is tu re .

INSTRUMENTATION1. Afte r rece ip t and inspection , a ll instrum ents shall be clearly m arked w ith tag

num bers. Item s shall be stored in accordance w ith the M ANU FAC TUR ERguid elin es fo r in strument e qu ipmen t p ro te ctio n d urin g fie ld s to ra ge . T he p la ce o fs to ra ge s ha ll b e r ec ord ed in p erma ne nt w ar eh ou se r ec or ds s o th at e ac h item c anbe eas il y l oca ted .

2. Instrum ents, instrum ent fittings, tub ing , and bulk insta lla tion m ateria l sha ll bes to red i n a c lo s ed wa rehouse bu ild in g p ro te c ted a gain s t weat he r, f lo odi ng , en tr y o fwa te r o r w i nd , a nd fr ee o f a ir bo rne dust , o il, a nd co rr os iv e vapo rs .No te : C hlo rin e c an r ea ct, a t tim e s e xp lo siv ely , w ith a n um b er o f o rg an ic m a te ria ls s uc h a s o il a ndg re as e fr om s ou rc es s uc h a s a ir c om p re ss or s, v alv es , p um p s, o il- dia ph ra gm in str um e nta tio n, a sw ell a s w oo d a nd ra gs fro m m ain te na nc e w ork . In stru me nts fo r s uc h s erv ic e s ha ll b e re ce iv ed ,s to re d , ma in ta in e d, c a li br at ed , a n d h and le d w it h c a re t o a v oid a n y a c ci de n ta l c o nt am in a ti on . T h isin c lu d es n e ce s sa ry s p ar e p a rt s a ls o .

3 . R elie f v alve s sh all b e p alle tize d, an d sto re d an d h an dle d i n an u prig ht p osition .4 . A t a ll tim es, the air shall be kept at a tem perature well above dew po in t. D elicatein str uments s ha ll b e s to re d w e ll a wa y from outs id e w alls , u nd er sid es o f ro ofs , o ff

f loo rs , and co rrosi ve chem ica ls .5 . If space does not a llow for a ll instrum ents to be in a warehouse, such item s asco ntro l va lve s, re lie f va lve s, and o th er larg e valve s m ay b e sto re d o utd oo rs,

p ro v id in g p re cau ti on s a re ta ken to p ro te c t t h em f rom the e lemen ts .6. Control panel storage, if required, shall be in a closed building

Rev Date Page Description Prpd Chkd Appd0 01/10/10 All Issued for Approval JF. TR. HBT.I 05/17/10 AS NOTED CUSTOMER COMMENTS ADDED JF. TR. HBT.2 09/16/10 All Document re-edited JF HBT HBT3 [ 0 / 1 1 / 1 0 As noted Customer Comments added JF HB HBT

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8/23


ERECTION PROCEDURE FORFRONT END AMMONIA FLARE STACKSUTOI/02 -25-U-I01l102 Train 1 & 2 & U-201

S.O. 9096357 Doc # 9096357-91MHI DOC # 6423MU350-00-10910-00Rev. 3

2. Erection SequencePlease consult and familiarize with John Zink drawings herein listed.

2.1 MHI to JZ DWG Reference TableThe following drawings" and documents are required to perform the erection andinstallation for the front end ammonia flare stack UTOl/02-25-U-101 /U-I02train 1 & 2and U-201General Note:JZDRAWINGSFor U-101 drawings series 1000For 0-102 drawings series 2000For U-201 drawings series 3000

MHI DRAWING:(MHI drawing for U-101 drawing 0-351)(MHI drawing for U-I 02 drawing 0-352)(MHI drawing for U-201 drawing U-356)

MHI DRAWING # JZDRAWING # DESCRIPTION.6423M U35X-OU-20100 00 General Arrangement-B-F-9096357-X202 10t 26423M U35X-OU-20101 00

B-F-9096357-X202 20f 2 General Arrangement- Details6423M U35X-OU-10221 00 Baseplate details and loads8-F-9096357-X203 10r 16423M U35X-OU-10223 00 Anchor bolt template8-F-9096357-X205 10t 16423M U35X-OU-20200 00 Flare tip assembly with WP2B-F-9096357-X301 10t 1 pilots6423M U35X-OU-20201 00 Windproof WP2 pilot assembly8-F-9096357-X302 10t 1 with thermocouples6423M U35X-OU-221oo 00 Liquid seal drum assy.

