TECHNICAL SPECIFICATIONS - Slovnaft

SLOVNAFT a.s. Refining & Marketing

This document is property of MOL Group. The use is only allowed with the written permission of MOL Group.

MOL Group

TECHNICAL SPECIFICATIONS - MECHANICAL -

1. Static Equipment 0. General requirements

MGS – S – REF – M – 1.0

Rev. 1.00.02

SLOVNAFT a.s. Identity code:

MGS-S-REF M- 1.0 Refining & Marketing TECHNICAL SPECIFICATIONS - MECHANICAL Release: Rev. 1.00.02 Static Equipment Date: 29.02.2016 General requirements Page/Pages: 2/19


Release list

Rev. Date Description Edited Verified Approved

0.00.00 31.12.2005 Basic release

1.00.00 30.06.2012 General issue see sign. sheet MGS-S-REF-M-LI R. Kopalek see sign. sheet

MGS-S-REF-M-LI

1.00.01 01.06.2014 Revision of Appendix SN S. Janega R. Kopálek Head of Technology

1.00.02 29.02.2016 Revision of Appendix SN S. Janega R. Kopálek see sign. sheet MGS-S-REF-M-LI

SLOVNAFT a.s. MGS-S-REF-M-1.0 Refining & Marketing

Rev 1.00.02 3/19

Contents 1. Foreword ................................................................................................................ 4 2. Equipment design ................................................................................................... 4 3. Requirements for basic equipping of appliance. ..................................................... 5 4. Steel Structures ...................................................................................................... 7 5. Corrosion protection ............................................................................................... 7 6. Conservation of equipment for transport and storage. ........................................... 7 7. On-site installation and adjustments ....................................................................... 8 8. Standards ............................................................................................................... 8 9. Appendix SN - Additional rules valid for Slovnaft refinery………………...….…….11


Rev 1.00.02 4/19

1. Foreword

Obligation determining: The standard is mandatory for all company departments, for project and assembly suppliers and stationary equipment suppliers after the negotiation and confirming of this standard into commercial contracts.

2. Equipment design

2.1 The standards EN, API, ASME can be applied for supplying of technological units and for reconstruction of existing equipment. Whichever standards will be applied, the PED (2014/68/EC) regulation is to be satisfied. The pressure equipment (vessels, heat exchangers, air coolers, filters, process piping, etc.), which comes under competence PED, shall be delivered with a Declaration of Conformity, which shall be issued by relevant equipment supplier (manufacturer).

2.2 Local regulations for technical equipment safety and health safety shall be fulfilled in case of international standards using.

2.3 The optimization of total lifetime cost shall be considered in determining the designed lifetime of the equipment. The minimum lifetime of critical equipment (e. g. columns, reactors, furnaces, heat exchangers, etc,) is 20 years lifetime. Four years uninterrupted operation shall be ensured.

2.4 The calculation control for prescribed loading shall be carried out for such equipments, which are subjected to seismic and wind loading.

2.5 The equipment surface contact temperature shall be less than allowed temperature during equipment operating. Additional precautions shall be carried out in the case that is not possible to keep this temperature for operating temperature or technical possibility reason.

2.6 Construction material shall be selected according to applied standards with fulfilling the PED requirement and for chemical industry conditions. Material selection philosophy shall be specified by Contractor/Vendor taking into consideration the most extreme operating conditions.

2.7 Positive material identification (PMI) shall be performed in Vendor’s shops during fabrication of equipment and on installation site during erection of piping systems. PMI is required to identify type of used alloy, austenitic and duplex materials. PMI shall be carried out by X-RAY spectrometers – e. g. Texas Nuclear 9200, or by apparatuses, which work at the same principle. The relevant certificates shall be provided and supplied till mechanical completion latest.

2.8 Coefficient “J” and “X” shall be stipulated for Cr – Mo steels, which are predisposed to thermal embrittlement and toughness degradation. This information shall be stipulated for everyone area of welding joints. The coefficient of 'J' and 'X' shall be defined by designer, and manufacturer shall verify the material meet this value by issuing a PMI report..

2.9 Welding procedure specifications shall be carried out according to EN 288 for all


Rev 1.00.02 5/19

weld works, which are carried out on the equipment.

2.10 Using of gaskets and components, which contain the asbestos, is not allowed.

2.11 Good and safe access shall be provided to all equipment for operation, inspection and maintenance purposes (disassembling, lifting and moving of all equipment shall be included).

2.12 For parts of equipment which weight is more than 200 kg and which can’t be reached by a mobile crane to assist in the maintenance work, trolley beams for manually operated hoists shall be provided.

2.13 Manufacturer shall carry out selection of the pipelines and pressure vessels for the periodical ultrasonic wall thickness measurement, selection of measurement points (see also Appendix SN, point A.13), providing the zero measurements and measurements frequency. Manufacturer shall provide the revision sheets with axonometric drawings and marked measurement points, all in digital vector format, further shall provide comment to the method of the measurement point’s selection and method of collection and evaluation measured data.

2.14 For piping with minimum flanged joints (for safety reason) shall be issued procedure for repetitive hydrostatic testing. For pressure vessels for which their Manufacturer does not recommend repetitive hydrostatic testing or it is not possible to carry out the testing for technical reasons, shall be prepared and issued alternative procedures and test methods.

2.15 Each of pressure vessels for hydrocarbons, hydrogen, and hydrogen sulphide, NaOH, DEA shall be manufactured from killed carbon steel. Vessels for H2S, NaOH and DEA service shall be subjected to PWHT.

3. Requirements for basic equipping of appliance

3.1 Construction of equipment shall allow safety equipment stopping, emptying and cleaning. The equipment construction shall allow safety reparation and carrying out prescribed tests and inspection.

3.2 The equipment shall be equipped by manholes and control openings for inspection performing during it’s lifetime in extent, which is prescribed by relevant regulations, further for technological inspections and cleaning.

3.3 The removable equipment parts with 25 kg weight and more shall be equipped by lifting lugs.

3.4 The removable covers of inspection manholes and manholes generally shall be equipped by lifting equipment (manipulation hanger).

3.5 The minimum inside diameter of circular manholes shall be DN 600 and minimum dimensions of rectangular manholes shall be 600 x 600 mm.

3.6 Internal parts shall be removable for inside inspection and reparations carrying out.


Rev 1.00.02 6/19

3.7 Internal parts shall have the dimensions, which allow their disassembly through the manholes

3.8 The passable clearance of access ways, which are situated one over second, shall be minimally 2100 mm.

3.9 The appropriate grease agent shall be used for bolts assembly.

3.10 Unless otherwise specified, the nozzle flanges shall be specified by EN but ANSI flanges may also be specified by MOL Group in the contract. For vacuum equipments the flanges shall be of grooved seal surface design. Minimum flange size: DN 50 (2").

3.11 The manholes shall be provided with cover turning device.

3.12 The minimum nozzle shall be DN 50.

3.13 Counter flanges for pressure vessels: each flange shall be designed and fabricated with counter flange with gasket, bolts, nuts and the spares of the screws; 10 % spares are required. 3.14 Below internal diameter of 1000 mm the vessel body shall be flanged to allow opening if required to replace or check the internals.

Pressure Vessels Name Plate: - The nameplate shall be manufactured by etching (or milling or similar technology)

and the color of the nameplate base shall be black. - Nameplate shall be located on the accessible and visible place from the ground-

floor and which is manufactured from corrosion and thermal influence resistant material

- The nameplate material shall be stainless steel. - The nameplate shall be fixed on the bracket by four (4) rivets. - The nameplate shall be placed on the bracket welded to the vessel’s shell. The

surface of these welds shall be smooth.

Additional details for pressure vessels - Each pressure vessels, where the Licensor specifies using of austenitic steel for

manufacturing, shall be manufactured of stabilized austenitic steel. - At points of pressure vessels insulation, for which UT inspection shall be carried

out for maintenance purposes, removable plugs shall be provided in the insulation.

- Test and inspection methods, which shall be applied after repairs of vessels, shall also be included in the documentation.

- For vessels, which is subjected to cyclic fatigue or material degradation (e. g. hydrogen atmosphere, hydrogen sulphide atmosphere etc.), and where is necessary to carry out the calculation checking of real lifetime after its design lifetime achieving, for such vessels is necessary to provide / to deliver necessary data for real lifetime calculation checking:

a. reference material structures and dimensions for creep case;


Rev 1.00.02 7/19

b. number of cycles for determined working parameters; c. test coupons (zero samples and samples for inserting into vessels)

- Licensee’s Contractor shall provide the detail description for hot bolting procedure, where the torque value related to the working temperature shall be defined

4. Steel Structures

4.1 Steel structures, platforms, access ways, stairs, ladders and escape ways shall be designed in accordance with relevant standards and the following safety regulations shall be observed:

− So far as practical, platforms, access ways, stairs and ladders shall be integral part of the equipment or groups of equipment concerned (columns, vessels, pipe bridges etc.);

− Any opening in platforms etc., staircases and railings shall be protected against accidental drop of tools, screws, etc., by the use of kick plates;

− Ladders shall be furnished with protective cages and self–closing barriers;

4.2 Elevation of each platform shall be indicated on the table and shall be fixed on the steel structure.

5. Corrosion protection

5.1 Corrosion protection of equipment concerning the outside environment according to ISO EN 12 944 shall meet the requirements of corrosion loading marked “C4”.

5.2 Painting systems, which will be applied on the inside equipment surfaces, shall be designed without the possibility of impact on technological medium. Painting system influence shall not degrade the technological medium.

6. Conservation of equipment for transport and storage

6.1 The conservation of the whole equipment shall be suitable for against the weather and general refinery atmosphere until the end of the guarantee period to ensure guarantee condition.

6.2 The equipment can be conserved only after the relevant prescribed tests.

6.3 If will be needed the conservation agent shall be removed by available method.

6.4 After completion of the production the equipments shall be carefully cleaned and drained. Mill scale, welding splashes and wastes shall be removed. The machined surfaces contacting with air shall be provided with an easily removable anti-corrosive coat. The nozzle connection shall be closed so that the terminations should protect the nozzles from the shipment till the erection against weather and mechanical damages.

6.5 In case of appliances built upon each other, underlay (shim) plates, fixed by tack weld and match marked, shall be delivered.

6.6 In case of fabrication according to local standards the specifications of the relevant


Rev 1.00.02 8/19

standards and EN 10204 standards, and the AD-Merkblätter 2000 specifications applying whilst for design and fabrication according to PED the relevant approximated (harmonized) EN standards shall be considered. The Manufacturer shall furnish all manufacturing documents and the as-built documentation, to the MOL Group.

6.7 Overweight equipments: Weight and size data of equipments protruding from the public road and railway clearances shall be collated with the MOL Group. 7. On-site installation and adjustments

7.1 The delivered equipment shall be stored till the installation at a place providing protection against mechanical damages, propped professionally, protected against external and internal corrosion, in order to ensure conservation and, meet the guarantee conditions. 7.2 At the site of the installation the equipment shall be subjected to hydro-test. This should be impeded by some mechanical damage or any other reason; the fault has to be eliminated according to the guarantee conditions. 7.3 The necessary contractor's works (final painting, heat insulation, etc.) may be carried out only after a successful pressure test. 7.4 The necessary platforms, ladders, circular footways, anchoring bolts, as well as other auxiliary steel structure elements form part of the delivery scope. 7.5 Specifications of the necessary contractor's works (painting, heat insulation, etc.) shall be included in the plan documents (either directly in the technical description or in form of enclosed data sheets). 7.6 During the course of the on-site installation provisions shall be made on setting the equipments into adequate horizontal or vertical position and, stress- free fitting of the nozzles. 7.7 Post welding heat treatment in the factory is permissible only if the entire equipment will be heat treated again or, workmanlike local heat treatment of the affected part will be solved (e.g. induction heat treatment with adequate blankets). The heat treatment diagram in all cases shall be delivered to the MOL Group. 7.8 During the course of the on-site installation the relevant labor safety and fire protection specifications in force as well as concrete local specifications of the MOL Group shall be adhered to.

7.9 Content of the plan documentation, as minimum shall meet the requirements of relevant specifications and the stipulations of the contract. The Manufacturer shall deliver the factory documenting and the as built documentation according to clause MGS-S-REF-M-5.4.2, to the MOL Group.

7.10 Column skirts, reactor skirts, vessel saddles and main steel structures (e. g. girders) shall be protected against fire for period of X (see: App.) minutes (by heat resisting material).

8. Standards

Vendor is obliged to use the below mentioned standard for Vendor’s scope of supply. Note: All Codes and standards listed below shall be read within the frame of European Community Pressure Equipment Directive 2014/68/EC (PED).


Rev 1.00.02 9/19

These standards will be applied in the order of precedence according to clarification with BUYER as below:

a) EU Directives and National regulations, Laws, Codes and Standards valid at the date of signing the Contract;

b) MGS – Standards; c) International and National Standards; d) Project specification e) Vendor’s specifications; f) Licensor‘s specifications.

The latest editions of standards valid at the date of signing the CONTRACT shall be applicable for design.

8.1 Material certificates: The following inspection documents are required:

where a material manufacturer has an appropriate quality assurance system, certified by a competent body established within the Community and having undergone a specific assessment for materials, an inspection document type 3.1 (EN10204)

or inspection documents type 3.2 (EN10204) for other manufacturers.

