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Discipline : Mechanical Page No.: Page 1 of 12

MECHANICAL DESIGN BASIS

Rev. Date Revision Description Issued By Checked By Approved By

Project: Page 2 of 12
Title: Mechanical Design Basis

TABLE OF CONTENTS
1.0 INTRODUCTION ............................................................................................................................................ 3
2.0 ABREVIATIONS.............................................................................................................................................. 3
3.0 DEFINITIONS ................................................................................................................................................. 3
4.0 APPLICABLE CODES AND STANDARDS ......................................................................................................... 3
5.0 ENVIRONMENTAL DATA ............................................................................................................................... 5
6.0 DESIGN REQUIREMENTS .............................................................................................................................. 6
6.1 GENERAL ....................................................................................................................................................... 6
6.2 STATIC EQUIPMENT ...................................................................................................................................... 7
6.3 ROTATING EQUIPMENT............................................................................................................................... 10

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Title: Mechanical Design Basis

1.0 INTRODUCTION

Contractor has been awarded by Client to design a Processing Facility for total stock capacity of
1,15,000 BOPD.

Client is developing the _location and area of the facility___.

Brief detail about the facility and type of equipment.

2.0 ABREVIATIONS

ASME American Society of Mechanical Engineers

IS Indian Standard

OEM Original Equipment Manufacturer

WRC Welding Research Council

3.0 DEFINITIONS

Client : Owner or its designated agent

Contractor : Company to whom the order has been placed for feed or
detailing.

Vendor : Company responsible for the supply of the equipment,

materials, or product related services in accordance
with this specification

4.0 APPLICABLE CODES AND STANDARDS

Latest edition of ASME / IS codes and standards shall be used for design and engineering.
List of major codes and standards is given below:

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Title: Mechanical Design Basis

American Society of Civil Engineers (ASCE)

Minimum Design Loads for Buildings and

ASCE 7-10
Other Structures

American Society of Mechanical Engineers (ASME)

Material Specification Part A Ferrous and

ASME BPV Section II
Part B Non- Ferrous
Specification for Welding Rods,
ASME BPV Section II C
Electrodes and Filler Metals

ASME BPV Section II D Material Properties

ASME BPV Section V Non-Destructive Examination

Division 1: Pressure Vessels
ASME BPV Section VIII Division 2: Alternative Rules for Pressure
Vessels
ASME BPV Section IX Welding and Brazing Qualifications

American National Standards Institute (ANSI)

ANSI B1.1 For bolting specification

ANSI B16.11 Forged Steel Fittings

Ring-joint Gaskets and Grooves for Steel

ANSI B16.20
Pipe Flanges

ANSI B16.28 For elbow and return bend

ANSI B16.47 Large Diameter Steel Flanges

ANSI B16.5 Pipe Flanges and Flanged Fittings

Factory Made Wrought Steel Butt

ANSI B16.9
Welding Fittings

British Standards (BS)

Metallic products-Type of inspection

BS EN 10204
document
Loading for buildings- code of practice for
BS 6399 – Part 2
wind load

International Standards Organization (ISO)

Quality management system –

ISO 9001-2008
requirements

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Title: Mechanical Design Basis

National Association of Corrosion Engineers (NACE)

Petroleum and natural gas industries -
NACE MR-0175 / ISO15156 Materials for use in H2S containing
environments in oil and gas production
Laboratory testing of metals for resistance
NACE TM-177 to sulfide stress cracking and stress
corrosion cracking in H2S environments
Evaluation of pipeline and pressure
NACE TM-0284
vessel steels for resistance to HIC
Design, Fabrication, and Surface Finish
NACE SP 0178 Practices for Tanks and Vessels to Be
Lined for Immersion Service
Methods and controls to prevent in-
service environmental cracking of carbon
NACE SP-0472
steel weldments in corrosive petroleum
refining environments
Welding Research Council (WRC)

Local Stresses in Spherical and

WRC Bulletins 107
Cylindrical Shells due to external loadings
Local Stresses in Cylindrical Shells due to
WRC Bulletins 297 external loadings-Supplement to WRC
Bulletin 107

5.0 ENVIRONMENTAL DATA

Elevation, m 800
Barometric Pressure, kPa 91.8
Ambient Temp, °C (max/min) 43/ -1
Temperature, °C (Dry Bulb) (max/min) 45.25/ -6.20
Summer Design Temperature, °C 38.4
Winter Design Temperature, °C 2.4
Relative Humidity, % 9.6 / 93.2
Ground Temperature,°C 0.1 / 36
Design Wind Speed, m/s 47
Zone Zone – 2

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Title: Mechanical Design Basis

6.0 DESIGN REQUIREMENTS

The project is divided Complete package design, procurement, and supply as per material
requisition are within Vendor’s scope. Foundation design and construction is also considered in
Vendor’s scope of work.
Package / Equipment design shall meet the following requirements as a minimum:
a. Owner’s Technical Standards, specifications and datasheets, if any.
b. Compliance to process requirement (service, temperature, pressure and corrosion).
c. Inter-changeability, wherever feasible.
d. Modularity in design for ease of transportation and relocation, wherever feasible.
e. Compliance to site and environmental conditions.
f. Ease of operation and maintenance as far as practicable / achievable.
g. Standardization of components wherever feasible.