8-F-9096357 -X303 10f 2

R ev Dale Page Description Prpd C hkd Appda alii all a All I ssu ed fo r A pp ro va l JF. T R . HBT .1 05/1711 0 AS NOTED C US T OMER C OMMEN TS ADDED JF. T R . HBT .2 09/16110 All Do cumen t r e- ed it ed JF HBT HBT3 10111/10 As noted C ustomer C omments added JF HB HBT

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9/23

JOHN ZINKJO HN ZINK COM PANY LLC

ERECTION PROCEDURE FORFRONT END AMMONIA FLARE STACKSUTOll02 -25-U-I01lI02 Train 1 & 2 & U-201


6423M U35X-OU-22101 00 Liquid seal drum assy.B-F-9096357-X303 20f 26423M U35X-OU-30510 00 Utility pipingB-F-9096357-X304 10t 4 Thermocouple conduit6423M U35X-OU-30510 00 Utility piping-

B-F-9096357-X304 20t 4 Pilot FFG lines6423M U35X-OU-30510 00 Utility piping-B-F-9096357 -X304 3of 4 Pilot fuel ass line6423M U35X-OU-30510 00 B-F-9096357 -X304 4 of 4 ACWL Conduit.6423M U35X-OU-40100 00 Platform assy. -1B-F-9096357-X305 1012 Elev. 4.75m (1S'-?,?6423M U35X-OU-40100 00 Platform assy.1- detailsB-F-9096357 -X305 2012 Elev. 4.75m (15'-7")6423M U35X-OU-40100 00 Platform assy. -2B-F-9096357-X306 10f 2 Elev. 10.75m (35'-3 114")6423M U35X-OU-40100 00 Platform assy.Z - detailsB-F-9096357-X306 20f 2 Elev. 10.75m (35'-3 1/4")6423M U35X-OU-40100 00 Platform assy. -3B-F-9096357-X307 1012 Elev. 16.75m (54'-117116")6423M U35X-OU-40100 00 Platform assy. -3 detailsB-F-9096357-X30720f2 Elev. 16.75m (54'-11 7/16")6423M U35X-OU-40100 00 Platform assy. - 4B-F-9096357 - X30B 1of2 Elev. 22.75m (74'-7 11/16")6423M U35X-OU-40100 00 Platform assy. 4- detailsB-F-9096357-X30820f2 Elev. 22.75m(74'-7 11/16")6423M U35X-OU-40100 00 Platform assy. - 5B-F-9096357 -X309 10i2 Elev. 2B.75m (94'-37/8")6423M U35X-OU-40100 00 Platform assy.5 - detailsB-F-9096357-X30920f2 Elev. 28.75m'(94'-3 7/B")6423M U35X-OU-40100 00 Platform assy. - 6B-F-9096357-X310 1of2 Elev. 34.75m (114'-0 1/B")6423M U35X-OU-40100 00 Platform assy. -6 detailsB-F-9096357 -X310 20f2 Elev.34.75m (114'-0 1/8")

6423M U35X-OU-40100 00 Platform assy. - 7B-F-9096357-X311 terz Elev. 40.75m (133'-B 5/16'1

Rev Date Page Description Prpd Chkd Appda 01/10110 All Issued for Approval JF. TR. HBT.I 0 5/] 71 1a AS NOTED CUSTOMER COMMENTS ADDED JF. TR. HUT.2 09/16/10 All Document re-edited JF HBT HUT3 10/11/10 As noted Customer Comments add cd JF HB HBT

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10/23


ERECTION PROCEDURE FORFRONT END AMMONIA FLARE STACKSUT01/02 -25-U-I01l102 Train 1 & 2 &U-201S.0.9096357 Doc # 9096357-91MHI DOC # 6423MU350-00-10910-00