8.2 Pressure vessels: a) Pressure Equipment Directive PED (2014/68/EC) b) ASME Section VIII Div.1 & Div.2; (PED conform)

− Section II Material specifications

− Section V. Non-destructive tests

− Section VIII Rules for production of pressure vessels

− Section IX Qualification of welds c) EN-13445 Unfired pressure vessels d) Series 1 – 16 of Norm EN 12952: Water-tube boilers and auxiliary installations e) AD-Merkblätter 2000 (PED conform) f) API 661 and ISO 13706 ( (Air Coolers); g) API 660, and ISO 16812 TEMA R (Heat Exchangers & Coolers); h) Material: ASTM (NACE for sour service) ) and PED or EN; i) Manufacturer: Manufacturers of pressure vessels have to be certified by ISO

9001 and authorized to manufacture pressure vessels. j) API 571 Conditions Causing Deteriorations or Failures (in pressure vessels) k) API 572 Inspection of Pressure Vessels l) EN 13463 Non electrical equipment for use in potentially explosive

atmospheres

8.3 Boilers a) ASME-I , AD -Merkblätter 2000, PED (EN 13445)


Rev 1.00.02 10/19

8.4 Storage tanks: a) Storage Tanks: API 650 - Welded Steel Tanks for Oil Storage;b) API 620 - Design and Construction of Large, Welded Low Pressure Storage

Tanks.

8.5 Fired Heaters: a) API 560 Fired Heaters for General Refinery Services;b) API 530 Calculation of Heater Tube Thickness in Petroleum Refineries;c) API 535 Burners for Fired Heaters in General Refinery Services;d) ANSI/ASME B31.3;e) ANSI/API RP 573 Inspection of Fired Boilers and Heaters.

8.6 Process &Utility Piping:

ANSI/ASME B 31.3 PED or EN 13480 Piping materials including valves for sour service shall be comply with recommendations for sour service in accordance with NACE MR 0103 and NACE MR 0175/EN ISO 15156 Standards. Units without piping classes system created - for revamps of such units shall be strictly required using of the MGS piping classes.

8.7 Welding Qualifications and Specifications: ASME IX and EN

For each type of material specified in Bidder’s specification, welding procedure specifications and qualification records (WPS, PQR) and welder qualification test reports will be provided.

8.8 Valve Inspection and Testing: API 598, EN 12266-1

8.9 Insulation: For Insulation the „ Insulation Specification „prepared by Bidder and reviewed by MOL Group will be used. Following standards

ASTM B 209; ASTM 547; ASTM C 592; ASTM C 795.

shall form a part of this specification. The MGS-S-REF-M–6.3 shall be followed.

8.10 Package Units: All elements and components of Package Units shall meet the requirements of main equipment directives, standards and specifications and shall be certified by relevant authorities.

8.11 ISO Certification: For equipment manufacturers the certification of their quality managing system in compliance with ISO 9000 or equivalent system shall be supplied.

8.12 Bolts, Nuts and Washers: All bolts, nuts and washers shall be designed in metric sizing, in principle. However, inching sizing can be applied for specific parts only as exceptions and shall be subjected to approval of MOL Group.


Rev 1.00.02 11/19

Appendix SN – additional rules valid for Slovnaft refinery:

A. Equipment design: A.1 In compliance with the legislation and with the regulations of Slovak Republic

Law No. 264/1999 Coll. in last wording and the Government Regulation (GR) No. 1/2016 Coll. in last wording (PED 2014/68/EC) new manufactured pressure technical equipments are considered as a „defined products“. These products (pressure vessels, heat exchangers, air coolers, filters, piping, etc.) shall be delivered with a Declaration of Conformity, which shall be issued according to the GR 1/2016 by relevant manufacturer. The construction and accessories of pressure equipment shall meet the requirements of Slovak Laws (e. g. Public Notice No. 59/1982 Coll.). The Public Notice No. 508/2009 Coll. shall be applied for modification, reconstruction, and reparation and operating of existing equipment and for the new equipment after its putting on the market and before its commissioning (official test). It is necessary to take into account following conditions for equipment design:

• Air temperature max. 38.6 °C

• Minimum Design Metal Temperature min. – 20 °C (if the relevant technical standard does not prescribe lower temperature)

• Minimum Design Temperature for outdoor installed instruments and electrical equipment min. – 20 °C

• Dry bulb temperature 36.0 °C • Relative air humidity average 74 % • Relative air pressure average 755 mm Hg • Rainfall intensity average 50 mm/day max. 84,6 mm/day • Wind velocity average 18 km/h max. 140 km/h • Wind rose north + north-east: 25.8 % east + south -east: 17.4 % south + south-west: 11.1 % west + north west: 33.4 % Non winding: 12.3 % Loading standards: Snow design loading STN EN 1991 (Eurocode 1)

Qk = 0.7 kN/m2, γF = 1.4

Earthquake category STN EN 1998 (Eurocode 8)

7 °M.C.S. (Zone II as in map 6.1)

A.2 The standards EN, API, ASME can be applied together with STN (or STN EN)

for supplying of technological units and for reconstruction of existing equipment. A.3 (to point 2.5) According to valid Slovak standards allowed hot equipment

surface contact temperature is 50°C from personnel safety point of view.


Rev 1.00.02 12/19

A.4 For pressure vessel, for which is not possible to execute the hydrostatic re-test on site during the period required by local code (Public Notice No. 508/2009 Coll.) or is not possible to execute the internal inspection during the period required by local code, for such pressure vessel the Vendor shall ensure relevant Notified Body’s (and/or Authorized Legal Person) written approval, confirming the procedure how the pressure vessel shall be tested during the period, required by local code. Vendor shall prepare the draft of such procedure, which will be commented by Buyer. The relevant Notified Body’s (and/or Authorized legal Person) written approval shall be incorporated into the “Pressure Vessel Record Book“(Passport). The necessary details shall be included in the vessel’s technical documentation. Test and inspection methods shall also be applied after repairs of vessels. Any data necessary for extended life calculation for such vessels shall be also is included in the documentation.

A.5 PMI is a verification process of supplied equipment materials, welding consumables (weld filler materials) and material certificates. Generally the main material quality testing elements are the following:

• any equipment or materials for equipment operating with media containing hydrocarbons, hydrogen, hydrogen sulfide, chlorine and its compounds, other highly flammable or explosive substances and superheated steam shall be delivered to Slovnaft stamped with the material used as well as with material certificates.

• Entrance check is made by comparing the material certificates and stamps imprinted on the material.

Delivery of new equipment Contractor is responsible for ensuring of PMI performance and PMI documentation delivery together with equipment. Contractor is responsible for:

• preparation of critical equipment list and its sending for approval by Slovnaft side;

• preparation of random PMI control method and its sending for approval by Slovnaft side.

Contractor is responsible to ensure verification PMI on site:

• for all critical equipment; • random control for other equipment (typically 10% of pieces, in special

cases pieces percentage based on approval). A.6 It shall be Vendor’s obligation to specify in Vendor’s equipment data sheets the

material type and grade in compliance with the ASME Code or other standards for pressure vessel design of which the concerned equipment shall be manufactured. The denomination like "Carbon steel” or “C.S.”, "Low alloy steel", “Stainless steel” or ”SS” etc. shall not be considered as satisfactory. All parts (sections) of vessels for hydrocarbons, hydrogen and hydrogen sulphide service shall be manufactured of the same grade of material (with exception of vessels with internal weld overlaying or internal bimetal plates applying).


Rev 1.00.02 13/19

A.7 Flanges according to STN (EN) shall be selected in accordance with nominal pressure rating as follows: PN 16; PN 40; PN 64; PN 100; PN 160; PN 250.

A.8 Column skirts, reactor skirts, vessel saddles and main steel structures (e. g. girders) shall be protected against fire for period of 120 minutes (by heat resisting material).

A.9 SELLER shall, in accordance with Code No. 264/1999, ensure prescribed certificates (e. g. Declaration of conformity) issued by relevant authority (and/or manufacturer) for valves, including the control valves. For certification SELLER shall ensure the Declaration of Conformity, issued by relevant manufacturer in Vendor’s country and shall ensure the Vendor’s documentation.

A.10 In line with the Slovnaft's technical policy technical appliances delivered to Slovnaft shall be based on tried-and-true solutions with references. Any technical solutions like prototypes, first time used solutions, are not allowed to be implemented.

A.11 Fire prevention should be realized by implementation of sound design of particular equipment, steel structures and buildings. Any contractor, vendor and designer shall take this request as one of the key inputs specification entering their project or delivery to MOL group particular subject. Fire protection shall be ensured by applying several of system components like:

• Fireproofing • Remotely operated isolation valves • High integrity pump seals • Fire, gas and smoke detection • Water deluge

Fire protection of steel structures and implementation of fireproofing measures are then one of the key elements of fire safety. Therefore it shall meet specified requirements. Fire prevention shall meet in general two basic resource requirements:

a. Legislative (national, EU) b. Relevant standards (national, International)

In particular the following legal and standards requirements must be met: 1. International standards for fire proofing: API 2218 and referenced

documents. 2. International standards for water deluge: API 2030. 3. particular equipment fire protection requirements specified in the

relevant sections of this MGS standard. A.12 According to Slovak legislation (Public Notice No. 508/2009 Coll., §3, article i/)

nitrogen (and/or other unbreathable gases) shall be considered as dangerous gas in all cases where its volume and/or concentration should jeopardize the people’s health or life (closed areas, spaces under terrain level, etc.). According to the Law No. 124/2006 Coll., §4, the project organization is fully responsible for this “nitrogen problem” solution and the “nitrogen problem” solution shall be done in line with the Slovak legislation rule – the Public Notice No. 508/2009 Coll..


Rev 1.00.02 14/19

A.13 To point 2.13: Selection of measurement points shall be carried out in line with the valid local SN regulation. Contractor/Designer/Manufacturer shall elaborate inspection sheets for piping and pressure vessels (see MGS-S-REF- M-5.1, Appendix SN, point E, Figures No. 1 and 2). The measurement points on equipment shall be marked permanently.

A.14 If required by SLOVNAFT, the manufacturer is obligatory to deliver material samples in the same quality as melt used for equipment manufacturing. The volume of samples shall meet the requirements of tests for equipment life time assessment carrying out (the number and dimensions of samples shall be determined by Slovnaft).

A.15 If required, manufacturer’s material attests shall contain impact test value measured as “transversal”.

A.16 CS materials grade J2 shall be used only (assured impact resistance defined by impact energy value 27J at 20°C).

A.17 If the stainless steel material is contaminated by another material (e. g. CS material), in that case cleaning of SS material shall be carried out by passivation. Mechanical cleaning shall not be used.

A.18 After end of all assembling operation on flange screw joints (combination: SS – flanges, CS - screws, nuts, washers) these joints shall be conserved by Teflon spray which is resistant against corrosion and atmospheric humidity. The screw joints shall be cleaned (removing of corrosion films from screw joint external surface, which can occur during assembly) before Teflon spray using.

A.19 Assembly drawings shall contain table, where is shown: • Torque moments/preloads for all flanges screw joints; • Friction coefficient of anti-seized paste used; • Types of gaskets used;

A.20 The anti-seized paste shall be applied for all bolts and nuts threads. A.21 Each kind of equipment installed shall not be manufactured more than 2 years

before date of contract approval/sign by Slovnaft. Each exception from this requirement shall be approved by Slovnaft in writing.

B. Requirements for basic equipping of appliance: B.1 Access ways shall be equipped by railings, which shall be designed for

horizontal and vertical loading value 500 Nm-1. B.2 Ladders, which lead to platforms, shall meet the requirements of STN 74 3282. B.3 Any openings in platforms etc., staircases and railings shall be protected

against accidental drop of tools, screws, etc., by the using of kick plates, which shall have minimally 100 mm height.

B.4 The plates of platforms (floors) and access ways shall be constructed for 5000 N of concentrated load uniformly distributed over area 200 x 200 mm.

B.5 Each kind of equipment shall be marked according to relevant standards and BP-06 (Safety regulation of Slovnaft).


Rev 1.00.02 15/19

C. Steel structures: C.1 Steel structures, platforms, access ways, stairs, ladders and escape ways shall

be designed in accordance with STN and the following safety regulations shall be observed: − Platforms, access ways, etc. shall be having zinc-coated steel grating (in

particular cases of lattice steel plate). The maximum opening for steel grating is 30 x 30 mm;

− Handrails shall be made of tubes; − All steel structures shall be primed and finish coated. The steel structures

shall be painted by color shade RAL 7004; − Main steel structure posts up to the load bearing members - these included -

shall be protected against fire for period of 120 minutes (by heat resisting material).

D. Corrosion protection D.1 Expected lifetime of external painting systems shall be minimally 15 years.

E. Conservation of equipment for transport and storage: E.1 The products surfaces shall be cleaned and degreased before is painting or

conservation applied. The surface preparation shall meet the requirements of relevant STN.

