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Pressure Systems

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Pressure Systems …

Pressure Systems
CONTENTS
0 INTRODUCTION
1 SCOPE
2 DEFINITIONS ADDITIONAL TO THOSE IN THE EP GLOSSARY
2.1 PRESSURE VESSEL
2.2 ATMOSPHERIC PRESSURE STORAGE TANK
2.3 VESSEL
2.4 PIPING SYSTEM
2.5 NON-PRESSURE PROTECTIVE DEVICE
2.6 ASSOCIATED RELIEF EQUIPMENT
3 APPLICATION OF PRINCIPLES
3.1 IMPLEMENTATION OF PEG 4
3.2 DESIGN, MANUFACTURE, REPAIR AND MODIFICATION
3.3 VERIFICATION OF DESIGN
3.4 GBHE REGISTRATION AND RECORDS
3.5 PERIODIC EXAMINATION
4 AUDITING
4.1 General
4.2 Scope of Audit
APPENDICES
A EQUIPMENT WHICH MAY BE EXEMPTED FROM GBHE REGISTRATION
C DOCUMENTATION FOR INCLUSION IN FILES OF REGISTERED EQUIPMENT
D ADDITIONAL REQUIREMENTS FOR THE PERIODIC EXAMINATION OF SPECIAL CATEGORIES OF EQUIPMENT
E DIAGRAMMATIC REPRESENTATION OF PRESSURE SYSTEMS PROCEDURES
F DECISION TREE FOR REGISTRATION OF PIPING SYSTEMS
G REGISTERED EQUIPMENT WHICH MAY BE EXEMPTED FROM DESIGN VERIFICATION
TABLES
1 REGISTERED VESSELS AND PIPING SYSTEMS: MAXIMUM EXAMINATION INTERVALS
2 EQUIPMENT TO BE CONSIDERED FOR CATEGORY LLT
FIGURES
1 SIMPLE PRESSURE RELIEF ARRANGEMENT
2 COMPLEX PRESSURE RELIEF ARRANGEMENT
DOCUMENTS REFERRED TO IN THIS INFORMATION FOR ENGINEERS DOCUMENT

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  • 1. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com GBH Enterprises, Ltd. Process Engineering Guide: GBHE_EP_0218 Pressure Systems Process Information Disclaimer Information contained in this publication or as otherwise supplied to Users is believed to be accurate and correct at time of going to press, and is given in good faith, but it is for the User to satisfy itself of the suitability of the Product for its own particular purpose. GBHE gives no warranty as to the fitness of the Product for any particular purpose and any implied warranty or condition (statutory or otherwise) is excluded except to the extent that exclusion is prevented by law. GBHE accepts no liability for loss, damage or personnel injury caused or resulting from reliance on this information. Freedom under Patent, Copyright and Designs cannot be assumed.
  • 2. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Process Engineering Guide: Pressure Systems CONTENTS 0 INTRODUCTION 1 SCOPE 2 DEFINITIONS ADDITIONAL TO THOSE IN THE EP GLOSSARY 2.1 PRESSURE VESSEL 2.2 ATMOSPHERIC PRESSURE STORAGE TANK 2.3 VESSEL 2.4 PIPING SYSTEM 2.5 NON-PRESSURE PROTECTIVE DEVICE 2.6 ASSOCIATED RELIEF EQUIPMENT 3 APPLICATION OF PRINCIPLES 3.1 IMPLEMENTATION OF PEG 4 3.2 DESIGN, MANUFACTURE, REPAIR AND MODIFICATION 3.3 VERIFICATION OF DESIGN 3.4 GBHE REGISTRATION AND RECORDS 3.5 PERIODIC EXAMINATION 4 AUDITING 4.1 General 4.2 Scope of Audit
  • 3. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com APPENDICES A EQUIPMENT WHICH MAY BE EXEMPTED FROM GBHE REGISTRATION C DOCUMENTATION FOR INCLUSION IN FILES OF REGISTERED EQUIPMENT D ADDITIONAL REQUIREMENTS FOR THE PERIODIC EXAMINATION OF SPECIAL CATEGORIES OF EQUIPMENT E DIAGRAMMATIC REPRESENTATION OF PRESSURE SYSTEMS PROCEDURES F DECISION TREE FOR REGISTRATION OF PIPING SYSTEMS G REGISTERED EQUIPMENT WHICH MAY BE EXEMPTED FROM DESIGN VERIFICATION TABLES 1 REGISTERED VESSELS AND PIPING SYSTEMS: MAXIMUM EXAMINATION INTERVALS 2 EQUIPMENT TO BE CONSIDERED FOR CATEGORY LLT FIGURES 1 SIMPLE PRESSURE RELIEF ARRANGEMENT 2 COMPLEX PRESSURE RELIEF ARRANGEMENT DOCUMENTS REFERRED TO IN THIS INFORMATION FOR ENGINEERS DOCUMENT
  • 4. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 0 INTRODUCTION This Information for Engineers document explains how PEG 4 ’Critical Pressure Equipment’ should be implemented. The PEGs state the necessary engineering requirements related to safety, health and environmental matters, and support the GBHE Safety, Security, Health and Environmental Policy. The principles given in PEG 4 are intended to ensure that Pressure Systems are correctly designed and manufactured and that they are managed effectively with respect to periodic examination, modification and repair once they have entered service. 1 SCOPE This document covers the implementation of PEG 4: Critical Pressure Systems. Sections 3.2 to 3.5 are presented in a form that can be used directly as the basis for local engineering procedures. Within the general framework provided by PEG 4 this document subdivides Pressure Systems into Vessels, Piping Systems, Pressure Relief Streams and Non-pressure Protective Devices because of their differing detailed requirements. Transport containers are not covered by this document (see PEG11). 2 DEFINITIONS ADDITIONAL TO THOSE IN THE GEP GLOSSARY 2.1 Pressure Vessel A Pressure Vessel is a container or structural envelope of any capacity subject to either internal or external pressure. The term includes process vessels, reactors, heat exchangers and vessels for the storage of fluid under pressure.
  • 5. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 2.2 Atmospheric Pressure Storage Tank An Atmospheric Pressure Storage Tank is a container or structural envelope subject primarily to hydrostatic pressure. Tanks with gas at low pressure, typically less than 0.1 bar, above the liquid are included in this definition. 2.3 Vessel A Vessel may be either a Pressure Vessel or an Atmospheric Pressure Storage Tank. 2.4 Piping System A Piping System is a defined section of pipework including piping and pipework components such as flanges and fittings, valves, bellows, anchors, supports, linings, insulation and protection. 2.5 Non-pressure Protective Device A Non-pressure Protective Device is any device which provides protection of the pressure envelope other than against pressure. 2.6 Associated Relief Equipment An item of Associated Relief Equipment affects the operation of a Pressure Relief Stream and requires periodic examination to ensure the continued safe operation of that Pressure Relief Stream. Such equipment generally limits the flow which a Pressure Relief Stream is required to pass but is not restricted to that duty. Examples are restriction orifice plates, control valves and non-return valves.
