1.

Introdu
uction

EmiratesSSteel(ES)hassexistingope
erationslocate
edintheInduustrialCityoffAbuDhabi(IICAD),AbuDh
habi,
UAE,whicchcurrentlyccomprisesanintegratedstteelmakingfaacility(Phase1)forthepro
oductionor
reinforcin
ngbarandwirrerodandan
nintegratedsteelmakingffacility(Phasee2)fortheprroductionof
structurallsectionsand
dsemifinishe
edproducts.TTheCompanyyhasrecentlyyacquiredanadjacent
steelmakingfacility,caapableofprod
ducing350KTTPAofsquareebillet,thein
ntentionbeingtoprovidebillet
feedstockktothePhase
e1longprodu
uctrollingmills.

TheComp
panyislocate
edinMussafaahIndustrialA
Area(ICAD1),,ontheNortthEastofAbu
uDhabi.Therreisa
localportintheMusafffahareaapproximately8kmfromthe siteandthemainMinaPortofAbuDh
habiis
pproximatelyy50kmfromthesite.TheCompanyha sasmalljettyyonthePhasse2siteforim
locatedap mport
ofironoxxidepellet;ho
oweveritisno
otsuitablefortheimport ofplantandeequipment.

Thearea isservicedbyaroadnetw
workwithinttheIndustria lCityofAbuDhabi(ICAD
D1)whichleaadsto
themainAbuDhabimotorwaynetw
workapproximately8kmffromthesite..

ufacturing un
The manu nits include a
a Direct Redu
uction Plant (DR Plants) o
on both Phasse 1 and Phaase 2.
Figure1b
belowshowstthelocationo
oftheDRproductionplantts(whichareidentical).

Figure 1: Emirates Steel

S Phase 1 & 2 Sites

DRP1

DRP2

Aspartoffaprocessim programme,ttheexistinge mergencyventingsystemsfortheDRP
mprovementp Plants
requireim
mprovementiintermsofth
heirventingcapability,atppresentaflarresystemisusedto
depressurrizethereactorincasesoffemergency.Thissystemddoesnotventtthereactorquicklyenou
ugh,
soitisintendedinfuturetouseacoldventtodepressurizethereactor,inplaceofthecurrentflare
systemwhenanyemergenciesoccur.

2.ESRequirements

ESrequirestheservicesofasuitablyexperiencedandqualifiedcompanytosupplythebasicand
detaileddesignsforanewseparatecoldventingsystem.Tosupply,manufactureandinstallthenew
coldventonbothDRPproductionunits,toalsocommissionthenewsystemonceinstalled.Thevent
shouldberoutedtothetopofthereactortowertoaheightthatcomplieswiththeenvironmental
regulationsrelatedtoemergencyvents.

Thedesignshallfacilitatethedepressurizationofthereactortoatleast0.5barinamaximumtimeof
10minutes.

ThenewsystemwillneedtohaveEnvironmentalapproval,whichisunderESresponsibility,the
contractorwillberesponsibleforprovisionofthenecessaryspecification(drawing,input,output,
emissionsetc.)whichshouldcomplywiththeUAEEnvironmentallawinadvanceinordertogetthe
requiredapproval.

ThesituationonthetwoDRPunitsisslightlydifferentasatieintothereactorquenchorificehas
alreadybeeninstalledontheDRP2reactor,atieinwillneedtobeinstalledontheDRP1reactor.The
followingsectionsdetailtheindividualrequirementforbothproductionunits.

2a.DRP2

Thetieinforthecoldventhasalreadybeeninstalledinthe
DRP2reactorquenchorifice,whichisdetailedindrawing
DP017SFE21M1401TD101Rev02.Thescopeofworkforthe
phase2coldventistoconnecttotheexistingquenchorifice
ventlineisolationvalve(V1)spectacleplate,asshown
opposite.