F. Standards F.1 These standards and rules shall be applied in the order of precedence

according to clarification with BUYER as below: a) Laws, Codes and Standards valid in Slovak Republic at the date of signing

the Contract b) The Authority Engineering and the Detail Engineering for the Plant and civil

work, equipment and execution of erection and installation work will comply with provisions of standards valid in the Slovak Republic STN (Slovak Technical Standard).

c) The compliance with standards of the Slovak Republic will be achieved either by contracting some kinds of work and supplies with local organizations, which are familiar with the relevant standards of the Slovak Republic or by application of suitable European standards with requirements of equal or higher-grade strictness than requirements of standards valid in the Slovak Republic. In cases, when the relevant International standard is less severe than standard valid in the Slovak Republic or in cases when standards valid in the Slovak Republic include particular requirements not provided by the relevant International standards, provisions of standards valid in the Slovak Republic will be adhered to.

d) The Public Notice No. 508/2009 Coll. shall be applied for “Classified equipment”. The quality of installation of all equipment that belongs to group A according to Public Notice No. 508/2009 Coll. shall be checked by the Authorized legal person (Official tests or repeated tests).


Rev 1.00.02 16/19

According to Law No. 124/2006 Coll. the list of Authorized legal persons is issued by National Labor Inspectorate of Slovak republic. These persons are entitled to carry out the Official Test required by Public Notice No. 508/2009 Coll. for classified technical equipment. Seller, manufacturer or Implementation Company is obliged to keep the steps described by Public notice No. 508/2009 Coll.:

• Detail engineering documentation (Authority engineering minimally) shall be submitted to approval by Authorized legal person (acc. to Law. No 124/2006 Coll. and Public notice No. 508/2009 Coll.) Note: See also MGS-S-REF-M-5.4.2, Appendix SN – additional rules valid for Slovnaft refinery, point A (Vendor documentation).

Seller, manufacturer or Implementation Company is obliged to arrange the Official test (according to Law. No 124/2006 Coll. and GR 392/2006 Coll.)

Activities during Official test: The Authorized legal person confirms fulfillment of:

installation conditions, testing, fixation of accessories and safety devices, accompanying documentation availability, availability of installation, operation and maintenance manual in

Slovak language. e) For the Authority Engineering and Detail Engineering particularly provisions

of standard concerning protection of industrial plants, buildings and storage areas against fire hazard Proclamation MVSR (Ministry of Interior) No. 94/2004 Coll., which determines technical requirements on fire protection during Plant construction and Plant operation – STN 92 0800 Fire safety of buildings and STN 92 0201 - 1 through 4 (fire risk, civil structures, escape ways and personnel evacuation, safety distances) shall be strictly adhered to.

f) Protection of underground water against pollution by hydrocarbons and other harmful substances shall be strictly adhered to.

F.2 Material certificates • STN EN 10204 - certificate type 3.2 for all pressure parts and details

welded to pressure parts with design pressure ≥ 375 bar(g);

• STN EN 10204 - certificate type 3.1 for all pressure parts and details welded to pressure parts with design pressure < 375 bar(g) and for plugs and bolt flanges, support lugs and other structural parts carrying mechanical loads;

• STN EN 10204 - certificate type 2.2 for all elements including bolts, nuts and washers.

F.3 Pressure vessels:


Rev 1.00.02 17/19

a) Definition, design, materials, fabrication, inspection, testing and documentation: Law No. 264/1999 Coll. in last wording and of Governmental Regulation (GR) 1/2016 Coll.

b) Public Notice No. 508/2009 Coll. c) STN EN 13445 d) STN 69 0012 Pressure vessels. Operating requirements e) 031/BTP/TI f) Material: STN (STN EN) g) Name plate:

STN EN 13445, 031/BTP/TI, STN 02 5080)

h) Pressure Vessel Record Book: STN (STN EN) i) Manufacturer: Manufacturers of pressure vessels outside Slovak Republic

must be certified by ISO 9001 and authorized to manufacture pressure vessels. Local manufacturer must be certified by Authorized legal person.

F.4 Boilers a) Public Notice No. 508/2009 Coll. b) STN 07 0000 - Terminology of steam and hot water boiler c) STN 07 0414-1 - Safety technique. Steam and hot water boilers. General

rules concerning strength calculation d) STN 07 0414-2 - Safety technique. Steam and hot liquid boilers. Calculation

of wall thickness of the components e) STN 07 0620 (/a, /b, /Z3, /Z4) - Design and outfit of steam and hot water

boilers f) STN 07 5801 (STN 07 5801/a) - Gas fuel burners. Technical requirements g) STN 07 0622 - Construction of steam and hot water boilers h) STN 67 3067 - Designation and evaluation of colors of paint coatings i) STN 07 0623 - Technical documentation of boilers j) STN 02 5080 – Name Plates. Technical requirements

F.5 Fired heaters: a) STN EN 746-2 Industrial gas-fired furnaces, basic regulations

F.6 Process& Utility Piping: a) STN EN 13480 – 1 to 7 (valid for existing equipment, built after new

legislation rules taken over from EU and after its coming in force, concerning e. g. spare parts, maintenance, etc.)

b) 032/BTP/TI for existing equipment, built before new legislation rules came into force, concerning e. g. spare parts, maintenance, etc.

c) Requirements of Law 264/1999 Coll. (in last wording) and GR 1/2016 Coll. (in last wording) shall be met.

F.7 Storage tanks STN EN 14015

F.8 Cryogenic storage tanks STN EN 14620

F.9 Valves Inspection and Testing: STN EN 12266 - 1


Rev 1.00.02 18/19

Requirements of Law 264/1999 Coll. in last wording, GR 1/2016 Coll. in last wording shall be met.

F.10 Safety: STN (Slovak Technical Standards) and Slovnaft standard BP06

F.11 Point 8.13 Water Pollution: STN (Slovak Technical Standards)

F.12 Air Pollution: STN (Slovak Technical Standards)

F.13 Noise: STN (Slovak Technical Standards) and Slovak legislation

F.14 Safety Regulations: Laws and Regulations of the Slovak Republic, Slovnaft standard BP6

F.15 Fire Resistant of Structural Steel: STN EN1363-1 to 2

F.16 Fire protection STN 92 0800 STN EN 13 501-1 STN EN 13 501-2 STN EN 1992-1-2 STN EN 1993-1-2 STN EN 1994-1-2 STN 65 0201 STN 65 0205 API 2218 and referenced documents API 2030

F.17 Civil Works: STN (Slovak Technical Standards)

F.18 Steel Structures: STN (Slovak Technical Standards) STN P ENV 1993-1-1 to 1-7 (STN 73 1401) Design of Steel Structures STN P ENV 1993-4-1 to 4-3 (STN 73 1401) Design of Steel Structures STN P ENV 1090-1 to 6 (STN 73 2601) Construction and

Installation of Steel structures

STN 1363-1 to 3 Fire Resistant of Structural Steel

STN EN ISO 14122-1-4 Safety of machinery. Permanent means of access to machinery.

F.19 Painting System: For Painting System the specification and requirements shall be used: − SSPC - Steel Structures Council, Volume 1 and 2 − SIS O5-59-00 - Swedish Standard for Surface


Rev 1.00.02 19/19

− RAL 840 HR - Präparation, Übersichtskarte RAL F2 zum Farbregister

F.20 Non pressure static vessels: STN 69 0005 F.21 Thermoplastic vessels: STN EN 12573-1



MOL Group


1. Static Equipment

A. Pressure Vessels (unfired)

1. Tanks, Separators, Columns, Reactors

MGS – S – REF – M – 1.1.1

Rev. 1.00.00

SLOVNAFT a.s. Identity code: Refining & Marketing MGS-S-REF-M- 1.1.1

TECHNICAL SPECIFICATIONS - MECHANICAL Release: Rev. 1.00.00 Static Equipment Date: 09.03.2012 Tanks, separators, columns, reactors Page/Pages: 2/9


Release list


0.00.00 31.12.2005 Basic release


MGS-S-REF-M-LI

SLOVNAFT a.s. Refining & Marketing MGS-S-REF-M-1.1.1

Rev 1.00.00 3/9

Contents 1. General description .................................................................................................... 4

1.1 Scope ...................................................................................................................... 4 1.2 Alternative designs .................................................................................................. 4 1.3 Conflicting requirements.......................................................................................... 4 1.4 Definition of terms ................................................................................................... 4 1.5 Referenced publications .......................................................................................... 4

2. Construction specifications......................................................................................... 5 2.1 Corrosion................................................................................................................. 5

3. Manufacturing requirements....................................................................................... 5 3.1 Welding ................................................................................................................... 5 3.2 Heat treatment......................................................................................................... 6

4. Test specifications...................................................................................................... 6 5. Additional details for pressure vessels ....................................................................... 7 Appendix SN – additional rules valid for Slovnaft refinery: .................................................. 8


Rev 1.00.004/9

1. General description

1.1 Scope These specifications contain the major requirements for design, fabrication and inspection of the traditional pressure-containing vessels with the maximal allowable working pressure greater than 0.5 bar. As traditional pressure-containing vessel the tanks, separators, columns and reactors indicated in the title shall be considered. Vessels, which are considered as non pressure vessels (with the maximal allowable working pressure lower than 0.5 bar and equal.), shall be designed, manufactured, tested and delivered in line with SEP (Sound engineering practise according to PED). 1.2 Alternative designs If the Vendor offers an alternative design deviating from the project specification or from the inquiry documents but equivalent with that, it can be accepted by a written consent of the MOL Group. 1.3 Conflicting requirements If some contradiction exist between this specification or the project specification and the content of the delivery contract, and then the contract is dominant. 1.4 Definition of terms For purposes of these specifications the definitions of terms used in EN harmonised standards, ASME VIII/1, AD-Merkblätter 2000 specifications and standards stated in part of MGS-S-REF-M-1.0 are accepted. 1.5 Referenced publications Each equipment as minimum shall conform to following specifications, unless otherwise stipulated in the given specification. Following standards shall be consistently applied and the deviations from these standards are possible only with the MOL Group’s approval only.

a) Safety Regulations for Pressure-Containing Vesselsb) Pressure Equipment Directive PED (2014/68/EC)c) PED, together with the approximated (harmonized) European Standards (EN),d) AD-Merkblätter 2000 (PED conform) EN standardse) ASME Boiler and Pressure Vessel Code (PED conform) (in brief: ASME Code)f) ASTM and PED or European (EN) material quality and material tests.g) API RP 572 Inspection of pressure vesselsh) Laws, standards and other requirements stated in part MGS-S-REF-M-1.0.i) Requirements of Inspection and Checking MGS-S-REF-M-6.1 and MGS-S-REF-

M-6.1.4.1.


Rev 1.00.00 5/9

2. Construction specifications

2.1 Corrosion The wall thickness of the pressure vessel may not be less than defined by strength calculations. In addition to this, the minimum wall thickness of the carbon steel and alloyed steel pressure vessels may not be less than the greater out of the following values:

Dinner + 2500 ------------------ or 5 mm

1000 For strength calculations of metal-clad equipments only the base material may be taken into account. Corrosion allowance shall be taken into account as follows: on inner side of jacket, bottoms, nozzles, manholes and blank flanges the total corrosion allowance. 3. Manufacturing requirements

Manufacturing process on site shall be agreed by MOL Group. 3.1 Welding The welds shall meet the specifications of the ASME IX. and PED, or the AD Merkblätter 2000 standards. For fabrication of the equipments only materials of quality as specified in the plans and verified by quality certificate may be used. Technological procedure test shall be carried out for all join types in case of welding alloyed steels or, when it is justified by the size of the piece or other circumstance (e.g. working order). Only welder or welding machine qualified for the corresponding procedure and welding position may perform welding on pressure vessel. Requirements as per EN 287 standard shall be met. 3.1.1 Welding specifications 3.1.2 Components of carbon steel content shall not be fitted directly to equipment elements of stainless steel or other high-alloy materials. The number of dissimilar welds shall be of minimum and subject to MOL Group's approval. 3.1.3 Connection welds of nozzles shall be made with full fusion, with the root-side gap corrosion hazard taken into account. 3.1.4 For manually welded, two-sided seams a general requirement is the back chipping. When the back chipping is the requirement in the manufacturer’s welding procedure, it shall be done to the pure base metal. 3.1.5 If feasible, the seams of all nozzles and smaller connections as well as the stiffening seams of the same shall be completely penetrated welds. The backing strap shall be removed, if feasible. 3.1.6 No welding after the stress-relieving annealing (PWHT – Post Weld Heat Treatment) is permitted.


