CERTIFICATION OF COMPLIANCE OF THE USERS DESIGN SPECIFICATION I, the undersigned, being experienced and competent in the applicable field

of design related to pressure vessel requirements relative to this Users Design Specification, certify that to the best of my knowledge and belief it is correct and complete with respect to the Design and Service Conditions given and provides a complete basis for construction in accordance with Part 2, paragraph 2.2.2 and other applicable requirements of the ASME Section VIII, Division 2 Pressure Vessel Code, ____2007_____ Edition with Addenda ___ 2008 ____ and Code Case(s)_____ NONE_______.

This certification is made on behalf of the organization that will operate these vessels_____________(company name)____________

Certified by:_________________________________________________ Title and areas of responsibility:__________________________________ Date: _______________

Professional Engineer Seal: Date: _______________

ORIGINATOR: ABC CONSULTANTS PROJECT: AIR BUFFER VESSEL AB-001 CONTRACT NO:

DOCUMENT NUMBER: UDS-AB-001 (REV 0)

JOB NO: AB-001

PAGE NO. 2 OF 14

USERS DESIGN SPECIFICATION FOR AIR BUFFER TANK VESSEL TAG NO. AB-001

0
REV

Issued for Purchase

DESCRIPTION OF REVISIONS PREPARED CHECKED APPROVED DATE

ORIGINATOR: ABC CONSULTANTS PROJECT: AIR BUFFER VESSEL AB-001 CONTRACT NO:
REVISION DETAILS Rev. 0 Section All Issued for Purchase

DOCUMENT NUMBER: UDS-AB-001 (REV 0)

JOB NO: AB-001

PAGE NO. 3 OF 14

Revision Description

ORIGINATOR: ABC CONSULTANTS PROJECT: AIR BUFFER VESSEL AB-001 CONTRACT NO:

DOCUMENT NUMBER: UDS-AB-001 (REV 0)

JOB NO: AB-001

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TABLE OF CONTENTS No. 1. 2. 2.1 2.2 2.3 3. 3.1 3.2 4. 4.1 4.2 4.3 4.4 4.4 5. 5.1 5.2 5.3 5.4 6. 7. 8. 9. 10. 11. 12. DESCRIPTION INTRODUCTION INSTALLATION SITE Location Jurisdictional Authority Environmental Conditions VESSEL IDENTIFICATION Vessel identification Service Fluid VESSEL CONFIGURATION Outline Drawings Vessel Orientation Vessel openings & Identification Principal Component Dimensions Support Methods DESIGN CONDITIONS Specified Design Pressure Design Temperature Minimum Design Metal Temperature Dead, Live & Other Loads OPERATING CONDITIONS DESIGN FATIGUE LIFE MATERIALS OF CONSTRUCTION LOADS & LOAD CASES OVERPRESSURE PROTECTION ADDITIONAL REQUIREMENTS CERTIFICATION COMPLIANCE 12 5 PAGE NO 4 5

7 7 9 9 11 11

ORIGINATOR: ABC CONSULTANTS PROJECT: AIR BUFFER VESSEL AB-001 CONTRACT NO:

DOCUMENT NUMBER: UDS-AB-001 (REV 0)

JOB NO: AB-001

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INTRODUCTION This specification, together with the related drawings, codes and standards constitutes a complete Users Design Specification as required by ASME VIII Div 2 Ed. 2007, Add 2008 Code. PURPOSE This specification covers all the requirements outlined in ASME VIII, Div 2 Code, Part 2.2.2 for the design and construction of Air Buffer Vessel (Item No AB-001). Any proposed deviation from this specification by the Supplier is to be made by written request for approval by the User and for a revision of this specification including recertification when this document is revised.

1.1

1.2

DEFINITIONS The following terms and definitions shall be used: COMPANY: ABC CONSULTANTS and their nominated or designated Engineering Contractor

ENGINEERING CONTRACTOR: party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation / maintenance of a company facility. SUPPLIER: organization supplying equipment, materials or services as per the terms of this document and company purchase order The USER, as referred to in the ASME code, is ABC CONSULTANTS, the firm or organization who will own and/or operate the vessel. The INSPECTOR is the person who carries out all the inspections as specified in ASME Sec VIII Div. 2. The word CODE indicates the ASME VIII Div.2, Ed. 2007/Add 2008 & other reference Codes The word shall indicates a mandatory requirement. The word should indicates a recommendation. 1.3 REFERENCE STANDARDS ASME Section VIII Division 2, Edition 2007 Addenda 2008 ASME Section IX, Edition 2007 Addenda 2008 ASME Section II Part A, C, D (Metric), Edition 2007 Addenda 2008 ASME Section V, Edition 2007 Addenda 2008 ASME B16.5 -2003 Pipe Flanges and Flanged Fittings

