Review of Reactor Piping Systems
ExxonMobil Beaumont - HydroCracker Unit
Recommendations and Comments
by Piping Engineering
R1 to R2 Piping
Final Report
JEG Project #: 07LY9220
Prepared by: Darpan Patel
Checked by: Rajan Patel
Jacobs Engineering Baton Rouge, LA
Issue Date: 8/19/2009
Review of Reactor Piping Systems R1 to R2 Piping
Objectives
To analyze the R1 to R2 piping system when exceeding the normal design conditions of 800F and 2593psig to
the maximum short term upset condition of 1100F.
Attachments
Appendix A Stress isometrics/comments
Appendix B Temperature vs MAWP curve
Appendix C Photos from the field
Appendix D Original P&IDs, Fabrication Isos, and Line Class ID
Requirements
Determine an acceptable working pressure at temperatures exceeding design conditions.
Analyze piping systems to determine if existing layout is suitable for temperatures up to 1100F
Suggest modifications if necessary to meet the alternate short term upset criteria
Brief Description of Studied System
R1 outlet side piping is 18 line # 37P-1001-AKL3-H (a.k.a. AP4000) that connects to the R2 inlet nozzle
(see Appendix A1). There are two 8 branch lines that connect to this main header:
o Reactor warm-up line # 37P-0128-AKL3-H (see Appendix A3)
o H2 recycle quench line # 37P-0145-AKL3 (a.k.a. AP 4001) (see Appendix A4)
A temperature/pressure curve has been generated on the basis of hoop stress calculations (see
Appendix B1)
o Temperature cases have been taken at:
50F increments from design to 900F
25F increments from 900F to 1100F
o MAWP has been determined at each corresponding temperature.
o The Temperatures vs. MAWP curves in this report are for piping only. Refer to Mechanical groups
report for reactors, exchangers, and nozzle analyses.
Analysis Approach
The Piping Engineering Department used Caesar II version 5.10 to analyze the piping in each system for
code compliance. Each system was analyzed at a maximum upset condition of 1100F.
Nozzle loads were submitted to the Mechanical group for finite element analysis. Loads were issued
from the 1100F case because it gives the highest loads due to greater thermal expansion.
Assumptions/observations
The lines in this system were walked down to ensure that the current routing and dimensions match
the fabrication isos that were available.
o This system was analyzed for a maximum upset condition of 575psig 1 at 1100F.
o Piping material and thickness, as well as line design conditions were taken from the original isos.
o The pipe spec for this line is AKL3, which is class 2500, A312-TP321 S.S. piping, with 0.1 corrosion
allowance (see Line Class ID in Appendix D4).
o The 8 warm-up line and the 8 recycle H2 branch lines were walked down to verify the routing on
the isos and for support locations.
1
The pressure used in analysis for this system is 110% of MAWP for CrMo piping near the R1 Outlet nozzle
Final Report 8/19/2009
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Review of Reactor Piping Systems R1 to R2 Piping
B31.3 SIF multiplier = 0 is considered for sustained stress
Wind has not been considered in analysis for temperatures exceeding original design conditions.
o The system meets code allowable stresses with 60mph wind case at original design conditions.
S.S. piping thickness is sch160 (1.781"). Full corrosion allowance of 0.1" and 12.5% mill tolerance has
been considered.
Because the process in both 8 branch lines flow into the 18 header, it is assumed that these lines are
not affected by the extreme conditions faced by the 18 header due to a runaway situation.
o The Reactor Warm-up line was modeled entirely at 800F for all conditions.
o The H2 Recycle line was modeled with the same conditions as the 18 header up to the check valve
(at node 335), and then with its design conditions of 250F for the carbon steal piping upsteam of
the check valve.
Recommendations
The load flange on the spring at the bottom of the 90ft vertical riser piping along the side of R2 is
bottomed out (node 171 on Appendices A2, C2, and C3) at normal line conditions (up to 800F). There
will be excessive loads at the R2 inlet nozzle as temperatures increase beyond original design criteria.
o Spring data for the spring at node 171 (see Appendix A2) was taken from a field walk down.
Approximately 5 total downward displacement is required from installed position. This is
approximately 4 additional downward displacement from the original spring design.
The trunion at this location will need to be trimmed approximately 4 to allow the spring to
operate as needed. The load flange should be raised (if possible), or replaced to allow the
spring to rest at the original cold setting with the shorter trunion. The load flange should then
be adjusted or selected such that it allows 5 downward displacement for the 1100F case.
An alternate solution is to move the entire spring can assembly down approximately 4, and
adjust the load flange to allow the pipe to rest at the original installed location when the system
is cold.
Per the suggestion of a Piping Tech & Products (PTP) technical support representative, it is
recommended that PTP examines the spring coil to verify that it is still operable.
The first support on the 8 quench line (node 345) should be removed to allow 3 downward
movement at that location (see Appendix A4).