Rev 1.00.00 6/9

3.1.7 Edges of the bolster plates contacting pressure parts of the heat exchanger shall be provided with perfectly closing seam, in order to prevent atmospheric corrosion of the bolster plate and the heat exchanger jacket. To enable execution of the tightness test, a hole of 6 mm diameter shall be drilled into the bolster plates. After completion of the test the hole shall be closed by a paste or plastic plug against oxidation. 3.1.8 Automatic submerged-arc welding is permitted also on the main load bearing welds, provided that the following conditions are met:

− Size of the seam built up in one run may not exceed 6 mm. − Each seam crossing, seam starting and ending points shall be subjected to

radiography test. 3.1.9 Prior to the structure examination and pressure test the welding seams shall be cleaned from slag, contaminations, oil, paint and other dirt. The manufacturing auxiliary devices welded to the equipment, such as fixtures, consoles, etc., shall be removed without damaging of the base material. 3.2 Heat treatment 3.2.1 The after-weld stress relieving heat treatment (PWHT) shall be accomplished according to the relevant standards (ASME VIII/1, AD-Merkblätter 2000, PED, EN). 3.2.2 Each of pressure vessels for hydrocarbons, hydrogen, and hydrogen sulphide, NaOH, DEA shall be manufactured of killed carbon steel. Vessels for H2S, NaOH and DEA service shall be subjected to PWHT. 3.2.3 If after-weld stress s relieving heat treatment (PWHT) is specified, it shall be carried out on completion of the welding works. After heat treatment no more welding is permitted. Should this be unavoidable, it can be made only with specifications of special measures (e.g. posterior local inductive heat treatment, etc.). 3.2.4 The heat treatment shall be carried out on the complete appliance in one piece, in closed furnace, with registered heating if applicable. In case of big length size or special construction the heat treatment can also be made in two parts, if entirely identical and documented execution thereof can be ensured. 3.2.5 During heat treatment the machined surface shall be protected. The equipments to be heat-treated shall be so supported as to prevent occurrence of any deformation.

3.2.6 The heat treatment documentation (PWHT procedure with heating-cooling rate, holding time and temperature, tolerances, etc.) shall be the part of the Supplier’s documentation.

3.2.7 The sealing surface of each flange and the threaded connections shall be provided with protection against oxidation, after the heat treatment

4. Test specifications

The requirement for Quality control plan, comment and approve manufacturing technical documentation, audits, check points and supervision shall be agreed by MOL Group taking into consideration MOL’s requirements defined in MGS-S-REF-M-6.1.4.1 standard specification.


Rev 1.00.00 7/9

5. Additional details for pressure vessels

5.1 Each pressure vessel shall be equipped by local pressure gauge, vent valve and drain valve location of these nozzles directly on the vessels is preferred. The temperature gauge shall be installed either on the pressure vessel or on the pipe downstream from vessel but in the vicinity of the outlet nozzle. The pressure safety valve shall be installed either on the pressure vessel or on the pipeline, which creates together with vessel one close loop.

5.2 Each pressure vessels, where the Licensor specifies using of austenitic steel for manufacturing, shall be manufactured of stabilized austenitic steel.

5.3 At points of pressure vessels insulation in which UT inspection shall be carried out for maintenance purposes removable plugs shall be provided in the insulation.

5.4 Test and inspection methods shall also be included which shall be applied after repairs of vessels. Any data necessary for extended life calculation for such vessels shall be also is included in the documentation.

5.5 Licensee’s Contractor shall provide the detail description for hot bolting procedure, where the torque value related to the working temperature shall be defined.


Rev 1.00.008/9


B. The vessels with maximal working pressure up to 0.5 bar are covered by STN 69 0005 at the Slovak territory. (it could be considered as a SEP – Sound engineering practice in line with PED)

C. Cladding for inside surface protection is non acceptable. We require applying of bimetal plate or weld overlaying.

D. Welding procedure shall meet the requirements of STN EN ISO 15609.

E. Additional details for pressure vessels:

E.1 The anti-seized paste shall be applied for all bolts and nuts.

E.2 It shall be Vendor’s obligation to specify in Vendor’s equipment data sheets the material type and grade in compliance with the ASME Code or other standards for pressure vessel design of which the concerned equipment shall be manufactured. The denomination like "Carbon steel” or “C.S.”, "Low alloy steel", “Stainless steel” or ”SS” etc. shall not be considered as satisfactory. All parts (sections) of vessels for hydrocarbons, hydrogen and hydrogen sulphide service shall be manufactured of the same grade of material (with exception of vessels with internal weld overlaying or internal bimetal plates applying).

E.3 For pressure vessel, for which is not possible to execute the hydrostatic re-test on site during the period required by local code (Public Notice No. 508/2009 Coll.) or is not possible to execute the internal inspection during the period required by local code, for such pressure vessel the Vendor shall ensure relevant Notified Body’s (and/or Authorized Legal Person) written approval, confirming the procedure how the pressure vessel shall be tested during the period, required by local code. Vendor shall prepare the draft of such procedure, which will be commented by Buyer. The relevant Notified Body’s (and/or Authorized legal Person) written approval shall be incorporated into the “Pressure Vessel Record Book“(Passport). The necessary details shall be included in the vessel’s technical documentation.

E.4 Pressure vessel strength calculation and pressure relief valve calculation shall be presented for acceptance by authorities (Notified body and/or Authorized Legal Person in Slovak Republic) and shall be also commented and approved by Buyer.

E.5 All pressure vessels shall be equipped, except the instruments defined by Licensor, also by local pressure and temperature gauges.

E.6 For any type of equipment asbestos-sealing materials shall be excluding.

E.7 Each weld on the vessel will be clearly marked by the welder’s check Nu. (By punching or by an identification plate welded to the vessels base material. A separate sketch or drawing will be attached to the documentation showing for each weld the check No. of the concerned welder.


Rev 1.00.00 9/9

E.8 If insulation is applied the bracket shall be design properly and the bracket shall be outside the insulation. The fully readability shall be provided.

E.9 Stamping on the pressure vessel is not allowed if the shell thickness is less than 6 mm (carbon steel plates) or 12 mm (for alloy steel plates). In that case the data shall be painted.

E.10 Materials for pressure vessels (including their internals) used in sour service shall be designed in accordance with the recommendations of the NACE.

F. Pressure Vessels Name Plate:

F.1 Each pressure vessel will be furnished with a nameplate in compliance with standards valid in Slovak Republic – STN EN 13445 (relevant part) and STN 02 5080.

F.2 The content of the nameplate shall meet the requirements of relevant standard (STN EN 13445, PED 2014/68/EC) and shall be agreed by Buyer.

F.3 The manufacturer’s quality control department stamp can be placed on the rivet and the weld only after successful hydraulic pressure test which shall be done in accordance with Slovak republic GR 1/2016 Coll. (PED 2014/68/EC; EN 13445).



MOL Group


1. Static Equipment

1. Pressure Vessels (unfired)

4. Filters

MGS - S – REF - M - 1.1.4

Rev. 1.00.00


Refining & Marketing MGS-S-REF-M- 1.1.4

TECHNICAL SPECIFICATIONS - MECHANICAL Release: Rev. 1.00.00 Static Equipment Date: 09.03.2012 Filters Page/Pages: 2/5


Release list


0.00.00 31.12.2005 Basic release


MGS-S-REF-M-LI


Rev 1.00.00 3/5

Contents MOL Group.......................................................................................................................... 1 1. General description .................................................................................................... 4

1.1 Scope ...................................................................................................................... 4 1.2 Design of filters........................................................................................................ 4 1.3 Alternative designs .................................................................................................. 4 1.4 Conflicting requirements.......................................................................................... 4 1.5 Definition of terms ................................................................................................... 4 1.6 Selection of filter types: ........................................................................................... 4 1.7 Referenced publications .......................................................................................... 4

2. Additional requirements for filters ............................................................................... 5


Rev 1.00.00 4/5


1.1 Scope This technical specification is valid for filters serving technological functions with bigger vessel diameter than DN 300. The filters serving pipe part function (standard production) are not subjected to this specification. It contains the relevant regulations, the main requirements of design, production and quality control. The content of the technical description for the device are of more importance than this specification. 1.2 Design of filters In principle filter is considered to be pressure equipment therefore the requirements stated in part MGS-S-REF-M -1.0, shall be taken into consideration by filter design accepted. 1.3 Alternative designs Should the Vendor offer an alternative design deviating from the project specification or from the inquiry document but equivalent with that, it can be accepted by a written consent of MOL. 1.4 Conflicting requirements Should any contradiction exist between this specification or the project specification and the content of the delivery contract, then the contract is dominant. 1.5 Definition of terms In this specification the definitions respective definition of terms included in clauses EN harmonised standards, ASME VIII/1 or AD-Merkblätter 2000 standards and standards stated in part MGS-S-REF-M-1.0 have been taken into account. 1.6 Selection of filter types:

1.6.1 General rule is that efficient filtering can be achieved at surface filtering by a particle size bigger than the pore size diameter, at subsurface filtering by a particle size 20-30% bigger than the average pore diameter. For selecting the preferred type (solution) the conditions hereunder in this specification have to be taken into account. The selection has to be discussed with MOL Group.

1.7 Referenced publications All devices have to meet at a minimum the following requirements, if the relevant specification does not refer to it differently. Out of the following standards those one have to be underlined according to which the design and the production of the device will be processed. This standard has to be taken into account during the whole process of design and production and can only be changed after the approval of MOL Group:

a) Pressure Equipment Directive PED (97/27/EC) b) ASME Boiler and Pressure Vessel Code (short: ASME Code) c) ASTM and PED or equivalent material qualities and material testing according to

European standards (EN). d) Laws standards and other requirements stated in part MGS-S-REF-M-1.0. e) Requirements of Inspection and Checking MGS-S-REF-M-6.1 and MGS-S-REF-

M-6.1.4.1.


Rev 1.00.00 5/5

2. Additional requirements for filters

2.1.1 In accordance with the national legislation filters are considered as pressure equipment. Design, manufacturing, installation, and commissioning of filters shall be carried out according to valid national legislation and Standards (application of the same principles as for pressure vessels).

2.1.2 Particular requirements for filters:

a) Design of filters shall allow its reliable cleaning.

b) The fineness of cleaning and allowable different pressure for filtering element shall be stated in the filter documentation.

c) In the case of filter element replacement due to loss of filter ability shall be filter safe disconnected from other pressure equipments and after it can be the filter body opened.

d) Heavy removable parts (with 25 kg weight and more, e. g. covers) of filter shall permanent hung on the davit or shall be equipped by lifting lugs for its manipulation.

e) The sufficient operating area shall be assigned for filter elements replacement and manipulation.

f) The Vendor shall assign and deliver the method solution of filter elements replacement in the case of filter location on difficult accessible places.

g) Filters with non-removable filter elements shall be safely disconnected from other pressure equipments before cleaning start of them.

h) Vendor shall determine the cleaning method of filters with non-removable elements, further shall determine the method of cleaning quality control and period of cleaning process (e. g. on the basis of flushing medium content analysis).



MOL Group


1. Static Equipment

2. Pressure Vessel (fired)

1. Fired Heaters

MGS – S – REF – M – 1.2.1

Rev. 1.00.01


MGS-S-REF M-1.2.1 Refining & Marketing TECHNICAL SPECIFICATIONS - MECHANICAL Release: Rev.1.00.01 Static Equipment Date: 29.02.2016 Fired Heaters Page/Pages: 2/21


Release list


0.00.00 31.12.2005 Basic release


MGS-S-REF-M-LI


SLOVNAFT a.s. MGS-S-REF-M-1.2.1 Refining & Marketing

Rev 1.00.01 3/21

Contents 1. General description .................................................................................................... 4 2. Requirements for construction and equipage ............................................................. 5 3. Burners ..................................................................................................................... 12 4. Combustion air pre-heater ........................................................................................ 13 5. Fireproof lining, materials (HSE) ............................................................................. 13 6. Stack, duct system and combustion chamber .......................................................... 14 7. Heat recovery ........................................................................................................... 15 8. Safety-technique equipment ..................................................................................... 16 9. Manufacturing and assembling ................................................................................. 17 10. Testing ...................................................................................................................... 17 11. Guarantee ................................................................................................................ 17 12. Major requirements for on-site installation and adjustment ...................................... 17 Appendix SN – additional rules valid for Slovnaft refinery: ................................................ 19


Rev 1.00.01 4/21


1.1 Scope

1.1.1 These specifications relate to mechanical engineering design, fabrication, acceptance and on-site installation of heating gas respectively heating oil fired natural or forced air supplied industrial fired heaters.

1.1.2 Technological task of the fired heater is to heat some medium (partial or full evaporation thereof) to the requested extent.

1.1.3 The design tasks for this reason can be divided into two – closely correlating - themes:

− designing resp. selection of the fired heater on basis of the technological designation and parameters,

− designing of the fired heater to position (installation, foundation plan, pipe connection, then piping plan, instrumentation plan, electrical plan).

− Major elements of the fired heater block: burners, combustion air and flue gas fans, inner tubes, chimney, heat recovery devices, furnace lining, soot blower, piping system blower, safety steam system, protection against fire and explosion, bursting doors, inspection windows, gas concentration meter, steel structure, operator’s walkways.

1.1.4 For the design of the fired heater, data as specified in the delivery contract shall be provided as data supply in form of data sheet (parameters of the material to be heated and those of the fuel, auxiliary material and auxiliary energy data, conditions for connection, handling, servicing and maintenance, issues correlating with the heat recovering device, etc.).

1.1.5 Vendor shall guarantee adequacy of the fired heater as an equipment complex consisting of several units including burners (combustion chamber thermal load, flame temperature distribution, furnace lining, heat receiver device, furnace regulation, etc.). The equipment shall operate properly in its integrated state.

1.2 Alternative designs If the Vendor offers an alternative design deviating from the project specification or from the inquiry documents but equivalent with that, it can be accepted by a written consent of MOL Group.

1.3 Conflicting requirements Should any contradiction exist between this specification or the project specification and the content of the delivery contract, then the contract is dominant.

1.4 Definition of terms

For purposes of these specifications, the term definitions used in API 560 standard are accepted.