ORIGINATOR: ABC CONSULTANTS PROJECT: AIR BUFFER VESSEL AB-001 CONTRACT NO:
2. 2.1 2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4 INSTALLATION SITE

DOCUMENT NUMBER: UDS-AB-001 (REV 0)

JOB NO: AB-001

PAGE NO. 6 OF 14

LOCATION Companys facility at ______________ located at _____________ in ___________ country JURISDICTIONAL AUTHORITY Not Applicable ENVIRONMENTAL CONDITIONS WIND DESIGN LOADS
ASCE 7-2005; WIND SPEED -160 km/hr; IMP FACTOR 1.15, Exposure C

EARTHQUAKE DESIGN LOADS Earthquake Loads: UBC 1997; ZONE 1; Soil Profile Sc, IMP FACTOR 1.25. SNOW LOADS Not Applicable LOWEST ONE DAY MEAN TEMPERATURE FOR LOCATION 5 deg. C as per Meteorological data available Minimum Design Metal Temperature to be considered for the vessel shall be 0 (Zero) degree C. VESSEL IDENTIFICATION VESSEL NUMBER & IDENTIFICATION Air Buffer Tank (Vessel Tag No AB-001) SERVICE FLUIDS & PROPERTIES Service Fluid: Compressed Air. Operating Liquid: Not Applicable. Design Liquid Level: Not Applicable. Design Density: Nil VESSEL CONFIGURATION AND CONTROLLING DIMENSIONS OUTLINE DRAWINGS Refer attached schematic sketch (Sketch No. ABC/U2-01 Rev 0) VESSEL ORIENTATION (VERTICAL or HORIZONTAL) Horizontal OPENINGS, CONNECTIONS & CLOSURES INCLUDING QUANTITY & LOCATION Nozzle N1 Nozzle N2 Nozzle N3 Nozzle N4 Nozzle M DN 80 , 600# , WNRF DN 50 , 600# , WNRF DN 50 , 600# , WNRF DN 50 , 600# , WNRF DN 600 , 600# , WNRF INLET PRESS. RELIEF VALVE VENT DRAIN MANWAY WITH BLIND FLANGE Shell top Shell Shell Top Shell Bottom Shell

3. 3.1 3.2

4. 4.1 4.2 4.3

ORIGINATOR: ABC CONSULTANTS PROJECT: AIR BUFFER VESSEL AB-001 CONTRACT NO:
4.4

DOCUMENT NUMBER: UDS-AB-001 (REV 0)

JOB NO: AB-001

PAGE NO. 7 OF 14

PRINICIPAL DIMENSIONS Size: 3000 mm inside Diameter x 5000 mm Tan Line / Tan Line End Closure Type: 2:1 Ellipsoidal heads on both ends. Internal Volume: _______ m3 (Approx.) SUPPORT METHOD Saddle supports: 2 nos. DESIGN CONDITIONS SPECIFIED DESIGN PRESSURE Design Internal Pressure: Maximum Allowable Working Pressure: Design External Pressure: 5.654 MPa (820 psig) 5.654 MPa (Considered same as Design Pressure) Not Applicable

4.5 5. 5.1

5.2

DESIGN TEMPERATURE Design Temperature: 80 C at specified coincident internal design pressure of 5.654 MPa Design Temperature for External Pressure: Not Applicable. MINIMUM DESIGN METAL TEMPERATURE (MDMT) MDMT: 0 C at specified coincident internal design pressure of 5.654 MPa DEAD, LIVE & OTHER LOADS Nozzle Load: Except for the manhole and nozzles of size DN 50(2) NPS or less (vent & drain), all nozzles shall be designed for the additional loads as per Attachment 1 of this document: Static Loads Approximate dead weight, hydro-test and operating loads are as follows (to be confirmed by the supplier in his design calculations): Weight Fabricated Weight Operating Weight Hydrostatic (Shop) Kg Kg Kg

5.3 5.4 5.4.1 5.4.2

5.4.3 6. 6.1 6.2 6.3

All loads and load case combinations are detailed in 9.0 below OPERATING CONDITIONS OPERATING PRESSURE Operating Pressure: 4.481 MPa (650 psig) OPERATING TEMPERATURE Operating Temperature: 50 C TRANSIENT THERMAL GRADIENT ACROSS VESSEL Not Applicable (Steady State Design Temperature condition)

