Detail Engineering Services For Engen Tank X368 Rebuild

DETAIL ENGINEERING SERVICES FOR
ENGEN TANK X368 REBUILD
DOCUMENT TITLE:
MATERIAL SELECTION REPORT FOR X368
DOCUMENT NUMBER:
FFIL-2020-08-P-302
Client: ENGEN REFINERY

Project Number: PS 02117
E Contractor: NAKO ILISO
Location: ENGEN REFINERY, DURBAN,
SOUTH AFRICA
0 11-05-2020 ISSUED FOR APPROVAL CPK CC CC
Rev Date Document Status Prepared Checked Approved

By By By
RECORD OF REVISIONS
Rev. Date Revision Details
0 11-05-2020 First Issue for Approval
TABLE OF CONTENTS
Doc. No. : FFIL-2020-08-P-302 Page 1 of 10

1. INTRODUCTION & PROJECT SCOPE...................................................................................3
2. ABBRIVIATIONS.................................................................................................................4
3. CODES AND STANDARDS...................................................................................................5
4. DESIGN LIFE.......................................................................................................................6
5. FLUID COMPOSITION........................................................................................................7
6. MATERIAL SELECTION.......................................................................................................8

1. INTRODUCTION & PROJECT SCOPE
Tank X368 was originally built as an Effluent Re-run tank in 1992. A project G0392 in 2007 was
commissioned to upgrade the tank from Effluent Re-run service to sour water service along with
project EREF01313 in 2010 to upgrade the tank X368 discharge pump, G9150, to maximum capacity.
These projects were successful and aimed at creating a buffering mode for the sour water stripper to
smooth out feed variations and improve process stability.
The sour water system has since been operating in continuous buffering mode. Due to the damage
to tank X368 in the refinery turnaround in February 2018, the sour water system has been forced to
be operated in non-buffered mode which is unsteady and leads to negative impacts on the sulphur
recovery unit (SRU) 3. The Superclaus cannot be kept online with a swinging/unsteady SWS off gas
feed due to the risk of a runaway reaction temperature. The most significant impact on the SRU is
the reduced recovery efficiency due to Superclaus stage being bypassed.
This project has been initiated to execute the rebuild of X368 as a like for like replacement with
minor modifications where necessary to adhere to current best design practices for tank design and
to improve the feed inlet mixing and buffering capacity of the new X368 tank.
This document intends material study for Tank X368 by review alternatives and justify the proposed
material selection is optimal from perspective of all engineering design and life considerations.

2. ABBRIVIATIONS
The following abbreviations have been used in this document:
CA Corrosion allowance
CO2 Carbon dioxide.
CP Cathodic protection.
CR Corrosion rate
H2S Hydrogen sulphide.
HDPE High Density Polyethylene
HE Hydrogen embrittlement.
NH3 Ammonia
ppm parts per million
TOLC Top of line corrosion.
UDC Under Deposit Corrosion
WT Wall thickness.

3. CODES AND STANDARDS
API 650 Welded Tanks for Oil Storage

Specification for the design and manufacture of site built, vertical,
EN14015 cylindrical, flat-bottomed, above ground, welded, steel tanks for the
storage of liquids at ambient temperature and above
Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials
ASTM A193 for High Temperature or High Pressure Service and Other Special Purpose
Applications
Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High
ASTM A194
Pressure or High Temperature Service, or Both
Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials
ASTM A320
for Low-Temperature Service
ASTM G4 Conducting Corrosion Coupon Tests in Plant Equipment
ASTM G31 Laboratory Immersion Corrosion Testing of Metals
ASTM G46 Practice for Examination and Evaluation of Pitting Corrosion
ASTM G81 Practice for Preparation of Metallurgical Specimens
NACE MR-0175
Sulfide Stress Cracking Resistant Metallic Materials for Oilfield Equipment
(now also ISO 15156)
Preparation and Installation of Corrosion Coupons and Interpretation of
NACE RP 0775
Test Data in Oilfield Operations