1.5 Referenced publications Heaters shall be designed in accordance with the latest revisions of all codes and standards referenced herein.


Rev 1.00.01 5/21

• API 560 Fired Heaters for General Refinery Services • API 530 Calculation of Heater Tube Thickness in Petroleum Refineries • Laws, standards and MOL Group’s requirements stated in part MGS-M-REF-M-1.0, • Machinery Directive 2006/42/EC • ATEX 94/9/EC and 99/92/EC • API 573 Recommended Practice for Inspection of Fired Boilers and Heaters • MGS-M-REF-M-6.1 and MGS-M-REF-M-6.1.4.2 Requirements of Inspection and

checking, Fired heaters

2. Requirements for construction and equipage On basis of API 560 standard and MOL Group practices. MOL Group prefers fired heaters of forced air supply, but this shall be collated in all cases with MOL Group.

2.1.1 Requirements for safe operation of the fired heaters

2.1.1.1 Working safety equipage for fired heaters (HSE) a) To the inspection window, compressed air is led to prevent occurrence of flame

blow-out. b) For cleaning of tubes fired heaters:

According to MOL Group’s instrumental specifications MGS–S-REF-I -21.

2.2 Required connections

2.2.1 Draught measurement: on level of the burners, at bottom of the convection zone under and above the butterfly,

2.2.2 See Appendix.

2.2.3 Oxygen analyzer: above the convection zone,

2.2.4 Flue gas temperature measurement: in the radiation zone, at top of the radiation zone, at top of the convection zone, under the butterfly valve. In case of high temperature heaters two pieces of temperature measurements are required.

2.2.5 Air quantity to fuel gas ratio: to be regulated on basis of the oxygen analyzer.

2.2.6 Emission values (flue gas NOx, flue gas SOx) Over 1.4 MW value emission measurements is compulsory. This in all cases shall be collated with the MOL Group. The oxygen analyzer and the emission meter shall be separate instruments.

2.2.7 Inspection slots – for all burners and full inspection of the tubes – safety doors and manholes are required.

2.2.8 Fire extinguishing steam is requested into the combustion chamber, steam curtain around the furnace.

2.2.9 Sectioning fittings of the fire extinguishing steam, the steam curtain and the operator shall be accommodated at a common place, at safe distance, beyond a fire protection wall.


Rev 1.00.01 6/21

2.2.10 Inlet-, outlet- and bypass fittings of the furnace shall be designed to a safe distance, in a collector-like manner.

2.2.11 Possibility for blinking of each furnace branch shall be provided on the fired heater itself and, for each furnace branch application of a nozzle of minimum DN 50 size with blind flange is required.

2.2.12 The chimney butterfly (chimney lid) shall be provided with position indicator.

2.2.13 All instruments, instrument nozzles, flanges as well as inspection slots shall be accessible from operator platforms.

2.2.14 The inner refractory of the fired heater and pipe supports shall be fabricated from heat-resistant steel suitable for the given thermal load.

2.2.15 The flame of burners shall not reach the tubes, not even at 125 % load, at the design air excess.

2.2.16 Inlet and outlet conduits and passages of the fired heater branches shall be so designed that the load of each branch is equal; with installation of control elements, if required.

2.2.17 The distance between the lowest structural elements of the fired heaters and the floor concrete (clearance height) shall be minimum 2200 mm.

2.2.18 For access of the radiation zone a manhole shall be provided on the floor plate for the vertical fired heaters and, on both ends for the horizontal fired heaters.

2.2.19 For handling of the burners each an inspection slot shall be provided. For checking of the refractory of the combustion compartment and tubes of the radiation zone as much inspection slots shall be provided as sufficient for observation of all tubes and the entire refractory. Safety (burst) doors (explosion dampers) are requested.

2.2.20 Connection for the fire extinguishing steam shall be designed. As fire extinguishing steam, only superheated steam can be used.

2.2.21 For each branch of the fired heater, before the connection flange, a DN 50 nozzle with blind flange is required for such purposes as drying of the fired heater, coke burning-off, etc.

2.2.22 Heat recovery pipes of the fired heater shall be capable of bearing the thermal load under normal operation of the fired heater, even without stream.

2.2.23 Pipe supports inside and outside of the furnace shall be solved in such a manner that occasional vibration of the piping is not transferred to the external piping system.

2.2.24 The fired heaters shall be so designed that the tubes will not become damaged, not even at 125 % fire load, at the design air excess.

2.2.25 Over 1.4 MW furnace capacity minimum 3 burners are requested.

2.2.26 Integration of fired heaters of different technological functions within a common


Rev 1.00.01 7/21

casing shall preferably be avoided. This in all cases shall be collated with the MOL Plc.

2.2.27 Heat recovery shall be made to keep the output temperature of the flue gas above the dew point of the flue gas. Issues of the heat recovery in all cases shall be collated with the MOL Group.

2.2.28 Provisions shall be made for protection of the main burners and the pilot flame burners against mechanical clogging. The main burner filter and the pilot flame burner filter shall be redundant and, independent of each other. Design of the filters shall facilitate their changeover during operation of the furnace. Requirements for the filter (mesh) shall be specified by the fired heater or burner vendor.

2.2.29 If integration of soot blower is proposed by the furnace vendor and approved by MOL Group, then it always belongs to scope of delivery of the fired heater vendor.

2.2.30 The fired heater refractory shall be capable of bearing the effect of the fire extinguishing steam.

2.2.31 Data supplying obligation of the furnace vendor extends also to the units which according to the contract do not belong to scope of his delivery. These can be the following: fan, blower, combustion air and flu gas conduits, instruments, etc.

2.2.32 Further data supplies: a) pressure of fuel gas before the burner shall be specified by the burner

manufacturer, b) foundation data.

2.2.33 Construction and design of individual equipment parts shall be resistant to meteorological conditions, loading impacts, vibrations and operating pressure and temperature.

2.2.34 Fired heater shell construction shall allow carry out uncomplicated maintenance of internal fired heater parts – their assembly, disassembly and replacement.

2.2.35 Radiation tube system shall not be in direct contact with burner’s flame.

2.2.36 The heat dilatation conditions shall be taken into account by the fired heater design including refractory.

2.2.37 Fired heater shall be situated in ventilated spaces.

2.2.38 Fired heater construction shall not allow the water ingress into the combustion space, duct system, combustion air system, etc.. Atmospheric water and snow shall be drained from shell horizontal surfaces.

2.2.39 Construction of fired heater parts, which are plugged or polluted, shall allow its uncomplicated cleaning and maintenance.

2.2.40 Construction of heating, which is determined for liquid fuel material using or combination of liquid fuel material and gas using, shall allow steam purifier cleaning use.


Rev 1.00.01 8/21

2.2.41 Parts with low lifetime shall be replaceable. Faulty installation possibility of these parts shall be excluded by its construction.

2.2.42 Regularly cleaned parts shall be easy accessible and simply disassembled. Maintenance shall be carried out without special kit using.

2.2.43 Joints of individual parts shall not be spontaneously released during the fired heater operating.

2.2.44 Construction of adjusting and safeguarding device shall eliminate the spontaneous change of adjusted position of them during fired heater operating. Design of control devices shall allow the simple operation of equipment.

2.2.45 Control devices (hand wheels, arm of fittings, manual switches, button switches) shall meet the requirements of ergonomics in point of view of their location and using.

2.2.46 Safeguarding or emergency devices shall be marked according to relevant standard and shall be easy accessible.

2.2.47 Fired heater shall be equipped by relevant number of observation doors due to combustion inspection or tube system inspection. Observation doors shall be equipped by covers and shall allow safe and reliable observing.

2.2.48 Observation doors for radiation chamber shall be designed for non-contact measuring of piping surface temperatures.

2.2.49 Each fired heater with forced combustion air flow shall be minimally equipped by one explosion damper, which shall have minimal active surface [m2] determined by formula 0,001 x volume of radiation chamber [m3]

2.2.50 Rectangular observation doors for each radiant chamber shall have dimensions minimally 600 x 600 mm. Circular observation doors are not allowed.

2.2.51 One observation door shall have dimensions minimally 600 x 600 mm or 600 mm in diameter for the stack and convection sections.

2.2.52 Access openings, which are determined for operating and cleaning, shall be reliable and tight closed and its spontaneous release and opening is not allowed during the operating.

2.2.53 Fired heater closed spaces shall be reliable sealed in the case of harmful substances occurring into them due to avoid of these substances leakage into working area.

2.2.54 The sampler shall be situated above the convection section due to content of oxygen, CO, CO2, NOx determination.

2.2.55 The floors of platforms shall be manufactured from zinc coated steel grating.

2.2.56 If is the main inlet gas valve situated above the fired heater in this case the main inlet gas valve shall be accessible by staircase or ladder with platform.


Rev 1.00.01 9/21

2.2.57 Working areas shall meet the requirements of hygiene rules in point of view of noise and vibrations according to relevant valid laws and regulations.

2.3 Construction from combustion standpoint

2.3.1 Fired heaters operating shall meet the requirement of gas fuel economical utilization. The solution of waste heat energy utilizing shall be designed.

2.3.2 The piping system fouling resistances shall be taken into account for heating efficiency design carrying out.

2.3.3 The heating fired heater project shall respect the heat energy requirements, which are needed for fired heater start, further it shall respect the requirements of technological procedures and requirements of fired heater pipes regeneration (decoking) and regeneration of reactor catalyst.

2.3.4 Construction solution shall contain the case of depressurizing and shutting down of fired heater when the pipe system feedstock flow is stopped.

2.4 Requirements for instrument arrangement

2.4.1 All instruments and inspection slots shall be accessible from operator platforms.

2.4.2 The interlocking system and other instrument-related issues are discussed in the MGS-S-REF-I-21 instrumentation specifications.

2.4.3 Details of electric motors required for the fans are discussed to details in the MGS-S-REF-E-4.10 electric specifications.

2.4.4 Each gas distribution pipe system shall be equipped by gas pressure (gauge) device. If the burners and its pipe system work with pressure air, in this case each of the burner and its pipe system shall be equipped by combustion air pressure gauge measurement.

2.5 Aspects for positioning of the fired heater

2.5.1 Aspects of the installation Possibilities of installation of the fired heater are determined primarily by rules of law. It is expedient to accommodate the fired heater at a separated place within the plant, possibly in a separate fire section.

2.5.2 Imported equipment shall be in conformity also with the domestic laws and standards. Therefore, occasional permits for deviation from the standard shall be collated with MOL Group.

2.6 General considerations for piping and duct connecting to the fired heater a) technological piping (radiation, convection, etc.) b) piping for fuel supply (does not belong to the furnace) c) auxiliary piping d) flue gas ducts e) combustion air duct (in case of closed systems).


Rev 1.00.01 10/21

2.6.1 When installing the fired heater, care shall be paid on serviceability of the fittings and possibilities for maintenance of the same.

2.6.2 Operator’s platform shall be provided to the burners and inspection windows. For size and load bearing capacity of the platform the maintenance requirements shall be taken into account.

2.6.3 Nozzles of the fired heater shall be so designed as to receive the loads transferred from the connecting piping (e.g. thermal expansion).

2.6.4 Application of compensators shall be preferably avoided. Quality of the pipe materials shall be suited to temperature of the streaming medium. In case of higher pressure values adequate duration strength shall be ensured.

2.6.5 In case of hydrogen base material, hydrogen pressure-proof material shall be used.

2.6.6 The fuel gas and fuel oil piping shall be provided with heat tracing and heat insulation.

2.6.7 For designing process and other piping the possible shortest construction ensuring low heat losses shall be chosen.

2.6.8 Diameter of the piping shall be so defined acc. to API 530 that the volume flow rate of the material heated up in the fired heaters and turning partially or fully into steam - taking into account the temperature and pressure values – is such that the pressure drop occurring in the system up to the next equipment (reactor, column, etc.) does not exceed the permissible value.

2.6.9 Possibility shall be provided for blow-out of the technological piping. This, depending on nature of the plant, can be e.g. steam, air or inert gas. In all cases the connection of the blow-out shall be so designed that the blow-off medium can be applied into the technological medium only in the requested case and direction, excluding entering in case of leaks of fittings (dual fitting with vent, blind flange connection with fitting, check valve, etc.).

2.6.10 For multi-section entry or due to any other reason, installation of cut-off fitting (e.g. control circuit or safety interlocking) into the inlet and outlet piping of the fired heater may become necessary. In such cases adequate provisions shall be made on exclusion of unauthorized cut-off (padlocking in opened state, or forced coupling).

2.6.11 Material of pipes for fired heater and its maximal allowed working temperature shall be selected according to API 530 or AD-2000.

2.6.12 Pipes for fired heater manufacturing shall be seamless.

2.6.13 Piping surface for heat exchanging is possible to enlarge by pipe ribbing using. Ribbing of piping shall be wrapped around the pipe and welded.

2.6.14 Removable pipe system joints shall be sufficiently reliable and sufficiently tight. These joints shall not be installed in the combustion chamber.


Rev 1.00.01 11/21

2.7 Piping and duct of the burners Piping of the burners is constituted by the fuel gas, fuel oil, atomizer steam, inert gas and instrument air and, in case of forced combustion air duct.