ORIGINATOR: ABC CONSULTANTS PROJECT: AIR BUFFER VESSEL AB-001 CONTRACT NO:
7. 7.1 7.2 7.3

DOCUMENT NUMBER: UDS-AB-001 (REV 0)

JOB NO: AB-001

PAGE NO. 8 OF 14

7.4

7.5

DESIGN FATIGUE LIFE Company has no past experience with this type of vessel and the supplier shall evaluate if fatigue analysis is required for this vessel as per the provisions of 4.1.1.4 & 5.5.2 of the Code. The vessel design life to be considered is 20 years. The vessel can be considered as Integral construction type as there are: No pad type reinforcement for nozzles. All nozzles are of self reinforced type forgings No threaded connections on the vessel No stud bolt type attachments All welds are of full penetration type No major thickness change between the members No attachment or nozzles in the head knuckle portion. The material specified for shell & head is SA 516M Gr. 485. This material has a minimum specified tensile strength of 485 MPa, which does not exceed 552 MPa. Fatigue screening criteria of Part 5.5.2.3 Method A can be applied. The vessel normally operates in the static state condition. However the following loading history can be considered for the purpose of fatigue evaluation: Planned annual shutdown requiring full depressurization: 2 per year Unplanned shutdown requiring full depressurization during first year of operation: 6 Unplanned shutdown requiring full depressurization after first year of operation: 2 per year Automatic shut down requiring full depressurization due to fire/emergency condition: 1 per year The vessels normal operating pressure is 4.481 MPa. The actual pressure variation shall be within 10% of this pressure. However the HP compressor may trip during the operation and can cause pressure variation exceeding 20% of operating pressure. Such trips are not expected to be more than 6 per year. The vessels normal operating temperature is 50oC and no fluctuations in temperature are expected during normal operation. However the shutdown conditions may cool down the vessel to ambient temperature of not less than 5oC. The vessel is of carbon steel and has no metals which have different coefficient of thermal expansion. MATERIALS OF CONSTRUCTION VESSEL MATERIALS: Materials of constructions: Material Type 1 (Table 4.2.3) P-No. 1 Gr 2 Shell / Heads Nozzle Flanges / Forged Necks Fasteners Saddle wear plates & Name plate bracket Saddle & base plates & other attachments Gaskets SA 516M Gr 485 (Gr 70) SA 105M (Self Reinforced type) SA 193M Gr B7 / SA 194M Gr 2H SA 516M Gr 485 (Gr 70) SA 36
SS316L GRAPHITE FILLED SPIRAL WOUND GASKETS WITH SS INNER & CS OUTER RINGS

8. 8.1

ORIGINATOR: ABC CONSULTANTS PROJECT: AIR BUFFER VESSEL AB-001 CONTRACT NO:
8.2 8.3

DOCUMENT NUMBER: UDS-AB-001 (REV 0)

JOB NO: AB-001

PAGE NO. 9 OF 14

CORROSION AND EROSION

3.0 mm internal corrosion allowances shall be considered. Erosion of the vessel due to fluid motion is not applicable (Compressed Air Service). The external surfaces of the vessel shall be painted. No external corrosion allowance. SERVICE CONDITIONS AFFECTING SELECTION OF MATERIAL Service Duty Lethal Service / Sour Service Hydrogen Service Specific Toughness Requirement Special filler metal requirements Continuous None None To be evaluated by supplier None

9. 9.1

LOADS AND LOAD CASES

Applicable Loads (As per Table 4.1.1 of Code):

Design Load Parameter P Ps D Description Internal Maximum Allowable Working Pressure External Maximum Allowable Working Pressure Static head from liquid or bulk materials (e.g. catalyst) Dead Weight of the vessel , Contents and Appurtenances , including the following: Weight of vessel including internals, supports. Weight of vessel contents under operating & test conditions. Refractory Linings, Insulation. Static Reactions from weight of attached equipment. Appurtenances Live Load Effect of Fluid Flow Earthquake Loads Wind Loads Snow Loads Applicability / Remarks Applicable Not Applicable Not Applicable

Applicable Applicable Not Applicable Not Applicable Not Applicable Not Applicable Applicable Applicable Not Applicable

L E W S

9.1

Applicable Design Load Combinations (As per Table 4.1.2 of Code) :

SR. NO. 1 2 3 Design Load Combinations P + Ps + D 0.9 P + Ps + D + (W or 0.7 E) 0.9 P + Ps + D + 0.75 (W or 0.7 E) + 0.75 L + 0.75 S General Primary Membrane Allowable Stress S S S

Notes: 1) 0.9 P is an Operating Pressure Condition. 2) S is Allowable Stress of material at applicable Temperature (Design / Operating).