Rev. 36423M U35X-OU-40100 00 Platform assy. 7- detailsB-F-9096357-X311 20f2 Elev. 40.75m (133'-8 5/16")

6423M U35X-OU-40100 00 Platform assy. -8B-F-9096357 -X312 10f2 Elev. 46.75m (153'-4 9/16")6423M U35X-OU-40100 00 Platform assy. 8- detailsB-F-9096357-X31220f2 Elev. 46.75m (153'-4 9/16")6423M U35X-OU-40100 00 Typical Ladder assy.B-F-9096357-X31310f1

6423ME325-00-0000500 DRAWING FOR AIRCRAFTNIA WARNING LIGHT

In addition to the above table the following drawings and documents are to be used forREFERENCE during the erection and installation of platforms and ladders for theAmmonia Stacks UTOI/02-25-U-101, U-102 TRAIN 1&2 and U-20!

General Note:When reading the drawings below listed, take into account the following convention.Part prefix convention:- Handrail: HR-XX (XX-Block No.)Frame: FR-XX (XX-Block No.)Bracket: BR-XX (XX-Block No.)(I.e. HR-01-4.75mts)

HR = Handrail01 = Platform No.4.75mt;;;; elevation

Drawlnn No. DESCRIPTION9096357-900-6-101-005 AMMONIA UNIT TAG U-101-TRAIN 1 & 2 STACK RAISER DETAIL9096357-900-6-101-006 AMMONIA UNIT TAG U-101-TRAIN 1 & 2 LADDER DETAIL (114)9096357-900-6-101-007 AMMONIA UNIT TAG U-101-TRAIN 1 & 2 LADDER DETAIL (214)9096357-900-6-101-009 .A MMONIA UNIT TAG U-101-TRAIN 1 & 2 PLATFORM DETAIL (4/4)9096357-900-8-101-010 AMMONIA UNIT TAG U-101-TRAIN 1 & 2 PLATFORM DETAIL (114)9096357-900-C-101-011 AMMONIA UNIT TAG U-1 01-TRAIN 1 & 2 PLATFORM DETAIL (2/4)

R ev Date Page Description Prpd C hkd Appd0 01/10(10 A ll I ssu ed fo r A pp ro va l JF . T R . HBT .I 05/17110 AS NOTED C U S T OMER C OMMEN T S ADDED JF . T R . HBT .2 09/l611 0 A ll Do cumen t r e- ed it ed JF HBT HBT3 lOll 1/10 A s n ot ed C ustom er C om men ts added JF HB HBT

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11/23

JO HN ZINK CO MPANY LLCERECTION PROCEDURE FOR

FRONT END AMMONIA FLARE STACKSUTOll02 -25-U-I01l102 Train 1 & 2 & U-201S.0.9096357 Doc # 9096357-91MHI DOC # 6423MU350-00-10910-00