2.7.1 Aspects for design of the fuel gas piping a) Possibility for venting, blow-off into flare or atmosphere e.g. to safe location b) In case of refinery fuel gas, drainage of the condensate hydrocarbon respecting

heating and insulation on the section before the burners (when cooling in winter, against penetration of the fluid produced by condensation after the control valve, into the combustion compartment).

c) Provisions for uniform distribution of the gas for each burner, in case of several burners.

d) Gas fuel distribution pipeline consists of main closing valve, filters, water separators, de-aerators, pressure regulators, protection facilities, pressure measurement facilities, temperature measurement facilities and of next facilities, which are installed in pipe system and which are in contact with the gas fuel.

e) The construction of gas fuel distribution valves shall meet the requirements of distributed medium and its working pressure. All piping materials shall be supplied with mill certificates 3.1 in accordance with EN 10204.

f) The main closing valve shall be installed before each fired heater. This closing valve shall ensure safe and reliable closing of fuel gas input into the fired heater.

g) Piping system, where is the condensate created, shall be designed with gradient minimally 0, 5% and this piping system shall be drained.

2.7.2 Fuel oil piping Provisions shall be made for heating, insulation, blow-off, draining of fuel oil piping as well as for avoiding occurrence of dead spaces and provisions for recirculation in certain cases.

2.7.3 Vaporizing steam piping Provisions for dewatering of vaporizing piping, pressure adjustment a higher value (approx. poil + 0.5 bar) referred to pressure of the fuel oil. poil + 0.5 bar).

2.7.4 Combustion air duct required in case of forced draught Establishing of adequate cut-off and manifold fittings for forced-draught air duct required for combustion, installation of sensor elements (P, F, T) of interlocks correlating with actuation of fans. Place of air suction (e.g. from explosion-free zone, actuation of stand-by fan e. g. collector or provision for changeover). The end of air suction duct shall be supplied with screen and winterization.

2.8 Auxiliary piping

2.8.1 Steam piping For soot blow-off, combustion compartment flooding (fire extinguishing steam), steam curtain or either for furnace starting as cooling medium for substitution of the technological material. It is important to ensure in all cases:

a) dewatering of the steam before entering, b) entry only at the wanted time (avoiding, excluding leaks),


Rev 1.00.01 12/21

c) handling from adequate distance (e.g. from 20 m fire extinguishing steam, steam curtain),

d) acoustical signal before steam curtain starting.

2.8.2 Air piping E.g. for soot blow-off or fuel oil back-pressing (into tank). Entering of unwanted air into the system shall be always avoided e.g. by sectioning, but protection against penetration of any foreign medium (steam, fuel oil) shall be also provided (check valve, blind flange, etc.).

2.8.3 Inert gas piping Inert gas piping is used for ventilation of the fuel gas system or, for protection of the technological system in case of fire (H2 furnace). Quick and safe intervention shall be made possible at adequate pressure but in such a manner that the technological material may not contaminate the insert gas system.

2.9 Flue gas exhaustion

2.9.1 Composition and quantity of the combustion products that is flue gas leaving the fired heater are determined by the nature of the fuel (refinery heating gas, natural gas, heating oil, vaporizing steam, etc.) and the air excess applied.

2.9.2 The temperature of the combustion products is influenced by the operating temperature and internal construction (radiation zone, convection zone, steam over heater, etc.) of the fired heater. Exhaustion of the flue gas to the atmosphere is effected through a stack or, it is passed through a heat recovery device preceding the stack. When installing a heat recovery device, however, possibility for direct exhaustion to the stack shall be also provided. Routing of the flue gas into proper direction is effected by damper (these can be either manually or automatically controlled devices).

3. Burners

3.1 The burners’ construction shall guarantee maximal heat energy transferring to pipe system and simultaneously shall meet the requirements of hygiene regulations and relevant standards.

3.2 The burners shall guarantee reliable combustion of fuel gas and flame diffuse without the impulse noise in the cold state, stationary state and for whole regulation band. Burners flame shall be stabile for all the operation states. Noise level shall not exceed 80 dB (A).

3.3 The construction of burner shall guarantee reliable control of flame lighting and burning.

3.4 The distance between the burners and the tubes shall be checked to verify that the flame don’t impinge on the tubes if the burners are operated at their maximum heat release.

3.5 Each fired heater shall be equipped by burners´ ignition device.

3.6 The flame sensor shall react only on the burner’s flame for which is intended. The flame sensor must not react on another source of heat or light energy.


Rev 1.00.01 13/21

3.7 The installation of burners shall guarantee simple disassembly, inspection, maintenance and repairing. The burner type shall be removable while heater is operating.

3.8 Burner’s box shall be designed as one unit. Burners´ box design shall take into consideration the condition of thermal dilatation of burners´ box independently on fired heater insulation lining.

3.9 Material and construction of burner shall be resistant against the deformation, which can be caused by temperature influence.

3.10 Burner parts on which are situated gas flux orifices shall be manufactured from that material that resists to fuel medium.

3.11 Gas fuel jets shall be durably marked by numbers, which determined the diameter of orifice in tenths of millimetre.

4. Combustion air pre-heater

4.1 The air pre-heater shall allow safe regulation of combustion air flow and simple adjustment of flame shape.

4.2 Combustion air pre-heater design shall guarantee delivery of required combustion air volume for burners. Operating of pre-heater shall not have an impact of prescribed emission limits of combustion products in consequence of excess or deficit of combustion air.

4.3 In case combustion air-pre-heater is required the design and delivery of stationary combustion air pre-heaters shall be of minimal maintenance and operating expenses, simple operating etc.

4.4 Combustion air pre-heater design shall allow simple cleaning.

4.5 Combustion air pre-heater shall be equipped by hot insulation which shall be removable type. The hot insulation shall be applied on the registers, guillotine blinds or special dampers.

4.6 Minimally one ventilator of combustion gases and two combustion air ventilators (one for reserve) shall equip combustion air pre-heater.

4.7 Te project shall solve the bypass of pre-heater for the case of operating in emergency (e. g. pre-heater system malfunction).

5. Fireproof lining, materials (HSE)

5.1 Design of hot insulation shall meet the requirements of maximal thermal energy saving. The surface temperature of radiation, convection section and duct system shall not exceed the temperature 60°C at the ambient air temperature 30 °C (see also Appendix SN – additional rules valid for Slovnaft refinery, point A.3).

5.2 The design of fireproof lining shall take into consideration the dilatation of each fired heater part. For multilayered insulation material using shall be designed lining connection


Rev 1.00.01 14/21

cleardowd.

5.3 The wall lining, where the burner flame is in direct connection with lining, shall be designed for minimal temperature 1550 °C or care shall be taken to prevent from having higher temperature.

5.4 For vertical walls ceramic fibre modules shall be used only. The lining material shall meet the requirements of its using by determined temperature. The fixing elements and the procedure for installation of lining shall be provided by Vendor.

5.5 . The burner blocks shall be designed for minimal operating temperature 1650 °C.

5.6 The manufacturer of refractory and the designer of the refractory shall supply the following specification:

Preparation of lining installation Refractory material data sheets Instruction of lining installation including drying procedure Inspection and test plan including the acceptance criteria

5.7 Access doors shall be protected against the radiation heat by fireproof material.

5.8 Each vertical wall of fireproof lining shall be anchored and supported by suitable construction steel. Anchor materials shall be designed according to API 560.

5.9 Steel supports of fireproof lining shall be firmly connected to the frame of fired heater shell.

5.10 Refractory concrete shall be used for all fired heater parts casting. Maximal allowed fired heater parts thicknesses, which are cast, is 200 mm.

5.11 The thickness for header box, duct system and stack can be minimally 50 mm.

5.12 The dilatation joint shall be designed around the burners´ box, fireproof lining and around all parts of combustion chamber.

5.13 Ceramic insulation fibrous or plate material can be used in all spaces of fired heater except for fired heater bottom, stack and duct system.

5.14 Minimal thickness of ceramic fibrous material and its assembly shall be carried out according to API 560.

5.15 Fireproof lining or refractory concrete installation into fired heater shall be carried out according to manufacturer’s instruction drying process timetable.

6. Stack, duct system and combustion chamber

6.1 The stack can be separated or accommodated on top of the furnace. When sizing the stack, the local regulations and standards in force shall be taken into account.

6.2 Diameter of the stack shall be determined on basis of quantity of the flue gas, draught demand of the furnace, respective on that of the working conditions of the flue gas fan (if


Rev 1.00.01 15/21

any). When determining the height of the stack, technological draught requirements, shall be taken into account.

6.3 Design of fired heater shall assign effective and reliable refresh (ventilation) of combustion space and duct system before torching of the first burner. During combustion space ventilation shall be the fuel gas input closed.

6.4 Design of combustion space, combustion chamber and duct system shall eliminate permanent accumulation of combustion gases condensate.

6.5 The stack, duct system and combustion product chamber shall be jointed by removable joints (bolts and nuts). These joints shall not be carried out by welding.

6.6 All stack; duct system and combustion product chamber openings (bolted joints, control openings) shall be hermetically sealed (gas tight).

6.7 When is more fired heaters connected to one common stack, in the case each fired heater shall be equipped by independently operated stack lid.

6.8 Thickness of stack shell shall be minimally 6 mm, thickness of duct system shall be minimally 5 mm including corrosion allowance.

6.9 The top of the stack shall be at least 6 m above the highest access platform, within a radius of 15 m around the stack.

6.10 The stack height shall be specified in accordance with the maximum permissible (by law or working environment std.) concentration of pollutant at grade inside or outside the plant fence.

7. Heat recovery

7.1 Utilization of the heat content of the flue gas – depending on its temperature and quantity – is expedient and necessary from energy points of view as well as on basis of technical considerations (e.g. due to the permitted maximum temperature for entry into the chimney). The most often used method for heat recovery is the steam generation, but it can also be utilized for air pre-heating or warming of the heating oil, too.

7.2 The heat recovery unit shall always be so designed that its operation or its halt down may not influence operation of the furnace and the changeover of the flue gas from the heat recovery unit directly to the stack may not result in interruption of the operation of the furnace. This shall be ensured by adequate forced couplings of the damper and the flue gas fan to each other.

7.3 The damper shall be suitable to bear the temperature differences between max. flue gas and normal environmental.

7.4 Even in case of partial or full utilization of the generated steam within the plant in general provisions shall be made for input of the steam into the header line respecting for satisfaction of the actual additional demand of the plant. Pressure of the generated steam shall be determined by the maximum pressure of the receiving system respecting by the regulated pressure thereof. In case of fuel oil or fuel gas it is expedient to generate steam


Rev 1.00.01 16/21

of 3-5 or 10-12 or 30-32 bar overpressure complying with the refinery’s steam system.

7.5 On one hand, the heat content of the flue gas can be best utilized in this manner whilst, on the other hand, this way can be ensured that the flue gas will not cool below the recommended 200 °C temperature where the sulphuric acid developing at the dew point may cause serious corrosion to the chimney structure or, it necessitates redundant cost raising e.g. due to acid-proof lining.

8. Safety-technique equipment

8.1 Safe operation of the fired heater is facilitated by proper design of accessories of the furnace and, the safety equipment. Safety-technique equipment of the furnace and conditions of the application thereof are determined by relevant local rules of law. The safety-technique equipment is furthermore determined by occasional authority specifications (e.g. steam curtain, gas concentration detector, etc.), too. These specifications depend on thermal power of the furnace, parameters of the heated material, mode of firing and, on accommodation conditions of the furnace. Safety of the furnace is served by the way of its matching into the entire technological system, determined by the technological conditions.

8.2 When designing safety-technique equipment of the furnace, fundamentally the following shall be taken into account:

a) Adequate design of the burner (oil burners, gas burners, mixed-firing burners), venting, with firing interlocking conditions, back-fire arrester.

b) Firing flame burner can be of fixed (pilot flame). Spark ignition or freely movable (flare) design,

c) The combustion safety device (flame guard) detects the flame and on extinction of the flame it outputs an adequate interlock intervention signal (e.g. halting of fuel supply).

d) Combustion product exhaustion (stack: The construction of the combustion product exhaustion is determined, in addition to fire protection specifications, by environment protection aspects, too.

e) Cut-off and adjusting fittings: Facilitate quick cut-off resp. requested adjustment of the fuel lines.

f) Interlocking system: Establishes pre-determined interventions in case of parameters representing definite hazard (e.g. heating halt, or material stream change, etc.).

g) Automation: Checks determined parameters of the fired heater by instruments and, regulates the parameters (temperatures, pressure values, quantities). (Above mentioned rules are included in the local law.)

a) Input of fire extinguishing steam into the combustion compartment and into the turning chambers (in case of pipe rupture or leakage, by manual intervention).

b) Steam curtain: For prevention of explosion hazardous mixtures originating from external hydrocarbon source getting to the burners.

c) The steel supporting structures shall be provided with fire-proof coating, to increase the fire-proofness.


Rev 1.00.01 17/21

9. Manufacturing and assembling

9.1 Manufacturing conditions

9.1.1 Only organizations, which are certified by relevant notified body for fired heater manufacturing, should manufacture, assemble and reconstruct the fired heaters.

9.1.2 Organizations, which produce technological fired heaters, shall use maximal number standardized parts for its design. .