One12ventcontrolvalve(V2)on/offneedstobeinstalled
afterthespectacleplate,thisvalvewillbefreeissuefrom
EmiratesSteelbutfittedbythecontractor,thespecificationof
thisvalveisdetailedinAppendix1.Theventline(P3)then
 P-1

needstobeinstalledtotravelfromtheventvalvetotheverytopof N2line
P-6
P-2
thereactortowerwherethegaswillbeventedtoatmosphere.The
V-1 V-3
existingspectacleplateneedstoberepositionedbetweentwonew SpectaclePlate
Ventline
flangesasshowninthediagramopposite.Allnecessarypipeand P-3 P-4 P-5
V-2

valvesupportsfromV1shallbeincludedinthecontractorsscope.Thecontroloftheventvalve(V2)
shallbeprovidedbythecontractorthisincludestheinstrumentairconnection,themodificationstothe
HMIscreensintheDRP2controlroomwillbecarriedoutbyES.Anitrogenpurgeline(P6)with
automaticcontrolvalve(V3)needstobeinstalledtotheventlineaftertheventvalve(V2).

2b.DRP1

Atiein,isrequiredtobeinstalledontheDRP1quench
orifice,thepositionofthetieinshouldsuittherouteofthe
ventpipework.Apotentiallysuitablelocationishighlightedin
thephotographopposite.TheBOMforthetieinisdetailedin
table1below.

Thevalvearrangementwillbeexactlythesameasthatfor
DRP2detailedinthediagramabove,exceptforbeingina
differentorientation.

Isolationvalve(VI)andventcontrolvalve(V2)willbefreeissuedbyESbutfittedbythecontractor,the
valvespecificationanddetailsarefoundinAppendixone.Aspectacleplateneedstobeprovidedbythe
contractorandinstalledbetweenV1andV2.AllnecessarypipeandvalvesupportsfromV1shallbe
includedinthecontractorsscope.Thecontroloftheventvalve(V2)shallbeprovidedbythe
contractor,thisincludestheinstrumentairconnection,themodificationstotheHMIscreensintheDRP
1controlroomwillbecarriedoutbyES.Anitrogenpurgeline(P6)withautomaticcontrolvalve(V3)
needstobeinstalledtotheventlineaftertheventvalve(V2).

 Bill of Material for DRP 1
SN Description/Size/Type Material Qty Unit Remarks Equipment
Specification/Dimension
1 12" NPS Pipe Sch 40 SS 304 L 1 Pc SS Cut to suit shell radius, Length Quench orifice
Seamless TBD connection (P2)
2 12"-150# RF Flange ASTM A 105N - ANSI B 5 Pcs V1, V2 and
Slip- On 16.5 spectacle plate

3 12"-150# RF Flange SS 304 L 1 Pcs V1 quench orifice

Slip- On side
4 12"-150# Gasket ASME B16.20 SPW (SS 6 Pcs Flexitallic Quench orifice
-Graphite filled)
5 12"-150# Spectacle ASTM A 105N - ANSI B 1 Pcs Flat Face - Machined and Serrated Between V1 & V2
Blind 16.5 Both Sides Smooth Finish

6 7/8" dia x 155 Long ASTM A93 Gr B7M & 24 Pcs For Spectacle Blind Spectacle
Stud Bolts & Nuts A192- Gr 2H

7 7/8" dia x 120 Long ASTM A93 Gr B7M & 36 Pcs For V1 and V2
Stud Bolts & Nuts A192- Gr 2H

8 12" Reinforcing Pad ASTM A240 19 mm thk 1 Cut and rolled to suit external shell Quench Orifice
radius same thickness of quench orifice
shell
9 Vent line TBD by contractor P3, P4 & P5

10 Nitrogen valve TBD by contractor 1 Pc V3 nitrogen

injection

11 Nitrogen line TBD by contractor P6

Bill of Material for DRP 2

1 12"-150# RF Flange ASTM A 105N - ANSI B 4 Pcs V2 and spectacle
Slip- On 16.5 plate