Rev. 3

JOHN ZINK

9096357-900-8-101-012 AMMONIA UNIT TAG U-101-TRAIN 1& 2 PLATFORM DETAIL (3/4)9096357-900-8-101-013 AMMONIA UNIT TAG U-101-TRAIN 1& 2 PLATFORM DETAIL (4/4)9096357-900-8-101-014 AMMONIA UNIT TAG U-101SUPPORT PAD DETAIL9096357-900-8-102-005 AMMONIA UNITTAG U-102-TRAIN 1& 2 LADDER DETAIL '(1/4)9096357-900-8-102-006 AMMONIA UNIT TAG U-102-TRAIN 1 &2 LADDER DETAIL (2f4)9096357-900-8-102-007 AMMONIA UNIT TAG U-102-TRAIN 1& 2 LADDER DETAIL ( '314)9096357-900-8-102-009 AMMONIA UNlTTAG U-102-TRAIN 1& 2 PLATFORM DETAIL (11419096357-900-8-102-010 AMMONIA UNIT TAG U-102-TRAIN 1& 2 PLATFORM DETAIL (214)_9096357-900-8-102-011 AMMONIA UNIT TAG U-102-TRAIN 1 & 2 PLATFORM DETAIL (314)_9096357-900-8-102-012 AMMONIA UNIT TAG U-1 02-TRAIN 1& 2 PLATFORM DETAIL (4/4)9096357-900-8-102-013 AMMONIA UNIT TAG U-102-TRAIN 1&2 SUPPORT PAD DETAIL9096357 -900-8-201-001 AMMONIA UNIT TAG U-201 KNOCKOUT DRUM DETAIL (113)9096357-900-8-201-005 AMMONIA UNIT TAG U-201 LADDER DETAIL (1/4)9096357-900-8-201-006 AMMONIA UNIT TAG U-201LADDER DETAIL (2/4)9096357-900-8-201-007 AMMONIA UNIT TAG U-201 LADDER DETAIL (114)9096357-900-8-201-009 AMMONIA UNIT TAG U-201 PLATFORM DETAIL (114)9096357-900-8201-010 AMMONIA UNIT TAG U-201 PLATFORM DETAIL (2/4)9096357-900-8-201-011 . AMMONIA UNIT TAG U-201 PLATFORM DETAIL (314)9096357-900-8-201-012 AMMONIA UNIT TAG U-201 PLATFORM DETAIL (414)9096357-900-8-201-013 AMMONIA UNIT TAG U-201 SUPPORT PAD DETAIL

R cv Date Pagc Description Pl1'd Chkd Appd0 01/[0/10 All Issued for Approval JF. T R . HBT.I 05/J 7 /J a AS NOTED C US T OMER C OMMEN TS ADDED JF. T R . HBT .2 09/ [6/10 At! Document re-edited JF HBT HBT3 1 0 /J I I lO As noted C ustomer C omments added JF HB HBT

Page 10of22


12/23

JO HN Z IN K C OM PA NY LLCERECTION PROCEDURE FOR

FRONT END AMMONIA FLARE STACKSUTOl/02 -25-U-I01l102 Train 1 & 2 & U-201

8.0. 9096357 Doc # 9096357-91MHI DOC # 6423MU350-00-10910-00

Rev. 3

JOHN ZINK

(Example ofPlatfonn sections labeling)

NOTE

NOTEStack sections have been designed to not require "spiders" to keep thecylinder round, as long as spreader bars are used and proper care is takenduring erection.Make sure that concrete foundation is leveled as required per MHI specification.Grouting may be used if necessary.

WARNINGMake sure that the foundation anchor base pattern matches the pattern of theequipment prior to any erection maneuverNOTE

Rev Date Page Description Prpd C hkd Appd0 011 10 /1 0 All I ssu ed fo r A pp ro va l JF. T R . HET .I 05/17/10 AS NOTED C U S T OMER C O MMEN T S ADDED JF . T R . HBT .2 09116110 All Do cumen t r e- ed it ed JF HBT HET3 10 /11 / 10 As n oted C ustomer C omments added JF HB HBT

Page 11 of22


13/23

JOHN ZINKJO HN Z IN K C OM PA NY LLC

ERECTION PROCEDURE FORFRONT END AMMONIA FLARE STACKSUTOll02 -25-U-I01l102 Train 1 & 2 & U-201


Construction tolerances will follow those noted per STS-1 Ed 2006 para 8.5sections c.(c) At the time of erection, the stack shall be true and plumb to within 2in.(50mm) in100ft (30m)

2.2 Lifting AnalysisU-lOl Flare stack.Total weight 58,126 kgs.

Individual section weights:Top section from elev 36.57to ely. 46.97mts :Middle top section from elev 24.38 to elv.36.57mts.:Middle bottom section from elev 12.2 to elv. 24.38mts :Bottom Section from elev 0.00 to elev. 12.2 mts:Flare tip:Misc.

7,538 kgs.10,019 kgs.16,528 kgs.23,146 kgs.1,724 kgs.895 kgs

Gravity center: Refer to strength calculation document No. 9096357-21(6423MU351-0U-60800-00) and extract shown on page 17

U-I02 Flare stack.Total weight 52,086 kgs.