  • 6. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 3 APPLICATION OF PRINCIPLES 3.1 Implementation of PEG 4 3.1.1 Documentary Requirements Implementation of the principles of PEG 4 requires a series of local procedures to be prepared. These procedures should incorporate requirements of the legislation of the region in which they are to be used so that a complete approach to the management of Pressure Systems is described. Because PEG 4 is concerned with equipment rather than processes, regional procedures within a single set of statutory requirements are likely to be appropriate. A key purpose of this Guide is to provide a basis for the preparation of local procedures for Pressure Systems. Accordingly, the text of 3.2 to 3.5 is presented such that it can readily be adapted to procedure form. Where GBHE requirements exceed those of legislation, then the GBHE requirements are intended to apply. As an aid to gaining an overview of the areas covered by PEG 4 and for which procedures are required, a pictorial representation is given in Appendix E. Both original design and manufacture of equipment and subsequent in-service events are illustrated in flow chart form. Whilst there are a number of ways of arranging Pressure Systems procedures a series of short documents, each dealing with a particular topic, has certain advantages, namely: (a) Sequential preparation and implementation; (b) Ease of updating; (c) Usability, e.g. inspection personnel will be concerned with periodic examination, design staff with design verification. Based on the above, a suggested documentation plan for the main procedures is as follows:
  • 7. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com (1) Registered pressure equipment: procedures and documentation: This should include: (i) An overview of the management system, with reference to the more specific documents listed below; (ii) A detailed summary of responsibilities for actions; (iii) A list of the full range of working forms. (2) Procedure for design, manufacture, repair and modification (see 3.2). (3) Procedures for the verification of design of Vessels, Piping Systems and Pressure Relief Streams (see 3.3.2, 3.3.3 and 3.3.4 respectively together with 3.3.1 and 3.3.5). (4) Procedures for the registration of Vessels, Piping Systems and Pressure Relief Streams (see 3.4.2, 3.4.3 and 3.4.4 respectively together with 3.4.1). (5) Procedures for the periodic examination of Vessels, Piping Systems and Pressure Relief Streams (see 3.5.1, 3.5.2, 3.5.3 and 3.5.4.1 for Vessels and Piping Systems and 3.5.1, 3.5.2, 3.5.3 and 3.5.4.2 for Pressure Relief Streams) An important aspect of documentation not covered in this Guide is the need for a series of working forms to support the procedures. The forms used are included in the references given in 3.2 to 3.5. They are listed in GBHE Engineering Procedure: Registered Pressure Equipment: Procedures and Standard Forms. Site instructions may also be required to allocate Pressure Systems responsibilities to individuals and to provide site-specific procedural direction. 3.1.2 Use of the Procedures Described in this Guide The procedures described in 3.2 to 3.5, whilst being comprehensive, allow appropriate flexibilities, e.g. in the extension of examination intervals where deterioration is shown not to be taking place and in the content of schemes of examination.
  • 8. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com In these areas and others, many aspects are at the Responsible Mechanical Engineer’s discretion. An underlying theme is that positive consideration is given to issues and that action taken is based on the resulting judgments. In addition to safety, the procedures are highly relevant to prevention of financial loss and the planning of preventive maintenance. Active use of the available flexibilities allows achievement of the benefits in the most economical manner. 3.1.3 Appointment of Authorities or Personnel In any case of difficulty in the identification of suitable authorities or personnel for appointment to undertake Pressure Systems responsibilities (e.g. Design Authority, Design Verification Authority) reference should be made to the Director of Engineering (or nominee), the Chief Engineer: International Standards and Professionalism or the Business Engineering Manager. 3.2 Design, Manufacture, Repair and Modification 3.2.1 General Design and fabrication activities for Pressure Systems equipment are required to be based on correct information, to be in accordance with recognized and reputable standards and practices, and to be executed with a high degree of proficiency, confirmed by appropriate examination and certification. 3.2.2 Design and Fabrication Requirements For new, repaired, modified and re-rated Pressure Systems equipment, procedures are required to be in place to enable the following key requirements to be met: (a) Design conditions and other process requirements are correctly established and formally documented as the basis for mechanical design and fabrication. With the exception of repairs the formal document (normally a data sheet) should take into account relevant matters arising from Hazard Studies (see PEG 6) and/or Works modification procedures (see Appendix E). (b) Appropriate national and/or GBHE Codes and Standards are specified and used.
  • 9. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com (c) Good design practice is employed in the preparation, checking and approval of drawings, calculations and purchase/fabrication specifications. (d) In-service examination requirements are considered at the design stage and facilities provided appropriate to the selected method of examination. (e) Appropriate expertise is brought to bear in the selection of materials and fabrication methods. (f) Non-destructive and other testing is appropriately specified. (g) Weld procedures and welder qualifications are validated. (h) Where not under the control of national/local authorities, suitably qualified inspection authorities are engaged for manufacture, repair and modification work. 3.2.3 Repair, Modification and Re-rating Details and methods of repair or modification are to be agreed between the Responsible Mechanical Engineer, the Design Authority and the statutory authority as appropriate. Considerations should include those listed in 3.2.2. Repairs, modifications and re-rating should in general be in accordance with the code or standard to which the equipment was designed. After completion of repairs, modification or re-rating, the equipment is required to be examined by an inspection authority. A pressure test is required in all cases where the activity in any way affects the pressure envelope unless: (a) The Responsible Mechanical Engineer confirms in writing that the test may be waived, after consultation with the Design Authority and where applicable the statutory authority, or (b) Written dispensation is obtained from the Responsible Executive. Special procedures and precautions are required where pneumatic pressure testing is to be carried out. Further information is contained in GBHE Engineering Procedure: In-service Pneumatic Testing of Pressure Vessels.
  • 10. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 3.2.4 Records Full documentation relating to original manufacture, repairs, modifications and re- rating are to be obtained and lodged in the registration files or its location referenced in the registration files (see Appendix C). 3.3 Verification of Design The procedures described in 3.3.1 to 3.3.5 are applicable when verification of design by an independent body or person, or a process which may be regarded as generally equivalent, is not carried out as part of the requirements of national/local authorities. Reference should be made to 3.1.3 of this Guide. Design Verification may be waived for the items of registered equipment listed in Appendix G of this Engineering Guide. 3.3.1 The Design Verification Process The purpose of design verification is to minimize hazards and costs arising from inadequacies in the design of equipment. Verification comprises examination of appropriate design documents by the Design Verification Authority and signature of a Design Verification Certificate (see Appendix B) upon satisfactory completion of the process. The depth of the examination undertaken, subject to the requirements of 3.3.2 to 3.3.4, is to a degree determined by the Design Verification Authority who will, in general, ensure that: (a) All relevant factors have been considered; (b) Appropriate design methods, design details and testing have been applied or specified; (c) Correct numerical values have been used for key properties. The Design Verification Authority will not necessarily carry out a full numerical check on the design. They may request any additional documents and work deemed necessary.
  • 11. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com It is the responsibility of the organization seeking verification to prepare the documentation package and submit it to the Design Verification Authority. It has to be ensured that calculations, drawings and other documents have been checked prior to submission. The design verification process does not require the Design Verification Authority to provide an absolute statement that the design is satisfactory for the stated duty. The confirmatory sentence on the Design Verification Certificate to which the signature applies should include the words "In my/our opinion". 3.3.2 Registered Vessels 3.3.2.1 Procedure for Verification The organization seeking verification is required to submit the following to the Design Verification Authority: (a) A complete set of design calculations. (b) A complete set of drawings. (c) Other documents which may be required to complete the description of the design. (d) A mechanical data sheet, where applicable. (e) A Design Verification Certificate bearing the design conditions and references to relevant documents. The Design Verification Authority has to be satisfied that the mechanical design of the Vessel is suitable for the conditions stated on the Design Verification Certificate, and in particular that: (1) Appropriate code design procedures have been followed; (2) Any non-code design procedures are appropriate and correct; (3) Appropriate NDT and pressure testing has been specified; (4) No major aspects have been omitted.