9.2

Calculation Method:
Vessel Calculations to be performed as per PART-4 of the Code (Design by Rules method)

ORIGINATOR: ABC CONSULTANTS PROJECT: AIR BUFFER VESSEL AB-001 CONTRACT NO:
10. 10.1 10.2 10.3 11. OVERPRESSURE REQUIREMENTS

DOCUMENT NUMBER: UDS-AB-001 (REV 0)

JOB NO: AB-001

PAGE NO. 10 OF 14

Company shall be responsible for design, construction and installation of Pressure Relief Valve & meeting the requirement of the Code. Pressure Relief Valve suitable for Compressed Air Service shall be provided on Nozzle N2. Type of over-pressure protection system: Pressure Relief Valve.

Requirement of any Jurisdictional Acceptance: Being a normal Air Buffer Tank in compressed air service, any Jurisdictional Acceptance is not required before operation of the vessel.
ADDITIONAL REQUIREMENTS:

11.1

Requirement related to NDE, Restrictive Chemistry & Heat Treatment:

Examination Group 1a as per Table 7.1 of the Code is applicable. Inspection of weld joint shall be as per Table 7.2 and shall as a minimum meet the following: WELD CATEGORY A B C D E TYPE 1 1 1 7 7 REQUIRED NDE EXAMINATION 100% RT & 10% MT 100% RT & 10% MT 100% RT & 10% MT 100% UT & 10% MT 100% MT

Additionally all welds shall be visually examined on internal & external surface as per 7.5.2 of Code. Post Weld Heat Treatment is required for complete vessel as per Part 6.4.2 & Table 6.8 of the Code. Impact testing requirements for materials and welds shall be evaluated by the supplier as per 3.11 of the Code. Impact testing is however mandatory for the hub type forgings. Impact test shall be carried out at MDMT or colder temperature and shall meet the Code requirements. All material shall comply with applicable material specifications and Part 3 of the Code.

Code marking shall comply with Part 2.F.1 of Code. Additionally the supplier shall provide a name plate showing name of the company, name of the supplier, Item number and date of hydrostatic test. Vessel shall be Hydro tested at suppliers facility before dispatch. Hydrostatic test media shall be water and metal temperature during test shall not be less that 17 deg C. After Hydro test vessel shall be fully drained, cleaned & dried. Complete external surface of vessel including saddle assembly & bottom of base plate shall be painted as per the painting specification provided with the contract.

ORIGINATOR: ABC CONSULTANTS PROJECT: AIR BUFFER VESSEL AB-001 CONTRACT NO:

DOCUMENT NUMBER: UDS-AB-001 (REV 0)

JOB NO: AB-001

PAGE NO. 11 OF 14

ATTACHMENT 1 NOZZLE LOADS FOR VESSELS (HORIZONTAL AND VERTICAL) 1.0 1.1 1.2 1.3 GENERAL The criteria specified shall apply to nozzles above 2 in. NB for vessels constructed of carbon steel and low alloy steels. The forces contained herein are considered minimum criteria in order to allow for an economical design of the connecting piping. Nozzle loading geometry is shown below for reference

ORIGINATOR: ABC CONSULTANTS PROJECT: AIR BUFFER VESSEL AB-001 CONTRACT NO:
2.0 2.1 2.1

DOCUMENT NUMBER: UDS-AB-001 (REV 0)

JOB NO: AB-001

PAGE NO. 12 OF 14

EXTERNAL FORCES AND MOMENTS ON NOZZLES Each nozzle shall be capable of withstanding forces from external piping under the design conditions and considered to be acting at the intersection of nozzle and shell in corroded condition. The value "D" in the formula below is the nominal nozzle diameter in inches. The Z-values in the formula depend on the rating of the nozzle flange and are as follows:

ASME B16.5 FLANGE RATING 150 300 600 900 1500

Z Values for calculating loads 0.6 0.7 0.8 0.9 1.0

2.3

Nozzle in Shells
Type of load Longitudinal bending moment Circumferential bending moment Resultant bending moment Torsional moment Longitudinal shear force Circumferential shear force Resultant shear force Axial Tension of compression force Formula ML = Z*130*D2 M = Z*100*D2 Mb = (ML2 + M2) = Z*164* D2 Mt = Z*150* D2 FL = Z*2000*D F = Z*1500*D Fr = (FL2 + F2) = Z*2500* D Fa = Z*2000* D Units Nm Nm Nm Nm N N N N