Individual section weights:Top section from elev 36.58 to ely. 46.97mts :Middle top section from elev 24.38 to elv.36.58I11ts.:Middle bottom section from elev 12.2 to ely. 24.38111ts:Bottom Section from elev 0.00 to elev. 12.2 mts:

6,811 legs.6,721 kgs.14,984 kgs.21,014 kgs,

Rev Date Page Description Prpd Chkd Appd0 0 1 / 1 0 / 1 0 All Issued for Approval JF. TR. HBT.I 0 5f l 7 11 0 AS N O TED CUSTOMER COMMENTS ADDED JF. TR. HBT.2 091l6flO All Document re-edited JF HBT HBT3 10111/10 As noted Customer Comments add cd JF HE HBT

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14/23


ERECTION PROCEDURE FORFRONT END AMMONIA FLARE STACKSUTOll02 -25-U-I01l102 Train 1& 2 &U-201


Flare tip.Misc.

1,542 kgs.1,014 legs

Gravity center: Refer to strength calculation document No. 9096357-22(6423MU352-0U-60800-00), and extract shown on page 18

U-201Flare stack.Total weight 50,268 kgs.Individual section weights:Top section from elev 36.58 to ely. 46.97mts :Middle top section from elev 24.38 to ely. 36.58mts.:Middle bottom section from elev 12.2 to elv. 24.38mts :Bottom Section from elev 0.00 to elev. 12.2 mts:Flare tip.Misc.

5,987 legs.6,721 kgs.14,984 kgs.21,014 kgs.

794 kgs.768 legs

Gravity center: Refer to strength calculation document No. 9096357-23(6423MU356-0U-60800-00) and extract shown on page 19

Section lifting lugs are designed only for horizontal lift of each riser section.Trunnions and tailing lug are designed for single-piece lift of each flare stacknser.All ladders, platforms, piping and conduit can be installed at ground level. Flaretip to be installed on vertical position.Impact Factors: 2.0 for lifting trunnion, lifting and tailing lugs

1.25 for local stress in stack and vessel shell, skirt, and baseanchor

Rev Date Page Description Prpd Chkd Appd0 01110/10 All Issued for Approval JF. TR. HBT.I 05/17/10 AS NOTED CUSTOMER COMMENTS ADDED JF. TR. HBT.2 09/16/1 0 All Document re-edited JF HBT HBT3 10/11/10 As noted Customer Comments added JF HB HBT

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15/23


FRONT END AMMONIA FLARE STACKSUTOll02 -25-U-I01l102 Train 1 & 2 & U-201S.0.9096357 Doc # 9096357-91

MHI DOC # 6423MU350-00-10910-00Rev. 3

JOHN ZINK

NOTE:For lifting and tailing lug details refer to drawing BF-9096357-X202 S2 andcorresponding strength calculations above referenced.

"Note: Trunnion position to be at 90 and 180 degrees in relation to 0 degreetailing lug.

2.3 Erection Sequence.1. Each section is marked in accordance with the Steel mark numbers per John

Zink drawing B-F-90963S7-X202. The sections must be welded together nearthe foundation. For correct fit-up, zero degree angle marks are also marked oneach section. Assembly on flat ground should be performed keeping the TailingLug at 12 O'clock position and the Lifting Trunnions oriented in the 30'clockand 90'clock positions at a site near the foundation. Specialized detailedprocedures such as welding procedures, lifting procedures etc will need to beprepared for individual activities by the relevant personnel and companies incharge of the installation and erection.

2. The flare stack sections are set horizontally on the ground. Each section shouldbe supported at a minimum of two (2) locations, so that permanent localdeformation does not occur. Weld each section per corresponding welding fieldprocedures. Make sure beveled edges are clean and free of oil or contaminants.After welding make sure to check alignment and plumbing. Erection crew tofollow tolerances per STS-1 Ed 2006 para 8.5 section c.

3. Install manways and connection nozzles which have been blanked with shippinggaskets and bolts. The correct Gaskets and Bolts are shipped loose, togetherwith the stacks.