  • 12. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Verification is directed primarily at the integrity of the pressure envelope but may by agreement be extended to cover other aspects. Thus in the case of a column with internal trays verification would take into account the loadings on the shell produced by the trays but not, unless agreed, the detailed design of the trays themselves. 3.3.2.2 New and Replacement Vessels Before any registered Vessel is put into service, a Design Verification Certificate is to be issued or a note placed in the Registration file stating that design verification has been waived in accordance with Appendix G of this document. 3.3.2.3 Existing Vessels Verification of design is not retrospective, however where there may be doubts about the suitability of a vessel, such as when there are no records, verification should be considered. 3.3.2.4 Modified or Re-rated Vessels The Responsible Mechanical Engineer, or nominee, is required to ensure that a Design Verification Certificate is issued before modified or re-rated Vessels are returned to service or a note placed in the Registration file stating that design verification has been waived in accordance with Appendix G of this Engineering Guide. For modifications, verification is required to cover only those parts of the Vessel affected by the changes. 3.3.2.5 Repaired Vessels A repair is work carried out which restores a Vessel to its original design and specification using original or equivalent materials, fabrication standards, heat treatment, etc. Provided the foregoing is satisfied design verification is not required. If changes are made such as by the introduction of a new feature, different materials or further welding then the work constitutes a modification and 3.3.2.4 applies. 3.3.2.6 Proprietary Vessels Verification of the design of proprietary Vessels may present problems because of the difficulty of obtaining full documentation. To minimize such problems the documentary requirements of verification should be addressed at the enquiry stage.
  • 13. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com For Vessels considered to constitute a potential hazard because of pressure and/or the nature of their contents, full verification is required. As a least preferred alternative, particularly for the smaller series or regularly produced Vessels such as intercoolers, aftercoolers and line filters on low hazard duties, the Design Verification Authority may accept a statement by the manufacturer giving the previous history of the design. The Design Verification Authority will use this information in the assessment but may also require supplementary calculations to be done from on-site measurements. 3.3.3 Registered Piping Systems 3.3.3.1 Procedure for Verification The organization seeking verification of design is required to submit the following, or equivalent, documents to the Design Verification Authority: (a) Documentation giving operating and design pressures and temperatures, the fluid contained, pipe diameter(s), material specification and details of protection/painting. (b) Insulation schedule giving thickness and type of insulation. (c) Isometric drawing showing material, non-destructive testing (NDT), pressure testing and other fabrication requirements. (d) Documentation relating to calculation of pipework flexibility, nozzle and anchor loadings and support and hanger loadings. (e) Evidence that loadings on nozzles, structures and supports have been accepted by the engineers who will use the information. (f) A Design Verification Certificate bearing the design conditions and necessary document references. The Design Verification Authority is required to verify that the design of the Piping System is suitable for the conditions stated on the Design Verification Certificate and in particular that: (1) The design of the pressure envelope including special features such as bellows is satisfactory for the stated duty and that suitable protection has been specified.
  • 14. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com (2) Piping flexibility has been appropriately analyzed. (3) Pipe hangers, supports and associated support structures have been properly designed or selected. (4) The loads exerted on machines, Vessels and structures have been considered and approved. (5) Appropriate NDT and pressure testing has been specified. 3.3.3.2 New and Replacement Piping Systems The procedure given in 3.3.3.1 applies to all new and replacement Piping Systems which are to be registered. 3.3.3.3 Existing Piping Systems Existing Piping Systems do not require verification of design. It is however strongly recommended that the Design Verification Authority carries out a simplified form of verification by careful visual external inspection and any other checks considered relevant. The Design Verification Certificate should state that verification has been performed by an on-site examination. The purpose of this examination is to ensure that there are no obvious signs that the design or protection of the Piping System is inadequate. The finding during this examination that a Piping System requires maintenance should not necessarily affect judgments on adequacy of design. 3.3.3.4 Modified or Re-rated Piping Systems The Responsible Mechanical Engineer, or nominee, is required to ensure that a Design Verification Certificate is issued before a modified or re-rated Piping System is returned to service. 3.3.3.5 Repair of Piping Systems Restoration of a registered Piping System to its original design and specification does not require verification. If these conditions are not fully satisfied the work constitutes a modification and 3.3.3.4 applies.
  • 15. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 3.3.4 Pressure Relief Streams 3.3.4.1 Procedure for Verification Associated Relief Equipment is to be considered when verifying Pressure Relief Streams. Attention is drawn to the definitions of Protective Device (see PEG 4) and Associated Relief Equipment (see 2.7 of this Guide) to highlight the range of equipment which requires inclusion in Pressure Relief Stream verification. The person or organization seeking verification is required to submit the following to the Design Verification Authority: (a) Engineering line diagram(s) showing all relevant details of the Pressure Relief Stream and Associated Relief Equipment. (b) Process engineering documents which provide the following information concerning protection against over and under pressure: (1) Design policy. (2) List of plant items protected. (3) Basis for design of the Pressure Relief Stream. (4) A sketch of the Pressure Relief Stream and Associated Relief Equipment. Process engineering calculations concerned with determination of the flows which relief streams are required to pass are not required but the results of these calculations are to be included under ’Basis for design of the Pressure Relief Stream’. (c) The Protective Device data sheet(s) and supporting sizing calculations including inlet/outlet piping pressure drops. (d) Blow off/test certificates for Protective Devices. (e) Data sheets and/or drawings of Associated Relief Equipment.
  • 16. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com (f) Detailed piping drawings of the Pressure Relief Stream together with information on discharge reaction forces and, for systems subject to significant variation from ambient temperature, piping flexibility loads on the Protective Devices. (g) Current data sheets or drawings of equipment protected by the Pressure Relief Stream. (h) Where appropriate, in-service inspection reports on testing and examination of Protective Devices. The Design Verification Authority is required to verify that the documents and calculations listed above, and referenced on the Design Verification Certificate, are complete, consistent and have been approved and that: (1) The design conforms to relevant codes and standards. (2) The design of the equipment is satisfactory for the stated conditions. (3) Good engineering practice has been applied. (4) No major aspects of design have been omitted. 3.3.4.2 New Pressure Relief Streams The requirements of 3.3.4.1 apply to all new Pressure Relief Streams and a Design Verification Certificate is required to be issued before the plant is put into service. 3.3.4.3 Existing Pressure Relief Streams Verification of design is not retrospective; however where there may be doubts about the suitability of a Pressure Relief Stream, verification should be considered. 3.3.4.4 Modified Pressure Relief Streams Where modifications are made to Pressure Relief Streams, the requirements of 3.3.4.1 is to be applied to the revised documentation and a Design Verification Certificate issued before the plant is returned to service. Modification requires verification irrespective of whether the Pressure Relief Stream has been previously verified.
  • 17. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 3.3.5 Administration of Design Verification 3.3.5.1 Appointment of Design Verification Authorities It is probable that different Design Verification Authorities will be required for Vessels, Piping Systems and Pressure Relief Streams. Suitable engineers and/or organizations, independent of the production unit/facility, are to be appointed by the Responsible Mechanical Engineer or Project Manager as appropriate. For plant being engineered by a chemical plant contractor it is permissible to appoint engineers within the contractor’s organization but not working on the GBHE project as Design Verification Authorities for the project. 3.3.5.2 Design Verification Documentation It will be necessary to prepare Design Verification Certificates and other forms for the support of the verification process. Completed Design Verification Certificates are to be placed in the equipment Registration files, and suitable storage facilities provided for approved verification documentation. 3.3.5.3 Responsibility for Preparation and Submission of Verification Packages For new plant the Design Authority will normally be responsible for obtaining verification. For existing plant the responsibility will in general lie with the Responsible Mechanical Engineer. Sufficient time is required to be be included in project programs to allow for design verification. 3.3.5.4 Local Engineering Procedures/Instructions As an aid to the preparation of local engineering procedures covering the execution and administration of the verification of design of Vessels, Piping Systems and Pressure Relief Streams reference to the following GBHE Engineering Procedures may be helpful: (a) Vessel Design Verification (b) Ordering and Design Verification of Proprietary Vessels (c) Design Verification of Registered Piping Systems (d) Pressure Relief Stream Design Verification
  • 18. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 3.4 GBHE Registration and Records Attention is drawn to 3.5.6 with respect to non-registered equipment. It is not acceptable for any equipment to operate indefinitely without a degree of examination. 3.4.1 Scope and Requirements of GBHE Registration GBHE Registration is a declaration within the Company of formal status given to selected equipment for the purpose of ensuring integrity. The following are required to be registered: (a) All equipment covered by national/local legislation; (b) All Pressure Vessels with the possible exception of those listed in Appendix A; (c) Atmospheric Pressure Storage Tanks which are in such location that a leak or failure could give rise to an Unacceptable Situation; (d) All Pressure Relief Streams and Associated Relief Equipment with the possible exception of those listed in Appendix A; (e) Piping Systems which are outside site boundaries or which are in such location that a leak or failure could give rise to an Unacceptable Situation (see 3.4.3); (f) Equipment other than the above, which for particular reasons the Works consider appropriate for registration (see 3.4.6). For items covered by (c), (e) and (f) above, Registration should also be considered where there is a known or suspected mechanism of deterioration. Registration of equipment under a GBHE scheme requires: (1) Allocation of and marking with a unique identification number.