9.1.3 Fired heater shall be manufactured according to technical documentation (technological procedures, welding procedures, etc.), which is accepted by MOL Group. MOL Group shall agree all fired heater’s manufacturing changes.

10. Testing

Inspection and test requirements to be followed are determined in MGS-S-REF-M-6.1 and MGS-M-REF-M-6.1.4.2.

11. Guarantee

11.1 Manufacturer is obliged to warrant that the equipment delivered is free of design, fabrication (production) and material defects and that it is of adequate (as specified) size and volume and, it is made of materials adequate to meet the specified conditions.

11.2 In addition to the mechanical guarantee described in above the vendor shall guarantee that:

a) Five years non-interrupted unit operation due to coking. b) The equipment will render satisfactory performance under continuous operation at

design conditions outlined on the fired heater data sheets. c) Satisfactory performance includes operation at the design throughput, at the design

heat absorption and specified process temperatures, at or below the specified pressure drop.

d) The thermal efficiency will not be less than that stated on the data sheet. e) The noise level will not exceed that stated on the noise data sheet. f) That heater parts are suitable for operation at up to 125% of design heat release with

10% excess air. g) Flue gas emissions (NOX, CO, particulates, hydrocarbons, etc.) will not exceed the

specified levels, in project specification of contract. h) Approval of drawings for construction, or release of equipment by an authorized

inspector, shall not relieve the vendor of responsibility for the heater nor alter the conditions of the guarantee.

12. Major requirements for on-site installation and adjustment

12.1 For operation of the fired heaters distinguished attention is requested because in case of both the process medium and the naked-flame firing equipment these hazards may sum up, during the course of installation, mounting and commissioning the following rules shall be adhered to:


Rev 1.00.01 18/21

i) When first putting the fired heaters into operation, the specifications of the Manufacturer shall be in all respects obeyed.

j) Duration of flooding of the furnace by steam shall be at least 10 minutes. k) By flooding of the space around the furnace it shall be impeded that combustion could

be caused by hydrocarbon pollution streaming from another area. l) Steel legs of fired heaters standing on legs and their bottom horizontal supports shall be

provided with fire-resistant coating (minimum 3-hour fire resistance value). m) Installation, mounting: The fired heater shall be installed preferably to the border of the

plant. In addition to specifications of the National Fire Protection Regulations (protective distances, access and through-pass, fire fighting places, etc.) the following shall be taken into account:

− area-, device and operation requirements for maintenance, − provisions for accessibility, serviceability, mounting and communication

clearances, − provisions for adequate lighting and pavement, − provisions to enable pull-out of fire tubes of the fired heater and internal parts of

the equipment, − adequate motion of the transporting vehicles shall be facilitated, − stable hoisting device shall be accommodated at adequate places, − power connections (electric, steam, water, inert gas, etc.) for maintenance shall

be installed.


Rev 1.00.01 19/21


A. Requirements for construction and equipage A.1 In point of view of health safety and safety of technical appliances the fired heaters

are considered as “classified technical equipment. Note: “Classified technical equipment” is equipment determined by Public Notice No. 508/2009 Coll. and the requirements of this Public Notice shall be applied to such equipment.

A.2 Fired heaters are sources of air pollution therefore the examination, control and evaluation of emission shall be carried out for such equipment. These appliances shall meet the requirements of Public Notice No. 356/2010 Coll.

A.3 Design of hot insulation shall meet the requirements of maximal thermal energy saving. The surface temperature of radiation, convection section and duct system shall not exceed the temperature 50°C at the ambient air temperature 30 °C.

B. Required connections B.1 Allowable surface temperatures of fired heater parts, where direct contact by

operator can occur, shall be determined by STN EN 746 - 2 (valid in the Slovak territory).

B.2 Each fired heater shall have sufficient operating areas for operators; dimensions are recommended according to STN EN 746 – 2.

B.3 Working areas shall meet the requirements of hygiene rules in point of view of noise and vibrations according to relevant valid Slovak laws and regulations.

C. Requirements for instrument arrangement C.1 The valve with electrical actuator shall meet the technical requirements of STN 07

5820 (valid in the Slovak territory).

D. Point 2.5.10 Requirements for protection facilities D.1 2.5.3.10.1Protection facilities for gas-fired heaters shall be designed according to

STN EN 746 – 2. Construction of protection facilities shall ensure automatic gas fuel input closure for all burners.

D.2 Electrical equipment requirements: D.3 Electrical equipment of fired heater shall meet the requirements of relevant valid

Slovak laws and regulations. D.4 Electrical equipment shall be connected from one power supply (source of voltage)

with using of main switch, which control element settings are marked by “0” and ”1”. Interruption of power supply and its repeated restoration or incorrect manipulation with control elements shall not cause dangerous state or endangering of operators safety.

D.5 Interruption of power supply and its repeated restoration or incorrect manipulation with control elements shall not cause dangerous state or endangering of operators safety.


Rev 1.00.01 20/21

D.6 Fired heater shall be protected against atmospheric or static electricity impacts according to relevant valid Slovak standards (STN 33 2030 – valid on the Slovak territory).

D.7 Lighting of work place shall ensure easy and safe orientation for control elements using and the light intensity shall be selected according to STN 36 0004 (valid on the Slovak territory).

E. Aspects for positioning of the fired heater E.1 Public Notice No. 508/2009 Coll. concerning the safety of health and safety of

technical equipment (technical equipment subjected to acceptance by relevant authorized body).

F. Piping of the burners F.1 Selection of pipes and piping material is recommended to carry out according to

STN 42 5710; STN 42 5711 – seamless threaded steel pipes (valid on the Slovak territory).

F.2 Austenitic material of furnace pipes shall be stabilized. F.3 Intergranular (intercrystalline) corrosion test results shall be an inseparable part of

furnace pipes attests for pipes made from austenitic material F.4 Flange and threaded joints can be used only in the substantiated cases. Threaded

joints can be used only to DN 50. F.5 The designing of gas fuel distribution system, regulation devices of fuel gas, gas-

tight closures, vents, drains, samplers etc. shall meet the requirements of STN EN 746 - 2.

F.6 Closing valves can be hand-operated or closing valves can be equipped by actuators (hydraulic, electric or pneumatic actuator). When actuator equips the valve, in this case shall be the settings “opened – closed” indicated in the operating room.

F.7 Fired heater gas piping shall be visibly installed for inspection and its installation shall meet the requirements of STN EN 746 - 2.

F.8 Gas pressure regulator shall be used for gas pressure reduction and its holding on the constant value in the piping systems for fuel gas.

F.9 Gas pressure regulator shall be installed on the safely and easily accessible places, which are enough ventilated. Gas pressure regulator shall be protected against extreme temperatures, vibrations and corrosion influences. The space above membrane is possible to vent together with safety valve by one vent pipe using. The closure device shall not be installed on the vent pipe.

G. Burners G.1 Manual ignition burners can be connected to gas piping system by rubber hose. G.2 The fired heaters shall be equipped by ignition and inspection slots, eventually by

one opening, which is intended for both activities. When are the burners equipped by electric ignition device in this case the ignition openings are not required.

H. Stack, duct system and combustion chamber


Rev 1.00.01 21/21

H.1 If the fired heater isn’t equipped by own chimney, in this case is possible to connect the fired heater to common chimney by central duct system.

I. Point 10. Testing I.1 According to Public Notice No. 508/2009 Coll. some parts of fired heaters are

considered as a “classified technical equipment” and such parts shall be subjected to acceptance by relevant notified body (in Slovak republic is it Authorized Legal Person). These parts shall be designed, manufactured, tested, supplied and commissioned according to this Public Notice.

J. Point 10.2 Assembly testing J.1 After the assembly of fired heater the assembly organization shall carry out the

pressure and tightness test of fuel gas piping. Pressure tests shall be carried out according to STN EN 746 - 2.

K. Point 10.4 3 Testing operation (run test) K.1 The conditions for fired heater commissioning and testing operation are defined by

STN EN 746 - 2. K.2 The STN 38 6405 - Gas equipment. A principle for operation– is mandatory for fired

heater operating.

L. Technical documentation requirements L.1 The scope and content of documentation for fired heater parts shall be determined

in accordance with Public Notice No. 508/2009 Coll.



MOL Group


1. Static Equipment

3. Heat Exchangers

1. Shell and Tube Heat Exchangers

MGS – S – REF – M – 1.3.1

Rev. 1.00.02


MGS-S-REF-M- 1.3.1 Refining & Marketing TECHNICAL SPECIFICATIONS - MECHANICAL Release: Rev. 1.00.02 Static Equipments Date: 29.02.2016 Shell and Tube Heat Exchangers Page/Pages: 2/11


Release list


0.00.00 31.12.2005 Basic release


MGS-S-REF-M-LI




Rev. 1.00.02 3/11

Contents

1.1 Scope ..................................................................................................................... 4 1.2 Alternative designs ................................................................................................. 4 1.3 Conflicting requirements ......................................................................................... 4 1.4 Definition of terms ................................................................................................... 4 1.5 Referenced publications ......................................................................................... 4 1.6 Design requirements ............................................................................................... 4 1.7 Corrosion ................................................................................................................ 6 1.8 Body flanges ........................................................................................................... 7 1.9 Stacked units .......................................................................................................... 7 1.10 Tube bundle ............................................................................................................ 7 2.1 Nozzles, flanges and gaskets ................................................................................. 9 2.2 Supports ................................................................................................................. 9 2.3 Size tolerances ..................................................................................................... 10

Appendix - additional rules valid for Slovnaft refinery…..………………… ……..……….10


Rev. 1.00.02 4/11


1.1 Scope This specification together with other relevant specifications contains the main requirements for design, fabrication and inspection of the tube and shell heat exchangers.

1.2 Alternative designs If the Vendor offers an alternative design deviating from the project specification or from the inquiry documents but equivalent with that, it can be accepted by a written consent of MOL Group. In some applications, it is acceptable the heat exchanger not to comply with all of the standards listed in the point 1.5. In this case the manufacturer’s standard shall be submitted to the MOL Group for approval. These cases can be: flue gas cooler, heater for storage tank, boiler blow down cooler, air heater.

1.3 Conflicting requirements Should any contradiction exist between this specification and the content of the delivery contract, then the contract is dominant.

1.4 Definition of terms For purposes of these specifications the determination of terms included in the TEMA, EN and the ASME VIII/1 specifications are accepted.

1.5 Referenced publications

1.5.1 Each heat exchanger as minimum shall conform with the last editions of the following specifications and standards, unless otherwise stipulated in the given specification.

1.5.2 Of the listed standards MOL Group marks by underlining the standard according to which the equipment has to be designed and fabricated. This standard shall be consistently employed. Deviation from this can be made with MOL Group’s approval only.

a) Safety Regulations for Pressure-Containing Vessels (local law)b) Pressure Equipment Directive PED (2014/68/EC)c) EN 13445 Unfired Pressure Vesselsd) ASME Boiler and Pressure Vessel Code (in brief: ASME Code)e) TEMA Standards

(Standard for Association of Tube-Bundle Heat Exchanger Manufacturers)f) API 660 / EN ISO 16812 Heat exchangers for general refinery servicesg) ASTM or equivalent European (EN) material quality and material tests.h) Standards stated in chapter MGS-S-REF-M-1.0 General requirements,

Requirements for designi) Requirements of inspection and checking MGS-S-REF-M-6.1, MGS-S-REF-M-

6.1.4.3 and MGS-S-REF-M-6.1.4.4

1.6 Design requirements

1.6.1 Unless otherwise specified, each heat exchanger shall meet the requirements of the TEMA Class R.


Rev. 1.00.02 5/11

TEMA Class B is acceptable in case of oil cooler and water cooler at pump, compressor package.

1.6.2 Minimum design pressure on tube bundle is 5 bar.

1.6.3 If more than one heat exchanger is included in an assembly unit, the heat exchangers shall be designed to maximum extent with use of interchangeable components.

1.6.4 Design of heat transfer:

1.6.4.1 Mean Temperature Difference (MTD) is allowable only when heat transfer curves are available. In case of several series connected heat exchangers the technological design temperature shall be the highest temperature. It is to be considered for strength calculation only.

1.6.4.2 The fouling factors are net values. The tube-side values shall be increased by ratio of the inner and outer surfaces. High-pressure, high-fouling or highly corrosive fluids shall wherever possible be on the tube side of exchangers, though high-fouling fluids should be avoided in U-tubes.

1.6.4.3 On basis of result of preliminary technological calculations the Designer shall define the spacing and arrangement of the deflectors, the cut-out in percentage of the free cross section or the inner diameter and, the type of cut-out for which the jacket-side heat transfer and pressure drop of the heat exchangers have been calculated.

1.6.4.4 Vendor shall check all tube bundles for the stream-caused or sonic vibration and, install mechanical elements as required for reduction of the vibration to minimum. Any modification can be made only with MOL Group's approval. Support or baffle plate distances can be smaller than specified by TEMA, if those are requested for reduction of the vibration. The heat transfer surface and the heat transfer factor shall be referred always to the effective surface of the tubes.

1.6.5 Specifications correlating with the design

1.6.5.1 Pull out tube bundle shall be used only. For application of any other type MOL Group’s consent is required. Below the average 50°C temperature difference rigid tube bundle heat exchangers and below 120°C rigid tube bundle heat exchangers with compensator can also be used, but this also needs MOL Group’s consent. The expansion joint shall have a sleeve welded to the upstream end to minimize deposits in the bellows.