R ev Date Page Description Prpd Chkd Appd0 01110/10 All Issued for Approval JF. TR. HBT.I 05117/10 AS NOTED CUSTOMER COMMENTS ADDED JF. TR. HBT.2 09/16/10 All Document re-edited JF HBT HOT3 10/11110 As noted Customer Comments added JF HB HBT

Page 14 of22


16/23


ERECTION PROCEDURE FORFRONT END AMMONIA FLARE STACKSUT01l02 -25-U-101l102 Train 1& 2 &U-201

S.0.9096357 Doc # 9096357-91MHI DOC # 6423MU350-00-10910-00Rev. 34. After the stack sections are welded, install platforms to the maximum extend

possible (EL 4.75, EL 10.75, EL 16.75, EL 22.75, EL 28.75, EL 34.75). Refer todrawings:

B-F-90963S7-X305-1&2/9096357-900-B-X01-010B-F-90963S7-X306-1&2 /9096357-900-B-X01-010B-F-90963S7-X307-1&2 19096357-900-B-X01-010B-F -9096357-X308-1&2 / 9096357-900-B-X01-011B-F-9096357-X309-1&2 /9096357-900-B-X01-011B-F-90963S7-X310-1&2 /9096357-900-B-X01-011B-F-90963S7-X311-1&2 /9096357-900-B-X01-011B-F-90963S7-X312-1&2 /9096357-900-B-X01-013

5. Install Air Craft Warning Lights supports on the 3600 access platform as perdrawing, B-F-9096357-X312-sheet 1 & 2

6. Install to the maximum extended possible the caged ladders, shop marked as :B-1930, B-1931(2), B-1932(2), B-1933 As per drawings :B-F-9096357-X313

*Ladders need to be installed to the fullest extent possible while horizontal. Atthis stage any damaged paint must be repaired.

7. Utility Piping can now be installed and welded together. Those have beendesigned with one anchor at the top and all the other supports are guides. Referto drawing B-F-9096357-X304 I, 2&3. for more details

8. Galvanized Conduits ( Thermocouple, ignition wire and ACWL lights) shouldnow be fitted to the stack. See B-F-90963S7-X304 sheets 1 through 4

Rcv Date Page Description Prpd Chkd Appd0 01(10110 All Issued for Approval JF. TR. HBT.1 05/17/10 AS NOTED CUSTOMER COMMENTS ADDED JF. TR. HBT.2 09/16/10 All Document re-edited JF HBT HBT3 10111/10 As noted Customer Comments added JF HB HBT

Page 15 of22


17/23

JOHN Z INK COMPANY LLCERECTION PROCEDURE FOR

FRONT END AMMONIA FLARE STACKSUTOll02 -25-U-I01l102 Train 1 & 2 & U-201S.O. 9096357 Doc # 9096357-91

MHI DOC # 6423MU350-00-10910-00Rev. 3

JOHN ZINK

9. At this point the entire dressed-up stack (except the Tip) may be lifted anderected on its foundation. The total calculated weight is 58,126 kgs for U - IO I ,for U-l 02 is 52,086 kgs. U-20 Iis 50,268 kgs. Use the lifting trunnions togetherwith a spreader bar and the tailing lug for lifting. Two cranes must be used, oneto lift at the trunnions (through a spreader bar) and the other at the Tailing Lug.Stack is designed to be lifted fully dressed with piping, ladders and platforms(except the Tip) but it is the responsibility of the erector to develop a detailedplan to safely accomplish the lift. (It is recommended that 25 ton G-2310 andtwo 35 Ton Crosby shackles together with a spreader bar should be used forlifting, which are not provided by John Zink).

Erection Company to use the following reference information to plan erection.