6.1 General

a. All equipment shall be designed for a life of 15 yrs with uninterrupted operation of 2 yrs subject
to meeting periodic maintenance as recommended by OEM.
b. The design, fabrication, inspection and testing of equipment shall be in accordance with the
pertinent PURCHASER specifications, datasheets and the latest editions (edition released up
to date) of the applicable codes and standards.
c. Unless specified otherwise, equipment shall comply with technical specifications, recognized
applicable international industry codes and standards. For items or scope of work not covered
by Technical Specifications, vendor shall follow the relevant governing international codes,
standards, local regulations and recommended engineering practices.
d. Facility for any known future expansion of plant capacity with a minimum of modifications or
shutdown.
e. Design Requirements for specific applications.
• Corrosion allowance for carbon steel components / equipment shall be minimum 3.0 mm.
Corrosion allowance on the heat exchanger tubes shall be considered as NIL. Corrosion
allowance for carbon steel components / equipment shall be minimum 1.5 mm for utility
and clean water services.
• All components / equipment shall meet the requirements of respective hazardous area
classification.

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Title: Mechanical Design Basis

• All couplings, gears, and exposed rotating parts shall be provided with adequate protection
guards, non sparking type if located in hazardous areas.
• Only asbestos free material shall be used.
f. All equipment shall be provided with a SS-316 name plate at prominent location.

6.2 Static Equipment

6.2.1 General

a. All equipment shall be hydrostatically tested, unless and until explicitly indicated or agreed by
the owner / purchaser, as per the code requirement.

b. Shop hydrostatic testing: Maximum induced stress on un-corroded thickness shall not be
greater than 90% of yield strength under hydrostatic condition, considering no wind load.

Site hydrostatic testing: Maximum induced stress on corroded thickness shall not be greater
than 90% of yield strength under hydrostatic condition, considering 30% wind load.

c. Weight of the equipment shall be considered with un-corroded thickness for all calculations
except for wind load calculations.

d. The lifting weight is defined as shop weight plus insulation, ladders, platforms, main piping and
fireproofing.

e. The equipment and relevant lifting accessories such as tailing lugs, trunnions and lifting lugs
shall be designed to withstand the equipment lifting weight considering an impact factor of 2
for installation at site.

f. All design and operating conditions shall be indicated in the individual component GA
drawings.

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Title: Mechanical Design Basis

g. Local stresses on equipment nozzles and attachments shall be determined using WRC Bulletin
number 107 or 297 or by finite element analysis. All nozzles shall be designed to withstand the
loads indicated in specification for pressure vessel as a minimum.

6.2.2 Pressure Vessels

Pressure vessels shall be analyzed for various conditions of internal design pressure, external
design pressure, maximum and minimum design temperatures, corrosion allowance, cyclic
conditions (where applicable), nozzle loads, wind pressure, seismic condition etc. Pressure vessel
shall be designed using proven / approved software such as PV Elite. Spreadsheet calculations in
part are acceptable only if standard software does not cover a particular design.

Design pressure specified shall be at the top of vertical vessel or at the highest point of horizontal
vessel. The design pressure at any lower point shall be determined by adding the maximum
operating liquid head and any pressure gradient within the vessel.

External loads such as wind, pipe nozzle loads, transport loads and thermal effects shall be
considered in the vessel design.

Vertical vessels shall be supported using leg / lug / skirt arrangement as per good engineering
practice on cylindrical shell with base ring / base plate. Skirt openings shall be provided for venting
and access. Horizontal vessels shall be supplied with one fixed saddle and another sliding saddle
to facilitate thermal expansion. For horizontal vessels, the stresses induced by the supports on the
shell shall be checked in accordance with L.P. Zick method.

6.2.3 Stack

a. Stacks shall be designed, fabricated, inspected and tested in accordance with the latest edition
of ASME STS-1.
b. Temporary lugs shall be adequate for lifting the stacks. Design of the same shall include the
analysis of localized stresses during erection.
6.2.4 Heat Exchangers

a. Air Cooled Heat Exchangers

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Title: Mechanical Design Basis

The design, materials fabrication, inspection and testing of air cooled heat exchangers shall
be in accordance with API 661, ASME Section VIII Div. 1 as applicable. Air cooled heat
exchanger design shall be carried out at 40 Deg.C air temperature.

Forced draft coolers shall generally be used based on ease of manufacture and maintenance.
The tube bundle shall be accessible from above and the fan and motor from below.
Consideration shall be given to reduce hot air recirculation and shading the tube bundle from
the sun, where ever possible.

Induced draft coolers shall be used only where process criteria require their use. For nozzle
loads, three times API 661 values shall be used.