  • 19. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com (2) Creating and maintaining a file containing prescribed documentation which proves that the equipment has been designed, manufactured, tested, repaired and modified according to its drawings and specifications and that it has passed examination associated with these activities. The file is to include all examination or test reports and other appropriate documents. Documentation to be included in Registration files is given in Appendix C. (3) The determination and recording of the classification, inspection grading, intervals for examinations and the nature of the examinations. (4) Inclusion in a notification system which displays the next due examination date and any overdue examinations. A list or register is required, for each plant or Works, of all items of registered equipment. The list may be part of a computer system used to schedule examinations (see 3.4.1(4)). The Registration files described in 3.4.1(2) are required to be kept fully up to date in all respects. Attention is drawn to the following which are referred to in C.1.2: (i) Abnormal Occurrences Any incident which may affect the condition and future safe operation of the equipment is to be recorded in the form of an abnormal occurrence report. The report is required be sent to the Responsible Mechanical Engineer and a copy placed in the Registration file. (ii) Specialist Reports Where a specialist in materials, design or other subject is engaged to study aspects of the equipment concerned with safety, periodic examination or operating constraints a report is required to be sent to the Responsible Mechanical Engineer and a copy placed in the Registration file. For new plant the Project Manager is responsible for ensuring that equipment is approved by the Design Authority, verified and registered. For existing plant the Responsible Mechanical Engineer is responsible for ensuring approval by the Design Authority, verification and Registration or amendment to Registration as appropriate.
  • 20. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com For new pressure equipment which is to be registered a pre-commissioning examination and a documentation check should be made by the personnel who will carry out subsequent periodic examination. The objectives of this are to check that the equipment has been installed in accordance with design and, if appropriate, make baseline measurements and observations and to confirm that the documentation required for Registration is in place and complete. GBHE Engineering Procedure: Pre-Commissioning Examination and Checks, covers this topic. Where equipment has been dismantled for overhaul or examination the need for a pre-service check should be considered to ensure that it has been correctly reassembled. In some locations the concept of "Critical Equipment" or "Safety Critical Equipment" is used. All pressure equipment within this category should be registered and given special attention with regard to examination content and interval within the GBHE Registration scheme. 3.4.2 Vessels Vessels should be identified from flowsheets, line diagrams and equipment lists, taking care not to overlook additions arising from plant modifications. Fired pressure equipment such as process heaters are required to be registered as Pressure Vessels with Registration covering both the pressure components and key aspects of the fire-side such as refractory lining. Vessels which were not designed for the intended duty or which have seen previous service either on another plant or external to the GBHE are not to be put into service unless they have been approved by the Design Authority, the design has been verified and they have been thoroughly examined and approved by an inspection authority. The approach to Vessels of this kind is given in GBHE Engineering Procedure: The Assessment, Documentation, Design Verification and Registration of Second Hand Vessels. 3.4.3 Piping Systems The responsibility for selection of Piping Systems for Registration lies with the Responsible Mechanical Engineer. Selection should involve consultation with inspection engineers, materials engineers and/or other specialists with relevant expertise. A decision tree to aid in the selection of Piping Systems for Registration is given in Appendix F.
  • 21. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com New and existing Piping Systems are to be considered for Registration. During plant life consideration is to be given to registering Piping Systems which have failed or deteriorated in-service, or which, through experience on similar duties elsewhere, have been shown to be susceptible to such failures. Reference to GBHE Engineering Procedure: The Selection of Piping Systems for Registration, may be helpful. Registration requires identification and classification of Piping Systems. Identification by line number with terminal points marked on line diagrams is usual. A Piping System can contain several lines, one line or part of a line. Experience has however shown that for examination and reporting purposes it is preferable to avoid definition of Piping Systems which are large and complex. 3.4.4 Pressure Relief Streams Identification of Pressure Relief Streams for the purpose of Registration should initially be via the schedule of Protective Devices. For each Pressure Relief Stream and its Associated Relief Equipment, components are required to be identified and numbered separately in so far as it is necessary to assign different schemes and intervals for periodic examination. Figure 1 shows a simple pressure relief arrangement to clarify further the definitions given in PEG 4 and 2.7 of this Guide. Figure 2 shows a more complex arrangement of the type sometimes used for plant containing highly toxic gases. To illustrate the approach to Registration, the header system may be regarded as part of the main Pressure Relief Stream with the other Pressure Relief Streams terminating at entry to the header. For the main Pressure Relief Streams, identification is required not only of the components affecting pressure relief but also of those items affecting the composition of the discharged gases. Examples of the latter are the vent scrubber liquor supply and the flarestack pilot burners. Pressure Relief Streams/Protective Devices on non-pressure equipment such as silos are required to be registered. Vents or panels to protect against dust explosion are examples of this type of equipment. Instrumented devices and systems providing protection against excess high or low pressure, such as those which isolate equipment from the source of pressure, are required to be registered as Pressure Relief Streams. Reference should be made to PEG 3.
  • 22. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Registration is intended to ensure that all components of Pressure Relief Streams and Associated Relief Equipment receive appropriate management and consideration for periodic examination.
  • 23. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 3.4.5 Non-pressure Protective Devices Devices and systems which provide protection of the pressure envelope of equipment other than against high or low pressure are required to be registered. Such items may protect against high or low excess temperatures, high or low fluid levels (e.g. boiler plant) or adverse fluid composition which would cause rapid corrosion, erosion or cracking. Other devices which may fall into this category are those which control the course or rate of a chemical reaction. Where such devices and systems make use of instrumentation, reference should be made to PEG 3. 3.4.6 Other Equipment Consideration is to be given to the Registration of non-pressure equipment such as silos and hoppers and of mechanical components such as non-return valves and bellows not covered by 3.4.2 to 3.4.5 which, upon failure or failure to operate, could give rise to an Unacceptable Situation. The Responsible Mechanical Engineer is encouraged to register any item of equipment considered to be a critical or weak point in a Pressure System. 3.5 Periodic Examination (see also Appendix D) 3.5.1 General The purpose of periodic examination is to detect any deterioration, fouling or other factors which may affect the continued safe operation of registered equipment. Clauses 3.5.2 and 3.5.3 describe a system for the determination of the examination interval, 3.5.4 gives guidance on the examination itself and 3.5.5 highlights important procedural and administrative aspects.