R ev Date Page Description Prpd Chkd Appd0 01110/10 A ll I ssu cd f or A pp ro va l JF , T R , HBT ,1 05/17/10 A S N O TED C US TO MER C OMMEN TS ADDED JF . T R . HBT .2 09/16/10 All Do cumen t r e- ed it ed JF HBT HBT3 10/11/10 As noted C ustomer C ommen ts added JF HB HBT

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18/23

JOHN ZINKJOHN ZINK COMPANY LLC

ERECTION PROCEDURE FORFRONT END AMMONIA FLARE STACKSUTOll02 -25-U-I01l102 Train 1 & 2 & V-201s.o. 9096357 Doc # 9096357-91MHI DOC # 6423MV350-00-10910-00Rev. 3

( ( [ 0 ] F~:~[N] FlnilN]0 315,385.2 527,096.915 318.oo2.B 519,841.730 323,059,9 511,707,$4S 333,413.5 501,000,3$0 ' 3 ,&7,174.6 42'3,478.475 358 .261 .7 4 4 1 . 3 . . " 1 490 578,913,6 0

4,71 329,300.7 499,21061:1 338 ,003 .7 481,819,954,J 232,995,4- 491,838,6

1Lilt a ng ie


19/23

JO HN Z IN K C OM PA NY LLCERECTION PROCEDURE FOR

FRONT END AMMONIA FLARE STACKSUTOll02 -25-U-I01!102 Train 1 & 2 & U-201S.0.9096357 Doc # 9096357-91

MHI DOC # 6423MU350-00-10910-00Rev. 3

JOHN ZINK

(-top

a [1 Fton[N] F t : : l u [ N )0 281,800.2 464,232.515 284,942.7 457,947.530 288,467.6 450,897.745 293,110.3 441,612.360 300,714.7 426,403.575 319,052.7 389,727.690 513,916.5 0481 294,293.9 439,245.2742 316,984.7 393,863.5

1Lift angle at maximum lug stress.2Uft angle at maximum weld stress.

U-I02 FLARE STACKL1=Distance from Center of gravity to top lug = 14738.84 mmL2 =Distance from Center of gravity to taillug = 17893.65 ImT IL3 =Distance from Vessel Center to tiallug = 1671.5 mm

Rev Date Page Description Prpd Chkd Appd0 01/10/10 All [ssucd for Approval IF . TR. HBT.1 05/17/10 AS NOTED CUSTOMER COMMENTS ADDED IF . TR. HBT.2 09/16/10 All Document re-edited IF HBT HBT3 10111/10 As noted Customer Comments added JF HB HBT

Page] 8 of22


20/23

JOHN Z INK COMPANY LLCERECTION PROCEDURE FOR

FRONT END AMMONIA FLARE STACKSUTOlf02 -25-U-IOlfl02 Train 1 & 2 & U-201S.0.9096357 Doc # 9096357-91

MHI DOC # 6423MU350-00-10910-00Rev. 3

JOHN ZINK

e x . [0 ] F1",,[N] Ft~i I [NJ0 269,196.5 472,064,615 272,392 465,673,630 275,976.4 458,504.945 280,697.5 449,062.860 288,430.1 433,597.575 307,077.5 396,302.790 505,228.9 0481 281,901 446,655,8742 304,974.7 40 0 ,50 80 4

lUff ang le a t m ax im um lug s tre ss .'


21/23

JOHN ZINK COMPANY LLCERECTION PROCEDURE FOR

FRONT END AMMONIA FLARE STACKSUTOll02 -25-U-101l102 Train 1 & 2 & U-20lS.0.9096357 Doc # 9096357-91MHI DOC # 6423MU350-00-10910-00Rev. 3

JOHN ZINK

More details can be found on documents.U-lOlU-102U-201

No. 9096357-21 (6423MU351-0U-60800-00)No. 9096357-22 ( 6423MU352-0U-60800-00)No. 9096357-23 ( 6423MU356-0U-60800-00)

10. Set the dressed-up stack assembly, in a vertical position correctly oriented onthe foundation with holes aligned with the anchor bolts, (Drawing BF-9096357-X203) which should already be in place. Install the nuts to the anchor bolts andtension bolts. Bolts should be tightened to a snug-tight condition, in crosshatchpattern. Snug tight is defined as the tightness that exists when the surfaces of thejoint are in finn contact. This may be attained by a few impacts of an impactwrench or the full effort of a man using an ordinary spud wrench. For moredetails refer to "Turn of Nut" method outlined in AISC ASD 9th Edition (Part 5-page 273 to 275).These bolts should have a torque of 140 N-m (103 Ib-ft).