2 12"-150# Gasket ASME B16.20 SPW (SS 5 Pcs Flexitallic Quench orifice
-Graphite filled)
3 7/8" dia x 155 Long ASTM A93 Gr B7M & 24 Pcs For Spectacle Blind Spectacle
Stud Bolts & Nuts A192- Gr 2H

4 7/8" dia x 120 Long ASTM A93 Gr B7M & 36 Pcs For V1 and V2
Stud Bolts & Nuts A192- Gr 2H

5 Vent line TBD by contractor P3, P4 & P5

6 Nitrogen valve TBD by contractor 1 Pc V3 nitrogen
injection
7 Nitrogen line TBD by contractor P6
Table1

2c.ControlSystems

Aspartofthemechanismsrequiredforoperatingthecoldventsafely,thefollowingitemsneedtobe
procuredandinstalledbythecontractor,theplantoperatingsystemsalsoneedtobemodifiedto
operateandmonitorthesenewlyinstalledsystemsonbothDRP1&DRP2.

PGHIsolation

Anautomaticisolationvalve(mentionvalvesizehere)needsto
beinstalledontheinlettothePGHasshowninthephotograph
opposite,permanentaccess(newfloorandhandrails)alsoneeds
tobeprovided.Thisvalveshallautomaticallyshutwhenthecold
ventlineisoperated.Thecontroloftheisolationvalveshallbe
providedbythecontractor,thisincludestheinstrumentair
connection,themodificationstotheHMIscreensintheDRP
controlroomswillbecarriedoutbyES.

NitrogenBlanket
N2injectionpoints
AN2blanketneedstobeprovidedbetweenthereactorandthe
PGHthatwillautomaticallyoperatewhenthecoldventis
operated.Thephotographoppositeshowsthetwofeedlinesfor
theO2enrichment,whichiswherethenitrogenshouldbe
introduced.Thesystemoperationshouldbe,assoonasthecold
ventsystemisoperatedtheO2mainisolationvalveclosesand
thenewN2valveopens.ThecontroloftheN2supplyvalveshall
beprovidedbythecontractor,thisincludestheinstrumentair
connection,themodificationstotheHMIscreensintheDRP
controlroomswillbecarriedoutbyES.

3.ScopeofSupply

1. AHAZOPstudyofthenewsystemandanycurrentsystemsorproceduresthenewsystemwill
impactonwillneedtobecarriedoutaspartofthedesignprocess.
2. Theprovisionoftheinformationnecessaryforenvironmentalapproval.
 3. Thecompletebasicanddetaileddesignfortheinstallationandcommissioningofacoldvent
system.Thisshallinclude,butnotlimitedto:
a. Optimumrouteandpositionforcoldventsystem.
b. Sizeoftieintoexistingquenchorificeandvalvespecification.
c. Interconnectingpipeworktonewvent.
d. Pipeworksupportingmethod.
e. Assessmentofexistingstructuralsteelworkintegrity.
f. Specificationofcoldvent.
g. Paintingandcorrosionresistancespecification.
h. Maintenanceandoperationalaccess.
i. Environmentalimpactstudy.

4.DesignCriteria

4.1DesignBasis

ThelatestInternationalandLocalCodes,Standardsandconsiderationsshallbeusedinthedesignofthe
coldventsystem.