  • 24. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 3.5.2 Classification All registered equipment is required to be classified as follows: (a) Class A All equipment covered by statutory requirements. (b) Class B All registered Vessels, Piping Systems, Pressure Relief Streams and Associated Relief Equipment, and other equipment not included in Class A. 3.5.3 Grading and Examination Intervals 3.5.3.1 Class A Equipment Where examination intervals stated in legislation are believed to be too long for the known or anticipated rate of deterioration of the equipment, reduced intervals should be considered, such as those given below for Class B equipment. 3.5.3.2 Class B Registered Vessels and Piping Systems Table 1 subdivides equipment into categories. Whilst a specific item may not coincide exactly with any of the categories, it should always be possible to use Table 1 for guidance. Whilst Table 1 gives a recommended initial period for examination, decisions on the timing of subsequent examinations of Class B equipment are matters of experienced judgment. Much depends on experience with similar equipment on similar duties. However, it should not be assumed that new plant or equipment is so similar to an existing plant that its equipment will behave in exactly the same way. For Vessels, Piping Systems or other equipment for which there is no previous history, the maximum initial examination interval is not to exceed 26 months. In some cases it may be appropriate to examine after a shorter interval. For convenience Class B equipment is divided into three inspection grades; Z, Y and X according to the frequency of examination judged necessary, grade Z having the most frequent examination. When equipment is installed, and before it is used, it is required to be allocated to an appropriate grade by agreement with the Responsible Mechanical Engineer who should take specialist advice where relevant. Depending on the results of examinations of equipment in-service, the Responsible Mechanical Engineer may decide to change the grading and the schedule of examinations.
  • 25. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Notes: (a) The tabulated intervals are the maxima between thorough examinations (which include external examination). Intermediate external examinations may be required for equipment where corrosion under insulation can occur (see GBHE Report: Corrosion Under Insulation). Where corrosion under insulation may be significant, suggested intervals for external examination are 26 months to 74 months depending on local conditions and experience. (b) For ammonia storage see Appendix D.5 (c) For sulfuric acid and petroleum storage see Appendix D.6 (d) These intervals are to be used when there are no national/local legislative requirements.
  • 26. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com (a) Inspection Grade "Z" This grade is appropriate for equipment where it is recognized that deterioration is possible and behavior in service is unpredictable. The intervals shown in Table 1 are maxima, and in some cases examination at shorter intervals will be required. If experience shows that deterioration is slow, the intervals may be extended to the maximum shown for grade Z and, if appropriate, a decision taken to transfer the equipment to grade Y. (b) Inspection Grade "Y" This grade is appropriate for equipment that is not expected to deteriorate significantly but where there is insufficient evidence to justify allocating it to grade X. When examination over a period has proved that insignificant deterioration is taking place, the equipment may be transferred to grade X. Thus for equipment which in Table 1 is to be examined after an initial period of 26 months and then examined again after a further interval of 50 months, it may be justifiable to re-grade it as X at this time, i.e. after a total of at least 74 months service. For equipment where Table 1 prescribes examination after an initial period of 74 months, it is acceptable for it to be regarded as X if that examination is satisfactory. When there is a group of Vessels or pipes of similar construction and service conditions, and the Responsible Mechanical Engineer judges them to be effectively identical as regards likely deterioration and that grade Y is appropriate for each, then sample Vessels or pipes may be chosen in rotation for examination. Where Table 1 shows the initial examination interval as 26 months, then a reasonable sample are required to be examined before the end of the initial 26 months period and a further sample before the end of 50 months. When at least one of the Vessels or pipes has been examined after 74 months service and provided that all of the Vessels or pipes have been examined at least once during that 74 months period and no significant deterioration found, then the group of Vessels or Piping Systems may be transferred en bloc to grade X.
  • 27. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com If on examination, unexpected deterioration is found in any item of equipment, then the inspection grading and the examination interval for the affected equipment, and for all equipment related to it, are to be reviewed and, if necessary, the grading changed to Z. (c) Inspection Grade "X" This grading permits examination intervals of up to twelve years but not longer. Allocating equipment to grade X may be justified in either of two ways: (1) If equipment has been examined on successive occasions and no deterioration found after a total of at least 74 months, then it may be decided to grade the equipment as X and schedule the next examination to be done after a further period not exceeding the total service life up to the last examination. This principle may be applied to groups of Vessels or Piping Systems allocated to grade Y. (2) Where a new or recently installed Vessel or Piping System performs a duty similar to that of an existing grade X item and is substantially the same as the existing item regarding materials of construction, design details, fluid composition, temperature and pressure. In such cases the new item may be classified as grade X and the interval to its first examination set at a period not exceeding that for the grade X equipment with which it is being compared. This interval remains in force until the initial examination of the equipment. Whilst the intervals of scheduled examinations for Class B equipment are not controlled by statute, no examination is to exceed the date specified for the next examination on the Report of Examination, without the authority of the Responsible Mechanical Engineer (see 3.5.5.6).
  • 28. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 3.5.3.3 Pressure Relief Streams 3.5.3.3.1 Categorization of Pressure Relief Streams Pressure Relief Streams are required to be categorized according to the risk of blockage or fouling due to the system contents: (a) Category 1 - Clean, non-corrosive duty. (b) Category 2 - Blockage/fouling possible but not likely. (c) Category 3 - Vulnerable to blockage/fouling. 3.5.3.3.2 Examination Interval for Protective Devices The maximum interval between the examination of Protective Devices and their ancillary equipment on Class B equipment should be 26 months. However, where the duty is clean and non-corrosive (Category 1) the interval may be extended to a maximum of 74 months provided the following conditions are met: (a) The Protective Device is of a type for which there is substantial evidence of satisfactory performance on the specified duty. (b) The duty is known from previous experience to be free from fouling and non-corrosive. (c) The case for each device to be placed on an examination interval greater than 26 months is agreed by the Responsible Mechanical Engineer and is appropriately documented in the Registration file. For instrumented Protective Devices (see also PEG 3) the interval between examination/test and the nature of testing is to be prescribed by the Design Authority. The inspector responsible for Pressure Relief Streams should be provided with a copy of this information, should have freedom to witness tests and should receive an annual statement, for record purposes, of the status of all required testing and examination.
  • 29. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 3.5.3.3.3 Examination Interval for Pressure Relief Stream Piping The examination interval for Pressure Relief Stream piping should be decided by the Responsible Mechanical Engineer, taking into account the Pressure Relief Stream category. The examination interval is not to exceed 74 months except for Category 1 streams where it is permissible to waive examination in cases where environmental effects are judged unlikely to prevent safe operation. Examination of Pressure Relief Stream piping may be at a different interval to that of the Protective Device but the two should be coordinated. 3.5.3.3.4 Examination Interval for Associated Relief Equipment The examination interval, which is not to exceed 74 months, should be decided taking into account the Pressure Relief Stream category and the examination intervals for Protective Devices and Pressure Relief Stream piping. 3.5.3.4 Non-pressure Protective Devices The scheme of examination and testing and appropriate intervals should be prescribed by the Design Authority. The inspector responsible for Pressure Relief Streams should have a copy of this information, should have freedom to witness testing and should receive an annual statement, for record purposes, of the status of all required testing and examination. 3.5.3.5 Other Equipment Appropriate schemes of examination and intervals should be agreed between the Responsible Mechanical Engineer and Design Authority. Table 1 may provide guidance in some cases. 3.5.4 Examination of Equipment 3.5.4.1 Vessels and Piping Systems Primarily a visual examination is required, supplemented as necessary by other techniques and measurements to determine fully the extent of loss of thickness, pitting, cracking or other defects. Both internal and external features require consideration.