Per 1993 ASME B31.3, the given allowables for SA312-TP321 S.S. piping over 1000F are valid only
when carbon content is 0.04% or higher. PMI verification is required to validate carbon content in S.S.
piping.2
Clearance for thermal displacements at elbows and supports have been verified as noted on stress
isos (see Appendix A).
o There is a structural steel column approximately 4 south of the installed position of the support at
node 320 on the 8 Reactor Warm-up line. Currently at normal operating conditions, the line has
moved enough for the column to cut into the insulation. Remove insulation in way of column
flange to allow additional movement. Loads on column are reasonably low no further action
deemed necessary.
The load of the pipe on the column at normal operating conditions (800F) is 2200lb.
The load of the pipe on the column at maximum upset conditions (1100F) is 4200lb.
MAWP of the 18 NPS line is 2443psig at 800F per ASME B31.3, 2000. According to the fabrication
isos for this line (see Appendix D3), the design pressure is 2593psig, which exceeds the MAWP.
2
PMI results were not available at time of report. PMI sampling by field maintenance required to validate final analysis results.
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Review of Reactor Piping Systems R1 to R2 Piping
o The rated design pressure should be reviewed and reduced if possible. The corrosion allowance
should to be reduced to a maximum of 0.016. Appendix B1 shows the MAWP curves for the 18
line with a full corrosion allowance of 0.1, as well as for a corrosion allowance of 0.
Conclusions
The 18 RTJWN flanges near the R1 outlet nozzle are estimated to weigh 1950lb each per flange
calculations by the Mechanical group.
o R1 outlet nozzle N1 exceeds code allowables above 1050F due to sustained weight of the piping
and four 18 RTJWN flanges. All stresses in this system are within creep allowables for 1% creep in
100,000 hours (see Appendix D5).
See Appendix B1 for a Temperature vs. MAWP curve at each temperature case between design
condition and 1100F. Line temperatures of 1100F shall not be exceeded.
Refer to Mechanical departments report for details and Temperature vs MAWP plot for R1 outlet and
R2 inlet nozzles.
Final Report 8/19/2009
Page
Appendix A
Stress Isos:
A1 18 R1 to R2 Line
A2 - 18 R1 to R2 Line
A3 8 Reactor Warm-up Line
A4 8 Recycle H2 Quench Line
Appendix A1 - 18" R1 to R2 Line
Appendix A2 - 18" R1 to R2 Line
Appendix A3 - 8" Reactor Warm-up Lin
Appendix A4 - 8" Recycle H2 Quench Line
Appendix B
B1 R1 to R2 Piping Temp vs MAWP Curve
3000
2500
MAWP (psig)
2000
1500
1000
500
800
850
900
925
950
975
1000
1025
1050
1075
1100
18" S.S. Pipe w/ C.A. = 0.1"
2443
2426
2391
2374
2357
2348
2339
2001
1663
1442
1217
18" S.S. Pipe w/ C.A. = 0"
2623
2605
2567
2549
2530
2521
2512
2149
1786
1549
1308
Des Press @ 800F
2593
2593
2593
2593
2593
2593
2593
2593
2593
2593
2593
Temp (F)
Notes:
1. The pressures on this table are based off of hoop stress calculations
2. S.S. piping thickness is sch160 (1.781"). Full corrosion allowance of 0.1" and 12.5% mill tolerance is considered.
3. Refer to Mechanical department's report for Temp vs MAWP curves for mechanical equipment and nozzles
Appendix B1 - R1 to R2 Piping Temp vs MAWP Curv
ExxonMobil Hyrocracker Unit - R1 to R2 Piping Temp vs MAWP
18" sch160 (S.S piping)
Appendix C
C1 R1 Outlet Nozzle and 4x 2500# RTJWN Flanges
C2 Node 171, bottomed out spring at R2 Riser Piping
C3 Node 171, bottomed out spring at R2 Riser Piping
C4 Guide on R2 Riser Piping
C5 R2 Inlet Nozzle, Graylock Hub flanges and RTJWN flanges
C6 8 Reactor Warm-up line (37P-0128-AKL3-H)
C7 8 Recycle H2 Quench Line (37P-0145-AKL3)
C8 8 Recycle H2 Quench Line (37P-0145-AKL3)
C9 - 8" Warm Up line - Vertical column has cut into insulation
Appendix C1 - R1 Outlet Nozzle and 4x 2500# RTJWN Flanges
Appendix C2 - Node 171, bottomed out spring at R2 Riser Piping
Appendix C3 - Node 171, bottomed out spring at R2 Riser Piping (close up
Appendix C4 - Gude on R2 riser piping
Appendix C5 - R2 inlet nozzle. Graylock Hub flanges and RTJWN flange
Appendix C6 - 8" Reactor Warm-up line (37P-0128-AKL3-H
Appendix C7 - 8" Recycle H2 Quench Line (37P-0145-AKL3
Appendix C8 - 8" Recycle H2 Quench Line (37P-0145-AKL3
NODE 320
Vertically Upward
C9 - 8" Warm Up line - Vertical column has cut into insulation
East
Vertical Column
Appendix D
D1 - Line List
D2 - Original P&IDs
D3 - Fabrication Isos
D4 - Line Class ID
D5 - Creep Allowables
D1 - Line List
D2 - Original P&ID'
D3 - Fabrication Iso's
D4 - Line Class ID
Ref: U.S. Steels
D5 - Creep Allowable
Ref: U.S. Steels