1. Safetyandenvironmentalrequirements(dispersion,smokinglimits,radiationlimits,noise,etc.).
2. Typeandquantitiesofreleasedgasesandnatureofflaringevent(toxicornontoxicfluids,
emergencyventing,etc.).
3. Constructionmaterialsrequirements(seawaterenvironment,corrosiveproductsofcombustion,
highheatflameintensity,intermittentoperation,multipletipsinclosevicinity,etc.).
4. Materialselectionsuitableforoperationaltemperatures,corrosion,erosion,hydrogen
embrittlement,temperaturecyclingembrittlement,etc.Materialselectionshouldtakeinto
considerationaspecialissueassociatedwithpotentialautorefrigerationfromdepressurizing.
5. Typicaloperatingconditions
6. Accesstoventusuallyrequiredformaintenanceandinspection.
7. Pipinginterfaceconnectionsshallbeflanged.
8. Buttweldsshallbefullpenetrationwelds.
9. Buttweldsshallbe100%radiographed.
10. RadiographicproceduresandacceptancecriteriashallcomplywithASMEB31.3.
11. Laddersandplatforms,includingboltingandotherattachments,shallbehotdipgalvanized.
 12. Materialsofstructuresandaccessoriesshallbeadequateforallloadconditionsatlowest
specifiedambienttemperature.
13. Earthing(grounding)ofthestructureshallbeasrecommendedbyBS6651orequivalent
nationalstandards.

4.2Materials

ThecoldventsystemshallbeconstructedofmaterialsspecifiedintheBOMandequipmentdatasheets,
andasspecifiedbythevendorsdesign.

4.3NoiseLevellimits

Theventshallbedesignedandsitedsuchthatnoiseatpositionsnormallyaccessibletopersonnel.Noise
levelsshallnotexceedthelevelssetbytheenvironmentalagency,thesetobespecifiedintheoffer.The
vendorsquotationshallprovideinformationonexpectednoiseemissionfromthevent

4.4Guarantees

TheContractorshallprovidethefollowingperformanceguaranteeforthecoldventsystem:

1. Performanceoftheventhydraulically,mechanically,andelectrically.
2. Capacityofventforspecifiedcompositionrange.
3. Noiselevelsoverspecifiedoperatingrange.
4. Noiseatdesignflow.
5. Guaranteesshallapplytobothsummerandwinteroperation.

5.Documentation

Adetailedoperatingprocedureandmaintenancemanualsshallbedevelopedfortheventsystem.

Theoperatingprocedureshouldincludethefollowingmajortopics:

1. Detailedsystemdescription.
2. Operatingrangeandoperatinglimits.
3. Operatortrainingrequirementsandtrainingfrequency.
4. ProcessConditions
5. UtilityRequirements
6. ErectionandInstallationGuidanceProceduresandBOM
 7. InstrumentandPipingDataSheets.
8. Drawings.

6.OtherStandards

ESEngineeringStandardsneedtobefollowedunlessthesehavebeensupersededbylocalregulations
theseareattachedinAppendix2.

7.Drawings

SupplieddrawingsaredetailedbelowandincludedinAppendix3:

DRP1DP017SFE21P4000AD501

DRP2DP02KBFE21P4000RD501

DP017SFE21M1401TD101Rev02ArrangementofProcessGasQuenchOrifice

8.Deliverables

Pleaseprovideanoutlineprojectplanwithyoursubmission.

Thetablebelowdetailstheresponsibilitymatrix.

Item Description Contractor ES

1 ProvisionofActualProcessOperatingConditions/Parameters ES

2 ProvisionofactualP&IDs,CivilandMechanicalDrawings ES

3 Study/ReviewofMinimumDepressurizingtimewithoutaffectingInternalsof Contractor
Equipment.
4 ReviewingofActualpipingCapacityforVentingtoachieverequiredventingtime Contractor

5 ReviewingofActualShutOffValvesCapacitytoachieveventingtime Contractor
6 DesignofNewColdVentFlare Contractor
7 PFDandP&IDsandGAdrawingForNewColdVents. Contractor

9 Environmentalapproval ES

10 Information/documentationfortheenvironmentalapprovalprocess Contractor

11 CarryoutHAZOPstudyforthenewmodification. Contractor ES

14 DesignofPipingInterconnection Contractor
15 Designofvent,pipeworkandmaintenanceaccessplatforms Contractor

17 PLCandHMIConfiguration/Logicmodification(??) Contractor ES
18 VentCommissioningProcedure Contractor ES