  • 30. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Internal examination by entry is strongly recommended where access is possible. However the Responsible Mechanical Engineer may agree to waive entry when satisfactory alternative means of internal examination are available. Waiving of entry for grade Z and Y equipment should be subject to careful consideration. For equipment such as complex tubular arrangements where access to surfaces by any technique is difficult, or for equipment such as water-tube boilers with extensive arrays of tubes, pressure testing may be the only practical way of demonstrating integrity. It should however be noted that pressure testing only confirms the ability of the equipment to hold pressure at the time of the test and does not provide equal reassurance of long term integrity to that gained from thorough examination of surfaces. As such it is not a generally preferred means of examination for any equipment. Guidance on the in-service examination of piping systems is given in GBHE Engineering Guide, and a procedure based on ASME codes utilizing a statistical approach to thickness measurement is given in the GBHE Engineering Manual, Section 2.600: Critical Piping Inspection Program Guideline. 3.5.4.2 Pressure Relief Streams 3.5.4.2.1 Protective Devices Information on the condition of Protective Devices in the as-removed conditions is essential in judging how they would have behaved on-line. (a) Safety Valves and Bursting Discs All devices should be examined on removal and before cleaning. Safety valves and other reseatable devices should be tested in-situ or on removal, as far as is practicable, as a guide to the pressure at which they would have lifted in service. If any device fails to operate within acceptable limits, the cause should be investigated. All devices should be cleaned, examined, shop reconditioned, and tested as appropriate. Records of all observations, testing, maintenance and replacement are to be maintained in the Registration file. The inspector is to be satisfied that adequate examination and testing has been carried out.
  • 31. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Based on the observations and test results, the suitability of the examination interval should be reviewed. Information on the periodic testing of safety valves is given in GBHE Engineering ProcedureS, and information on use of the ’Trevitest’ technique for on-line testing is given in GBHE Engineering Procedure . (b) Instrumented Protective Systems for Pressure Protection The inspector is to have access to the records of such routine testing, calibration and maintenance of the devices specified by the Design Authority as necessary to maintain the required availability. The inspector is to be satisfied that the above activities have been properly carried out and may elect to witness some or all of the work. The inspector is required to ensure that all records are placed in the Registration file. 3.5.4.2.2 Pressure Relief Stream Piping Piping is to be examined for blockage and corrosion as appropriate to the Pressure Relief Stream category. 3.5.4.2.3 Other Equipment in the Pressure Relief Stream All other equipment such as scrubbers, separators, flare stacks and relevant ancillaries to these items are to be examined as required to ascertain their continuing ability to meet the design requirements of the Pressure Relief Stream. 3.5.4.2.4 Associated Relief Equipment Examination is required to ascertain that orifice sizes have not enlarged by such means as erosion or corrosion, that unauthorized changes in equipment have not been made and that the design basis of the Pressure Relief Stream has not been otherwise altered. 3.5.4.2.5 The Assembled Pressure Relief Stream Prior to commissioning, or re-commissioning after overhaul, the completed Pressure Relief Stream is required to be examined to ensure that it has been assembled in accordance with the design specification. A record that this examination has been satisfactorily completed should be lodged in the Registration file.
  • 32. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 3.5.5 Procedural and Administrative Aspects of Periodic Examination 3.5.5.1 Independence of Inspection Personnel Where a site’s own employees are appointed to carry out periodic examination it is essential that the site can demonstrate that those employees are not influenced by production pressures in so far as their judgments on safety are concerned. 3.5.5.2 Training of Inspectors Inspectors should have qualifications considered appropriate by the Responsible Mechanical Engineer or the national/local authority. They are required to have received formal training in the specialized requirements of inspection work. The training is required to ensure that an inspector has knowledge of the subjects grouped under (a) below and has acquired skills in the subjects groups under (b) concerning the periodic examination of equipment. These skills are to be developed to the practitioner level in order to impart a proper appreciation of the data associated with specialized equipment. (a) Statutory requirements; GBHE procedures; regulations regarding entry of personnel to the Works plants and entry into enclosed spaces; organization and functions of the inspection section; basic characteristics of the principal chemicals produced or used; relevant design codes and specifications; sources of specialist advice. (b) Recognition and reporting of deterioration and faults in Pressure Vessels, Piping Systems, Protective Devices, and similar equipment; special techniques for examination e.g. crack detection, thickness measurement, spark testing, leak testing and optical aids; hydraulic and pneumatic pressure testing; assessment of repair methods, and examination of repairs. Upon achieving the acceptable proficiency the inspector is to be certified accordingly.
  • 33. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 3.5.5.3 Scheme of Examination The Responsible Mechanical Engineer is required to ensure that a scheme of examination is prepared for all items of equipment which are to be registered. The scheme should specify the extent, nature, preparatory work and frequency of examination and should be approved by the Responsible Mechanical Engineer or nominee. 3.5.5.4 Preparation for Examination Prior to carrying out an examination the inspector is required to study previous examination reports as a guide to selecting appropriate features to examine and as a basis for assessing the rate of any deterioration. To allow the preparation of equipment for examination to be planned, the inspector is required to state the degree of cleaning of surfaces and the extent of removal of fittings, insulation and other coverings necessary to permit satisfactory examination, in accordance with the scheme of examination. 3.5.5.5 Report of Examination On completion of examination, the inspection service should immediately notify the Responsible Mechanical Engineer, or nominee, whether the equipment is suitable to return to service or whether further assessment or repair is necessary. A formal report of examination is required to be entered in the Registration file within 28 days of the completion of the examination. Signature of the report by the Responsible Mechanical Engineer, or nominee, is required to acknowledge acceptance. The report should record fully the extent of examination and the findings. In particular all forms of deterioration should be detailed as quantitatively as practicable. Other features such as fouling or coloration should also be noted. Reports should enable the change in condition between examinations to be assessed reliably. 3.5.5.6 Equipment Overdue For Examination The Responsible Mechanical Engineer is to be notified in advance of equipment which is required to remain in service beyond the due examination date.
  • 34. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Where it is necessary for Class A equipment to remain in service beyond the due examination date, the Responsible Mechanical Engineer is required to notify or obtain the agreement of the national/local authority as appropriate. For Class B equipment the Responsible Mechanical Engineer is required to provide written authorization, up to a maximum of 6 months beyond the due examination date, that equipment may remain in service. For postponement of examination beyond 6 months, written authorization by the Responsible Executive is required. 3.5.5.7 Action Following Examination It is the responsibility of the Responsible Mechanical Engineer to ensure that decisions arising from the examination are implemented. Such decisions may include repair, down rating, the imposition of operating limits and change of examination interval or scheme. Following all examinations, the examination interval and the scheme of examination is required to be reviewed. 3.5.5.8 Changes of Duty Changes of duty, identified by the site modification procedure or otherwise, which may affect the periodic examination requirements are required to be notified to the Responsible Mechanical Engineer and recorded in the Registration file. 3.5.6 Non-registered Equipment Some Vessels, a significant fraction of Piping Systems and equipment excluded under Appendix A will not be registered. However it has to be ensured that adequate examination and maintenance policies exist and are applied in order to ensure the continuing fitness for purpose of such equipment. In particular, all nonregistered piping, including structures and supports, should be subject to external visual inspections at appropriate intervals.
  • 35. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 4 AUDITING 4.1 General An independent engineering auditor or audit team should periodically audit the implementation of and compliance with the principles of PEG 4. 4.2 Scope of Audit (a) The local engineering procedures used by a Works, Site or Facility to implement the GBHE and statutory requirements should be examined for consistency with PEG 4 and for the completeness and effectiveness of the measures detailed to apply the requirements. (b) The knowledge and understanding of appropriate personnel of the content of the local engineering procedures and of local management practices for Pressure Systems should be ascertained. (c) The adherence to the local engineering procedures should be ascertained by examination of equipment record files and inspection of equipment on site.