*The crane should continue to support the dressed-up stack assembly untilall bolts have been installed and tightened to specified torque.

11. Electrically ground the lower section.12. Install the flange gasket (Item #9 DWe B-F-9096357-X301) on the body flange

located at the top of the lower section. It is recommended that some adhesive beused to keep the gasket in place during assembly.

13. Verify at ground level that the respective flare tips models: U-66,U-60, U-36are properly orientated prior to lift-up, assembly. (dwg B-F-9096357-X301).Remove pilots prior to erect as they can fall ifnot properly attached.

Rev Date Page Description Prpd Chkd Appd0 01/10/10 All Issued for Approval JF. TR. HBT.1 05/17/10 AS NOTED CUSTOMER COMMENTS ADDED JF. TR. HBT.2 09/16/10 All Document re-edited JF HBT HBT3 10111/10 As noted Customer Comments added JF HB HBT

Page 20 of22


22/23


FRONT END AMMONIA FLARE STACKSUTOl102 -25-U-I01!102 Train 1 & 2 & U-201S.0.9096357 Doc # 9096357-91

MHI DOC # 6423MU350-00-10910-00Rev. 3

JOHN ZINK

14. Flare Tips can now be raised to its position at the stack top. Once the Tip hasbeen made secure at its mounting flange on top of the stack ApproximateWeight will be found on the corresponding drawings.

ForU-IOI : B-F-9096357-1301For U-I02 : B-F-9096357-2301For U-201 : B-F-9096357-3301

Tight the bolts to the upper stack section (dwg B-F-90963S7-X301) Boltsshould be pre-tensioned using "Turn of Nut" method outlined in AISC ASD 9thEdition (Section 5- pages 273-275).

16. Install Pilots and manifold. Tie connections to their corresponding utilities andelectrical services. Refer to drawings B-F-90963S7-X30J, B-F-90963S7-X302

17. Complete to install the ladders and platforms if needed as per drawings.18. Install junction boxes for thermocouples, and ACWL .19. Complete to install ladders and platforms as required.2.4GENERAL NOTES

Ignition and fuel gas piping to be furnished in 6000mm RANDOM lengthswith loose fittings for field installation; (installation by others, NOT JZ)

Piping 3S.1mm[ 1 ! t i " ] and smaller are NOT supplied prefabricated. Minimum bend radius for pipe to be 5 times the nominal pipe diameter. Guide brackets for ignition, fuel gas piping and conduit installed at approx 10'

centers

Rev Date Page Description Prpd Chkd Appd0 01/10/10 All Issued for Approval JF . TR. HBT.1 05/17/10 AS NOTED CUSTOMER COMMENTS ADDED JF. TR. HBT.2 09/16/10 All Document re-edited JF HBT HBT3 1 0 / 1 1 / 1 0 As noted Customer Comments added JF HB HBT

Page 21 of22


23/23

JO HN ZINK COM PANY LLCERECTION PROCEDURE FOR

FRONT END AMMONIA FLARE STACKSVTOl102 -25-U-IOllI02 Train 1& 2 & V-201S.0.9096357 Doc # 9096357-91

MHI DOC # 6423MV350-00-10910-00Rev. 3

JOHN ZINK

Stud bolts to be SA-193-B7 with SA-194-2H Hex nuts (zinc plated) If-bolts and machine bolts are A-307 with Zinc-plated hex nuts. U-bolts are for guide/expansion only and furnished with 4 hex nuts each,

(Backup/jam nuts), DO NOT TIGHTEN V-bolts against pipe or conduit.Strain-rei ief devices and cable grip support grips Keellem I =Grip type aresuggested to be used when installing wiring. ( to be furnished by others)

Rev Date Page Description Prpd Chkd Appd0 01/10/10 All Issued for Approval JF. TR. HBT.1 05/17/10 AS NOTED CUSTOMER COMMENTS ADDED JF. TR. HBT.2 09116110 All Document re-edited JF HBT HBT3 10/11/10 As noted Customer Comments added JF HB HBT

Page 22 of22

Installation Manual Urea Flare Stack

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Transcript of Installation Manual Urea Flare Stack