2.3

Nozzle in Heads
Type of load Resultant bending moment Torsional moment Resultant shear force Axial Tension of compression force Formula Mb = (Mx2 + Mz2) = Z*164* D2 Mt = Z*150* D2 Fr = (Fx2 + Fz2) = Z*2500* D Fa = Z*2000* D Units Nm Nm N N

ORIGINATOR: ABC CONSULTANTS PROJECT: AIR BUFFER VESSEL AB-001 CONTRACT NO:

DOCUMENT NUMBER: UDS-AB-001 (REV 0)

JOB NO: AB-001

PAGE NO. 13 OF 14

FATIGUE SCREENING CRITERIA as per Part 5.5.2.3, Method A: STEP 1: The following loading history has been provided in the UDS The vessel normally operates in the static state condition. However the following loading history can be considered for the purpose of fatigue evaluation: Planned annual shutdown requiring full depressurization: 2 per year Unplanned shutdown requiring full depressurization during first year of operation: 6 Unplanned shutdown requiring full depressurization after first year of operation: 2 per year Automatic shut down requiring full depressurization due to fire/emergency condition: 2 per year The vessels normal operating pressure is 4.481 MPa. The actual pressure variation shall be within 10% of this pressure. However the HP compressor may trip during the operation and can cause pressure variation exceeding 20% of operating pressure. Such trips are not expected to be more than 6 per year. The vessels normal operating temperature is 50oC and no fluctuations in temperature are expected during normal operation. However the shutdown conditions may cool down the vessel to ambient temperature of not less than 5oC. The vessel is of carbon steel and has no metals which have different coefficient of thermal expansion. STEP 2: The expected pressure cycles N FP are estimated on the following basis: i) As per operating procedure, this plant does require annual shutdown. Consider 2 shutdowns in a year. Therefore total cycles for 20 years of plant life will be 40 (Total - 40) ii) Unplanned shutdown requiring full depressurization of Air Buffer Tank during first year of operation do not exceed 6 @ 1 per 2 months (Total - 6) iii) Unplanned shutdown requiring full depressurization of Air Buffer Tank after the first year of operation do not exceed 2 per year. (Total - 38) iv) Automatic shutdown requiring full automatic depressurization of the Air Buffer Tank 1 per year (Total - 40) v) Total No. of pressure cycles N FP are therefore 40 + 6 + 38 + 40 = 124 STEP 3: The expected operating pressure cycles N PO are estimated on the basis that during normal operating condition, Air Buffer Tank operates at 4.481 MPa. However when the compressor trips due to any other faults the pressure exceeds 20% of operating pressure. Total such trips are expected not to exceed 6 (1 every 2 months) in a year. Hence cycles due to operating condition is 6 X 20 = Total 120 STEP 4: The expected temperature differential cycles N TE are estimated on the basis that there will be always hot compressed air incoming to the Air Buffer Tank to avoid vessel cool down to ambient temperature. Only planned & unplanned shutdown may result in a cool down of the Air Buffer Tank. The temperature differential of 45 C will result in maximum factor of 1 as per Table 5.8. Total cycles therefore are estimated to be 124 x 1 = 124. STEP 5: The expected temperature cycles N T are zero as there is no weld between metals which have different coefficient of thermal expansion. Total cycles are therefore estimated to be 0.

ORIGINATOR: ABC CONSULTANTS

PROJECT: AIR BUFFER VESSEL AB-001

DOCUMENT NUMBER: UDS-AB-001 (REV 0)

CONTRACT NO:

JOB NO: AB-001

PAGE NO. 14 OF 14

The expected number of cycles per Para 5.5.2.3, Method A, for cycles Step 2 to Step 5 is as follows: Step 2: Full Range Pressure Cycles Step 3: Operating Pressure Cycles Step 4: Metal Temperature Differential Step 5: Metal Coefficient of Expansion Differential

N FP

124 120 124 0 368

N PO
N TE

N T

N FP + N PO + N TE + N T
Check for Integral type construction:
a) use of pad type reinforcements or of fillet welded attachments b) The use of pipe threaded connections c) The use of stud bolted attachments d) The use of partial penetration welds e) Major thickness changes between adjacent members f) Attachments and nozzles in the knuckle region of formed heads

NO NO NO NO NO NO

Hence the vessel meets the integral type construction requirements of the Code As per Table 5.9 of the Code, the maximum number of cycles permitted without carrying out fatigue analysis for integral type construction with no nozzles in the knuckle region of the head = 1000 which is > 368 Conclusion: No fatigue analysis is required for this vessel as the intended vessel operation satisfies the Part 5.5.2.3 of ASME code section VIII Div. 2 for the considered vessel design life of 20 years.