  • 36. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com APPENDIX A EQUIPMENT WHICH MAY BE EXEMPTED FROM GBHE REGISTRATION Provided legislation permits, and provided that the equipment is suitable for the working conditions, the following equipment may, after careful consideration of all relevant factors, be exempted from Registration by the Responsible Mechanical Engineer: (a) Vessels containing gas or liquid at a temperature above its atmospheric pressure boiling point where: (1) The product of design pressure (bar g) and gross volume (m3) does not exceed 0.25 bar m3, and the design pressure is less than 15 bar g, or (2) The product of design pressure (bar g) and gross volume (m3) is less than 1, and design pressure is less than 0.5 bar g, or (3) The design pressure is less than 0.1 bar g. (b) Vessels subject only to a pressure between atmospheric and minus 1 bar g. (-14.5 psi g.) where failure under external pressure would not create an Unacceptable Situation. (c) Vessels containing liquids which cannot communicate with a pressurized gas or vapor and are at a temperature below their atmospheric pressure boiling point, where failure would not give rise to an Unacceptable Situation. (d) Pipe coils designed to a national or international standard other than those forming parts of fired heaters and when not part of a registered Piping System. (e) Equipment such as jacketed pipe heat exchangers and strainers made from standard piping components and designed to a national or international standard and having a gross volume less than 0.5 m3. (f) Vessels of small volume which are connected to or form part of instruments, such as differential pressure cells and condensation chambers.
  • 37. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com (g) Pressure Relief Streams and Non-pressure Protective Devices where failure to operate will not result in an Unacceptable Situation, e.g. thermal relief safety devices for non-harmful fluids. (h) Radiators in vented heating systems for warming buildings. (j) Hydraulic power cylinders other than those communicating with a gas loaded accumulator. (k) Pneumatic power cylinders. (l) Equipment containing highly viscous polymers or pastes which are not pressurized by gas or vapor, e.g. extruders, dies, melt filters. (m) Sample bombs of proprietary design having a gross capacity of less than 0.5 liter and which are not subject to corrosion. (n) Plate heat exchangers and similar equipment where there are no fabricated headers.
  • 38. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com APPENDIX C DOCUMENTATION FOR INCLUSION IN FILES OF REGISTERED EQUIPMENT C.1 GENERAL C.1.1 Assembly of Equipment Registration Files Equipment Registration files should form complete and ongoing master records covering all aspects of equipment. In many cases it will not be practicable to keep all documents actually in the files but where storage elsewhere is necessary, for example of Vessel fabrication dossiers, reference to the document location should be included in the file. C.1.2 Additions to Equipment Registration Files To the documentation listed in C.2 and C.3 should be added reports of periodic examinations, full records of repairs and modifications and other documents such as abnormal occurrence reports, specialist reports and letters relevant to the integrity of the equipment. C.2 NEW EQUIPMENT C.2.1 Vessels (a) Registration form. (b) Design Verification Certificate. (c) Certificate of Compliance, Certificate of Inspection and Testing, Pressure Test Certificate or equivalent. (d) Drawings. (e) Equipment dossier containing orders, calculation references, and fabrication details. (f) For Vessels not protected by Pressure Relief Streams, a document giving the basis of design against excess pressure. (g) The scheme for periodic examination.
  • 39. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com C.2.2 Piping Systems (a) Registration form. (b) Design Verification Certificate. (c) Engineering Line Diagram (P and I diagram). (d) Piping System Specification. (e) Data sheet or equivalent for special items such as bellows and piped-in flexibles. (f) Isometric drawing and Spring Support Schedule. (g) Installation Certificate. (h) Pressure Test Certificate. (j) The scheme for periodic examination. C.2.3 Pressure Relief Streams (a) Registration form. (b) Design Verification Certificate. (c) Documents referred to on the Design Verification Certificate. (d) A drawing or sketch showing all components of the Pressure Relief Stream and the Associated Relief Equipment. (e) Details of Associated Relief Equipment. (f) Test Certificate(s) for Protective Device(s). (g) Pressure Relief Stream Installation Certificates. (h) The scheme of periodic examination.
  • 40. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com C.2.4 Non-pressure Protective Devices (a) Registration form. (b) Details of device. (c) A document giving the basis of design. (d) The scheme for periodic examination. C.3 EXISTING EQUIPMENT The documentation listed below is required when registering equipment which is already in service and for which the full documentation required by C.2 may not be available. C.3.1 Vessels (a) Registration form. (b) Such documentation as is available per C.2.1 (c) to (e). (c) For Vessels not protected by Pressure Relief Streams a document giving the basis of design against excess pressure. (d) The scheme for periodic examination. C.3.2 Piping Systems (a) Registration form. (b) Design Verification Certificate if required (see 3.3.3.3). (c) Up to date sketch or isometric drawing showing approximate dimensions and position and type of supports. (d) Up to date Engineering Line Diagram (P and I diagram). (e) Piping System Specification. (f) Details of special items such as bellows and piped-in flexibles. (g) The scheme for periodic examination.
  • 41. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com C.3.3 Pressure Relief Streams (a) Registration form giving the Pressure Relief Stream number and identification of the components and Associated Relief Equipment. (b) Design Verification Certificate, where applicable. (c) A drawing or sketch showing all components of the Pressure Relief Stream and the Associated Relief Equipment. (d) Such information per C.2.3 (c) to (g) as is available. (e) The scheme for periodic examination. C.3.4 Non-pressure Protective Devices (a) Registration form. (b) Details of device. (c) A document giving the basis of design. (d) The scheme for periodic examination.
  • 42. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com APPENDIX D ADDITIONAL REQUIREMENTS FOR THE PERIODIC EXAMINATION OF SPECIAL CATEGORIES OF EQUIPMENT D.1 LIMITED LIFE CATEGORIZATION Vessels and Piping Systems may have limited life because either: (a) They operate at high temperature, and design stresses are based on creep data, or (b) They are subjected to pressure cycling by process conditions or frequent start up and shut down, which may cause fatigue cracking if the cycle life of the equipment is exceeded. Equipment subjected to such conditions are required to be categorized as either: (1) Having a life limited due to temperature (LLT), or (2) A life limited due to pressure cycling (LLC), In addition to being classified A or B and graded X, Y or Z, and are to be allocated a "Code Life" which is to be entered on the registration documentation. The "Code Life" is determined by the Design Authority during design and is the life for which the equipment is known to be safe in terms of the criteria used in design. For equipment already in service which may be subject to these conditions, reference to the Design Authority and materials engineer should be made for guidance. D.1.1 Equipment Categorized LLT - Limited Life due to Temperature Where equipment has a limited life due to temperature the following applies: (a) Prior to the equipment entering service, baseline measurements are to be recorded in order that they may be compared with subsequent in-service measurements to detect creep strain. (b) Operating temperature and pressure are to be recorded and stored in the equipment registration file.
  • 43. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com (c) When 80% of the "Code Life" has expired, a detailed review of the examination reports and process history of the equipment is required in order to determine its future life and to make any changes in the examination frequency which may be considered necessary. (d) During all in-service examinations, high stress areas such as nozzle to shell welds are required to be examined for cracking since experience has shown that such areas can suffer creep damage before expiry of "Code Life". As a guide, equipment should be considered for classification LLT if the operating temperature is above those shown in Table 2. D.1.2 Equipment Categorized LLC - Limited Life due to Pressure Cycling Where equipment has limited life due to pressure cycling the following applies: (a) Records are to be kept of the number and magnitude of pressure cycles to which the equipment is subjected in service and entered in the equipment registration file. (b) During examination, special attention should be given to highly stressed areas where cracking is likely to initiate. Guidance on such areas should be obtained from the Design Authority. (c) A formal review of the equipment’s history should be made at appropriate intervals, including a review when 80% of the "Code Life" has expired, and an assessment made of its remaining life.