4. DESIGN LIFE
Design Life considered for Corrosion allowances and design of tank is 20 years

5. FLUID COMPOSITION
Inlet fluid Composition to Tank X368 as per FEL2 (E.REF. 013768) and PFD Stream No.3:
X368 Inlet Feed Composition
Components Mass % / Mass Flow
H2S 0.77% / 833 kg/hr (7692 ppmwt)
NH3 0.38% / 417.4 kg/hr (3846 ppmwt)
H2O 98.85% / 107177 kg/hr
Hydrocarbons Slugs only, to be contained in 10.5 m 3.
Tank (X-368) Vapor Space Composition (Refer Flash/Vapor Calculation Report):

X368 Vapor Space Composition
Components Mass % / Mass flow
H2S 96.52% / 461.6 kg/hr
NH3 00.27% / 1.27 kg/hr
Water 3.22% / 15.4 kg/hr

6. MATERIAL SELECTION
Following is the basis for selection of appropriate material

- Suitable for Process Conditions and fluid composition.
- Listed by the relevant design code for use within the stated design requirements;
- Standardized by recognized national and international standardization bodies;
- Readily available in the market and stocked by relevant dealers;
- Readily weldable, if welding is relevant, and known by potential fabricators;
- Past experience record for the applicable use, e.g. same type of component and
dimensional range
Operating Atmospheric storage Tank X-368 stored with Sour Water having H 2S and NH3
Service Content + Hydrocarbon slugs
Maximum 50°C
Temperature (Min Design Metal Temperature = 20 °C)
Pressure Atmospheric
Corrosion Tank X-368 to be resistant to H2S, NH3 and Hydrocarbon liquids. Tank vapor
Damage space will be exposed to acidified vapors /gases due to flash gas which is rich in
Mechanism(s) H2S from Sour water. However corrosion rates are not expected to be high at
ambient temperature and atmospheric pressure.
Corrosion Rate based on inlet molar flow of H2S and operating temperature 50
deg C is considered as 10 mils/year (6 mm corrosion allowance required for 20
years life)
However tank shell and roof thickness shall be based on mechanical strength
requirements.
Materials Shell: SA 516 60N (HIC)

Roof: SA 516 60N (HIC)
Bottom: SA 516 60N (HIC)
Structural: SA 516 60N (HIC) / SA36
Flanges: SA 516 60N (HIC) / SA 105
Nozzle Necks: SA106-Gr B
Bolts & Nuts: SA 193-B7M / SA 194-2HM
Gaskets: Filler – Flexible Graphite, Hoop – 316L SS, Inner Ring – 316L SS, Outer
Ring – C.S

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DETAIL ENGINEERING SERVICES FOR

ENGEN TANK X368 REBUILD

Client: ENGEN REFINERY

0 11-05-2020 ISSUED FOR APPROVAL CPK CC CC

Rev Date Document Status Prepared Checked Approved

Rev. Date Revision Details

0 11-05-2020 First Issue for Approval

Doc. No. : FFIL-2020-08-P-302 Page 1 of 10

Doc. No. : FFIL-2020-08-P-302 Page 2 of 10

Doc. No. : FFIL-2020-08-P-302 Page 3 of 10

The following abbreviations have been used in this document:

Doc. No. : FFIL-2020-08-P-302 Page 4 of 10

API 650 Welded Tanks for Oil Storage

Doc. No. : FFIL-2020-08-P-302 Page 5 of 10

Doc. No. : FFIL-2020-08-P-302 Page 6 of 10

Components Mass % / Mass Flow

H2S 0.77% / 833 kg/hr (7692 ppmwt)

NH3 0.38% / 417.4 kg/hr (3846 ppmwt)

H2O 98.85% / 107177 kg/hr

Hydrocarbons Slugs only, to be contained in 10.5 m 3.

Tank (X-368) Vapor Space Composition (Refer Flash/Vapor Calculation Report):

Components Mass % / Mass flow

H2S 96.52% / 461.6 kg/hr

NH3 00.27% / 1.27 kg/hr

Water 3.22% / 15.4 kg/hr

Doc. No. : FFIL-2020-08-P-302 Page 7 of 10

Following is the basis for selection of appropriate material

Materials Shell: SA 516 60N (HIC)

Doc. No. : FFIL-2020-08-P-302 Page 8 of 10

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