At least two fans shall be provided for each bay. Otherwise, stand-by shall be kept in shop for
immediate replacement incase of any break down. Tube fins shall be of the embedded /
extruded type as per API code requirements.

b. Shell & Tube Heat Exchanger

Shell and tube heat exchanger shall be designed, fabricated, tested and inspected in
accordance with API 660 & ASME Sec. VIII Div.1. The nomenclature used in TEMA Standards
shall be used to describe the shell & tube heat exchanger. Design pressure, design
temperature, operating conditions, fluid properties, pressure drops and fouling factors shall be
as specified on the exchanger datasheet. If ASME Section VIII, Division 1 specifies two
allowable stresses for the design of pressure parts, the lower value must be used for the design
of tubesheets, bolted flanges, and flat cover plates.

6.2.5 Filters / Coalescers

Filters / Coalescers housing including their supports, shall be designed in accordance with ASME
Section VIII Div.1 requirements. Internal filter elements shall be designed to suit the service
requirements and maintenance intervals. The filter elements shall be readily accessible, easy to

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Title: Mechanical Design Basis

handle and simple to replace. Standard design as supplied by vendor shall be used for filter
element.

6.2.6 Storage Tank

Storage tank shall be designed, fabricated, inspected and tested in accordance with the
requirements of API 650. Storage tank shall be designed for 100% filled condition with minimum
1.0 specific gravity of contents.

Shell thickness for API 650 tanks shall be calculated by One-Foot method unless otherwise
explicitly agreed with owner / purchaser. Thickness provided at any shell course shall not be less
than the course above.

All fixed roof tanks shall have a frangible joint between the top angle and the roof plates or the
tanks shall be provided with a pressure relief device as per API 2000 for emergency venting. Tank
vendor shall size and provide any necessary vacuum venting devices.

Shop assembled API 650 tanks shall comply with Appendix J except that a minimum of Spot
radiography shall be applied with a joint efficiency of 0.85.

Only conical roof shall be used for storage tanks unless and until agreed explicitly by the owner /
purchaser.

6.3 Rotating Equipment

6.4.1 General

All major rotating equipment shall be located inside a shelter complete with overhead crane for
maintenance, refer to section 6.5.6. No prototype or unproven equipment or equipment built to
unknown manufacturing standards shall be incorporated.

Design of rotating equipment shall take into account the need to operate at less than rated
condition. Liquid containing system shall be completely self drainage type without dismantling (part

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Title: Mechanical Design Basis

or fully) the equipment. All couplings, gears and exposed rotating parts shall be provided with
adequate protection guards.

6.4.2 Gas Compressors

The reciprocating / screw compressor package to be designed and built to API 618 / API 619
standard respectively.

The compressor packages shall be modular in design. Modular sizing shall be suitable for easy
shipping to site from the point of manufacturing. It is anticipated that each single unit shall consist
of a compressor skid with motor / engine skid and for each stage. The inter stage and after cooler
bundles shall be housed in a single air cooled heat exchanger. This air cooled heat exchanger
shall be located on a separate skid. Suctions scrubbers and strainers (complete with
commissioning mesh) shall be supplied for all compressor packages.

Each compression stage shall have dedicated pressurized lube oil system. Pressurized lube oil
system shall be common for compressor, driver, gear box assembly (if required) and motor. Lube
oil system shall include oil reservoir of adequate capacity, main and auxiliary lube oil pumps of
gear / screw type, emergency pump (if required), run down tank, oil filters and oil coolers (air-
cooled, fin/fan type).

6.4.3 Centrifugal Pumps

a. Equipment Qualification Criteria

Pumps selected shall be from the regular manufacturing range of the manufacturer. At least
one of the units shall have completed 52 weeks operating hours in the field.

b. Seals
The pumps shall be provided with mechanical seals as per API 682. Seal vendor
recommendations shall be governing for providing the suitable seal plan. Air cooling shall be
preferred cooling method. Plans with requirement of cooling water should not be considered
as far as possible. Gland packing shall not be acceptable.

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Title: Mechanical Design Basis

c. Couplings for rotary equipment with driver rating higher than 160 KW shall be designed in
accordance with API 671.

6.4.4 Miscellaneous Pumps

The design, construction, testing, installation and performance of the other Non API Centrifugal
pumps shall be in accordance with the requirements of the one of the following:
a. ASME B73.1 for Horizontal End Suction Pumps
b. ASME B73.2 for Vertical Inline Pumps
c. ISO-5199 Technical Specification for Centrifugal Pumps and ISO-2858 end-suction centrifugal
pumps (rating 16 bar) – designation, nominal duty point and dimensions.

The design, construction, testing, installation and performance of motor supplied shall comply with
project specification.

6.4.5 Positive Displacement Pumps

a. The design, construction, testing, installation and performance of positive displacement

reciprocating pumps shall be in accordance with the requirements of API 674.
b. Metering pumps shall be in accordance with the requirements of API 675.
c. Positive displacement rotary pumps shall be in accordance with the requirements of API 676.
d. In rotary pumps, screws and shaft shall be designed for maximum stiffness and minimum shaft
deflection. Screw pump shall consist of replaceable liner.
e. A separate pressure relief valve in the discharge shall be provided to protect the pump and its
associated piping system.

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