  • 44. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com D.2 ATMOSPHERIC PRESSURE STORAGE TANKS Registered Atmospheric Pressure Storage Tanks which are deemed to be subject to external corrosion only may be exempt from internal examination by the Responsible Mechanical Engineer. Consideration should be given to the risk of the contents becoming contaminated with corrosives. In these circumstances appropriate monitoring should be specified. D.3 REFRIGERATION SYSTEMS Experience has shown that refrigeration systems using such fluids as ’Arcton’ do not deteriorate on the refrigerant side. The refrigerants are non-corrosive and there is little risk of contamination as they are contained in a closed system. It is therefore considered that internal inspection and pressure testing of the refrigerant side of evaporators, condensers and receivers, where access is normally very limited may be waived provided the following examinations prove satisfactory: (a) an appropriate external examination which may include an NDT (ensuring that any removed or damaged insulation is replaced and resealed to the original specification), and (b) an internal examination of the non-refrigerant side of these Vessels, as far as the construction allows, together with a check for leakage of the refrigerant from the tubes and tube plate. For receivers, where access into the refrigerant side is provided, internal examination should be carried out. D.4 CRYOGENIC VESSELS: "COLD BOX" INSTALLATIONS Cold box enclosures are used for insulating cryogenic Vessels and pipework on, for example, air separation plants for the production of nitrogen and oxygen. The purification of the process streams ensures, in general, that the Vessels are not subject to conditions which could initiate or sustain corrosion. Experience in the U.K. and Europe has confirmed that these Vessels do not deteriorate. In view of this history and the inaccessible nature of the equipment, consideration should be given to seeking dispensation from periodic examination. Such dispensation should be authorized by the Responsible Executive in each case, and be subject to the following requirements:
  • 45. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com (a) the Responsible Mechanical Engineer is required to ensure that when a cryogenic Vessel is taken out of service for modification or maintenance, the accessible areas are examined and the results recorded by an inspection service; (b) a check for water ingress into the insulation should be made when the equipment is taken out of service for prolonged periods; and (c) the Pressure Relief Stream is registered and periodically examined. D.5 AMMONIA STORAGE SPHERES Reference should be made to Procedure: The Examination of Ammonia Storage Spheres. D.6 SULFURIC ACID AND OLEUM STORAGE Reference should be made to Procedure: The Periodic Examination of Sulfuric Acid and Oleum Storage Tanks. D.7 DEAERATORS Reference should be made to Procedure: Periodic Examination of Deaerators on Steam Raising Plant. D.8 GRP VESSELS Reference should be made to Procedure PEG 3. D.9 STORAGE SPHERES FOR OTHER THAN AMMONIA Reference should be made to Procedure: Periodic Examination of Storage Spheres.
  • 46. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com APPENDIX E DIAGRAMMATIC REPRESENTATION OF PRESSURE SYSTEMS PROCEDURES Notes: (a) Diagram is simplified, e.g. reporting routes are not shown. (b) P2, P3 etc. refer to the principles given in PEG 4, and amplified in this document. (c) - -- - indicates that the item is required by PEG 4 and this document but is not covered in these documents
  • 47. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com APPENDIX F DECISION TREE FOR REGISTRATION OF PIPING SYSTEMS Notes: (a) At this point the remainder of the decision tree should potentially be entered twice: (1) Consider leakage from a minimum size failure equivalent to a 7 mm diameter hole. This size has an experimental basis from gasket tests and also accords conservatively in many cases with leak size at discovery from other causes. Where the fluid is flammable or corrosive the further consequences of the leakage on mechanical integrity should be taken into account.
  • 48. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com (2) If the consequences of a 7 mm diameter hole would not lead to registration a decision is required on whether a larger failure could reasonably occur and its size. This needs consideration of past experience, process characteristics such as corrosion, erosion, fatigue, fluid hammer and non-process factors such as external impact, fabrication quality, corrosion protection, examination and standard of maintenance. If it is reasonable to anticipate the possibility of such larger failure the decision tree should be re-entered. (b) The Responsible Mechanical Engineer may judge that a Piping System requires to be registered irrespective of formal consideration of the consequences of failure. (c) At Works discretion. Reference to GBHE Engineering Procedure "The Selection of Piping Systems for Registration" may be helpful in application of the above decision tree.
  • 49. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com APPENDIX G REGISTERED EQUIPMENT WHICH MAY BE EXEMPTED FROM DESIGN VERIFICATION The equipment listed below may be exempted from Design Verification at the discretion of the Responsible Mechanical Engineer or in the case of capital projects at the discretion of the Project Manager after careful consideration of all relevant factors. (a) Vessels containing non-flammable, non-toxic gases and/or liquids where (i) The design pressure does not exceed 15 bar g. and (ii) The product of design pressure (bar g.) and volume (liters) does not exceed 5000. Note: The above relaxation of the requirement for Design Verification is based on the highest P×V figure which the draft European Pressure Equipment Directive allows without independent third party checking of design. It applies only when stored energy is the only hazard. Where exemption is granted a note recording the decision is to be placed in the Registration file.
  • 50. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com DOCUMENTS REFERRED TO IN THIS INFORMATION FOR ENGINEERS This Information for Engineers document makes reference to the following documents: GBHE RESPONSIBLE CARE MANAGEMENT SYSTEM GBHE Safety, Security, Health and Environmental Policy (referred to in clause 0) GBHE ENGINEERING PROCEDURES PEG 3 Critical Safety Instrumented Systems (referred to in 3.4.4, 3.4.5 and 3.5.3.3.2) PEG 4 Critical Pressure Equipment (referred to in clause 0, clause 1, 3.1.1, 3.3.4.1, 3.4.4, 5.1, 5.2 and appendix E) PEG 6 Hazard Studies for Safety, Health and Environmental Protection (referred to in 3.2.2) PEG 11 Transport Containers and Terminals for the Distribution of High Hazard Materials (referred to in clause 1) GBHE INFORMATION FOR ENGINEERS Transport Containers and Terminals for the Distribution of High Hazard Materials (referred to in clause 1) GBHE ENGINEERING PROCEDURES  Pressure Relief Stream Design Verification (referred to in 3.3.5.4)  Design Verification of Registered Piping Systems (referred to in 3.3.5.4)  Vessel Design Verification (referred to in 3.3.5.4)  Ordering and Design Verification of Proprietary Vessels and Heat Exchangers (referred to in 3.3.5.4)  Registered Pressure Equipment : Procedure and Standard Forms (referred to in 3.1.1)  The Selection of Piping Systems for Registration (referred to in 3.4.3)  In-service Pneumatic Testing of Pressure Vessels (referred to in 3.2.3)  The Assessment, Documentation, Design Verification and Registration of Second Hand  Vessels (referred to in 3.4.2)
  • 51. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com  Periodic Testing, Examination and Reconditioning of Safety Valves (referred to in 3.5.4.2.1)  The Use of the ’Trevitest’ Safety Valve Simulation-Testing Technique (referred to in 3.5.4.2.1)  Examination of Sulfuric Acid and Oleum Storage Tanks (referred to in appendix D)  The Examination of Ammonia Storage Spheres (referred to in appendix D)  Periodic Examination of Deaerators on Steam Raising Plant (referred to in appendix D)  Periodic Examination of Storage Spheres (referred to in appendix D)  The Examination of GRP Vessels (referred to in appendix D)  Pre-Commissioning Examination and Checks (referred to in 3.4.1) GBHE ENGINEERING GUIDES Inspection of In-Service Piping (referred to in 3.5.4.1) - Corrosion Under Insulation - Report of Working Party (referred to in Table 1) - Plant Engineering Manual: Critical Piping Inspection Program Guideline (referred to in 3.5.4.1).
  • 52. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com