1.6.5.2 U-tube heat exchangers may be used only in case of clean, that is least depositing medium. An advantage of this type is the simple construction and for this reasons it can be applied to high pressures and high temperature differences, too. U-tube heat exchanger shall not be used for water coolers due to the high deposition.

1.6.5.3 Floating head heat exchangers can be used also in case of media apt for dirtying, for high temperature and pressure differences as well. Since after dismounting the external head the turning chamber of the floating head is also dismountable, the entire heat exchanger structure is dismountable. By this, the tubes are accessible for cleaning both


Rev. 1.00.02 6/11

inside and outside.

1.6.5.4 For application of heat exchangers exceeding 15 ton mass and 1200 mm tube bundle diameter, MOL Group’s consent is required due to the maintenance reason.

1.6.5.5 The designer shall specify the way of how to pull out the bundle considering the available local facilities. The tube bundle removal method shall be designed during the detailed design phase. For all the removing bundle with diameter more than 1000 mm bundle, rollers shall be used.

1.6.5.6 The tube bundle shall be provided with ring bolt, push-off screws, tube bundle flange grooving, required for the pull out operation, and fixed tube sheet fastening bolts (4 - 6 pcs.).

1.6.5.7 Tubes of the tube bundle shall be seamless steel tubes. Tubing shall be furnished from single length pieces, circumferential welds are not allowed.

1.6.5.8 When cleaning of the tube bundle is needed, quadrangular pitch shall be designed and used. Triangular and rotated triangular pattern shall only be used in services where the shell side fluid has a low fouling factor.

1.6.5.9 Where the load on one saddle is higher than 2500 kg or justified by the high temperature difference and supporting length, roller-type saddle shall be used. Fix saddle shall be placed near the bigger pipe connecting nozzle. The sliding plate shall be designed to prevent these support elements from deterioration.

1.6.5.10 The maximal dimensions of tube bundles – maximal diameter – 1.5 m; maximal length – 6 m are allowed.

1.6.5.11 Internal system of exchanges shall allow medium draining from all exchanger spaces.

1.6.5.12 For shell and tube heat exchangers where the design pressure of one side is considerably higher than the other, the design pressure of the lower pressure side shall be made 10/13 of that of the higher side. This will avoid the need for provision of relief facilities on the lower pressure side in the event of a tube rupture.

1.6.5.13 Interchangeable tube bundle shall be designed at heat exchangers (e.g. E- A/B/C) if the technological parameter is the same. In addition to the mechanical guarantee described in the Purchaser Order, the vendor shall extend a thermal and hydraulic guarantee covering the performance of the unit for conditions shown on the applicable material requisition. Supplier shall also guarantee unit against flow induced and/or sonic vibration damage.

1.7 Corrosion

1.7.1 Corrosion allowance for metal clad (weld overlaying or bimetal) parts is not needed on the carrier metal, under the metal clad. Total thickness of the metal cladding shall be taken into account as corrosion allowance.

Totally welded clad without any gap with the base material can be acceptable only. The


Rev. 1.00.02 7/11

manufacturer shall justify this.

1.7.2 Thickness of the metal cladding may not be taken into account in tensile strength calculation for pressure.

1.8 Body flanges

1.8.1.1 Each body flange shall comply with specifications of ASME Code VIII. Div.1 or relevant EN standards.

1.8.1.2 The flanges shall be of forged design, with welding neck.

1.8.1.3 In case of application of grooved gaskets, the groove shall be on the tube bundle wall, on the inlet chamber lid and on the turning chamber lid.

1.8.1.4 Quality (roughness) of surfaces contacting the gaskets depends on type of the gasket used. For this reason it shall be always specified with a definite roughness value or, reference to a standard. The surface roughness of the flange face shall be of minimum between 3.2 – 6.3 µm Ra.

1.9 Stacked units

For stacked units, vendor shall shop-assemble and hydrotest the units in the stacked position. As a minimum the vendor shall assemble the stacked units to verify proper flange and support fit-up prior to shipping.

1.10 Tube bundle

1.10.1 The pipes of the tube bundles shall be of min 19.1 mm (3/4 inch) outer diameter and 6000 mm length. In water cooler application the pipes shall be of min 25.4 mm (1 inch). Pipes diameter shall be selected to make possible the water cleaning. Min wall thickness shall be BWG14 (2.1 mm) The tolerance of the tubesheet holes’ diameter shall be harmonized with the tolerance of the tubes outside diameter within the tolerances specified in TEMA. The purpose is to avoid a gap between the tubesheet holes and tubes, which can cause corrosion. The inspection of the welded seam and the acceptance criteria shall be specified by designer. Calculations for tube vibration and verification of compliance to Standard Drawing shall be submitted to MOL Group for review.

1.10.2 Each „U” tube shall be fabricated preferably from one piece. Bending of the „U” tubes may not be less than 1.5-fold rated diameter of the pipes. Should extension of the “U” tubes be unavoidable, then place of the weld shall be at least 200 mm from the curved end.

1.10.3 Only seamless tube shall be used.

1.10.4 Protrusion of the pipes from the tube sheet: min. 3 mm.


Rev. 1.00.02 8/11

1.10.5 Where the jacket-side dirtying can be removed by chemicals or solvents, the pipes can be of triangle arrangement design. For other operation mode the pipes shall be designed in squared arrangement, with a minimum spacing of 6 mm between the pipes. The tube pitch shall be defined according to TEMA.

1.10.6 Holes of the tube bundle wall shall be machined with at least two grooves of 3 mm width and 0.4 mm depth each. In case of metal clad tube bundle walls both grooves shall be in the base material.

1.10.7 Pass partition grooves of the cladded (weld overlaying or bimetal) tube sheets shall also be cladded.

1.10.8 In case of high temperature and pressure, integrated tube sheet and chamber can be used, with MOL Group’s consent.

1.10.9 Erosion plate shall be used in order to prevent the tubes from direct effects (abrasion, thermal shock, etc.). The use of perforated plate is not permitted. The inlet cross section shall meet the TEMA specifications.

1.10.10 In case of application of shell side with longitudinal deflector (type F), the plans of the deflector and the gasket shall be approved by the MOL Group.

1.10.11 In case of hydrogen-content medium or if the design pressure is higher than 70 bar and/or the temperature is higher than 530 °C, the tubes shall be fixed by strength weld to the tube bundle wall.

1.10.12 In case of pipes secured into the tube sheet by pressing the distance between edges of the pipe holes and the seal grooves shall be not less than 2.5 mm; for welded-in tubes 1 mm. The tolerance shall be - 0.5 mm.

1.10.13 The tube bundles shall be provided with skid bars. Minimum two skid bars shall be used, inclined at the bottom to about 15 ° angles from the centre line of the apparatus.

1.10.14 Tube-to-tube sheet joints

1.10.14.1 Regardless of the type of the tube-to-tube sheet joint the first step of the manufacturing procedure is the tube contact expanding in the hole. The purpose of this is to fix the tube in the hole of the tube sheet against turning away in the hole to reduce the risk of crevice corrosion from the shell-side fluid. The thinning of the tubes shall be smaller than 0.05mm.

1.10.14.2 In case of strength welded joints, the procedure of expanding the tubes in tube-hole grooves shall follow the welding process.

1.10.14.3 The following selection philosophy of the application of the tube-to-tubesheet joint shall be followed: 1. Strength welded in cylindrical tube-hole1)

The process criteria for application:


Rev. 1.00.02 9/11

max. temperature difference between shell and tube side is dT < 60 °C or max. pressure difference between shell and tube side is smaller than 15 barg

2. Expanding in tube-hole grooves The process criteria for application: max. temperature difference between shell and tube side is 60 °C<dT<160 °C

or max. pressure difference between shell and tube side is 15 barg <dP<20 barg

3. Strength welded and then expanding tubes in the tube-hole grooves The process criteria for application: max. temperature difference between shell and tube side is larger than dT>160 °C

or max. pressure difference between shell and tube side is smaller than dP>20 barg

Type of third joint shall be applied when the heating medium is steam. (Note: 1) - see also Appendix SN – additional rules valid for Slovnaft refinery)

1.10.14.4 In case of rigid tube bundle heat exchangers, the tube-to tube sheet joints shall be allowed to be prepared by using automatic welding machine only. Deviation from this rule is allowed with MOL’s written consent.

1.10.14.5 For the purpose of verifying by MOL the expanding process for tube-to tubes sheet joints, the probe expanding process shall be applied before commencing the expanding or welding procedure. MOL verification is required in all cases.

1.10.14.6 In case of copper tubes the following manufacturing process shall be applied for tube-to-tube sheet joints:

• brazing for tube wall thickness being up to 1.5 mm

• expanding in tube-hole grooves for tube wall thickness being greater than 1.5 mm

The use of copper tube bundle is allowed only after having the written permit of MOL.

1.11 Nozzles, flanges and gaskets

1.11.1 Primarily EN or ANSI type welding neck flanges shall be used. Unless otherwise specified, the nozzle flanges shall be EN standard design. The minimum nozzle size shall be DN 25. All spaces of the heat exchanger shall be provided with vent and drain nozzles.

1.12 Supports

1.12.1 Bolt holes in the saddle at one of the ends of the heat exchanger shall be elliptic for assuring of the thermal expansion occurring due to the working temperature. In case of bigger displacement, a slide plate (low-friction pads) shall be installed into the concrete base or, roller-type saddle shall be used.

1.12.2 The vertical heat exchangers shall be provided with support shoes welded to the jacket.


Rev. 1.00.02 10/11

Heavy vertical heat exchanger shall be supported by a skirt.

1.13 Size tolerances

1.13.1 The size tolerances shall meet the TEMA specifications as well as the specifications of the design documents.


Rev. 1.00.02 11/11

Appendix - additional rules valid for Slovnaft refinery:

A. Stiffening collars of the nozzles shall be made of material identical to that of the jacket. Stiffening collars of the nozzles shall be provided with threaded test hole of 10 mm diameter and M10 screw.

B. In case of units mounted on each other the sealing surface of flanges of the connection nozzles shall be raised face type.

C. Substitute materials instead of the specified ASTM or EN materials can be built-in only with Slovnaft’s Client’s approval.

D. Temperature of the medium used for hydro testing shall be from 5 °C to 50 °C range.

E. The Official test for heat exchangers (if applicable) shall be carried out according to Part MGS-S-REF-M-1.0 General requirements.

F. Cladding for inside surface protection is not acceptable. We require applying of bimetal plate or weld overlaying.

G. To point 1.10.14.3 In all cases, when the tube-to-tubesheet joint is manufactured by expanding of tube in tubesheet hole only, in that cases the joint shall be equipped by tightness weld.



MOL Group


1. Static Equipment

3. Heat Exchangers

2. Plate Heat Exchangers

MGS – S – REF – M – 1.3.2

Rev. 1.00.00


TECHNICAL SPECIFICATIONS - MECHANICAL Release: Rev. 1.00.00 Static equipment Date: 20. 03. 2012 Plate Heat Exchangers

Page/Pages: 2/15


Release list


0.00.00 31.12.2005 Basic release


MGS-S-REF-M-LI


Rev 1.00.00 3/5

Contents

1. GENERAL DESCRIPTION......................................................................................... 4

1.1 Validity..................................................................................................................... 4 1.2 Alternative solutions ................................................................................................ 4 1.3 Inconsistent prescriptions ........................................................................................ 4 1.4 Referred norms, prescriptions ................................................................................. 4

2. CONSTRUCTION REQUIREMENTS......................................................................... 4 2.1 Requirements of designing...................................................................................... 4 2.2 Prescriptions to manufacturing ................................................................................ 5

3. QUALITIES OF MATERIALS ..................................................................................... 5 3.1 Structural material ................................................................................................... 5 3.2 In general ................................................................................................................ 5 3.3 Supervision and control of manufacturing ............................................................... 5 3.4 Radiographic test .................................................................................................... 5 3.5 Crack detection ....................................................................................................... 5


Rev 1.00.004/5

1. GENERAL DESCRIPTION

1.1 Validity This specification, together with the relevant other prescriptions contains, the designing, manufacturing, control, and the minimal preconditions to the receipt on site of the plate type heat exchangers. This specification does not exempt the Manufacturer from its responsibility to deliver the reasonably constructed equipment that ensures the safe and effective operation of the pro-ject.

1.2 Alternative solutions When the Supplier offers an alternative designing solution, different from the specification of the project, or from the requirements of the offer, which however represents equivalent design value, it may only be considered as accepted, by the written consent of the MOL Group.

1.3 Inconsistent prescriptions In case of any contradiction between this specification or that of the project, and the con-tent of the Contract for delivery, the directions of the Contracts are to be followed.

1.4 Referred norms, prescriptions Except it is not ordered differently in the given specification, the heat exchanger has to comply the latest versions of the prescriptions, norms. This specification refers to the following international standards and European Directives, to comply with is the minimum requirement of the Client.

• EN ISO-15547 API 662 Plate Heat Exchanger for General Refinery Service• ASME Boiler and Pressure Vessel Code (abbr. ASME Code)• EN 13445 Unfired Pressure Vessels• AD-Merkblatt-2000, European Norms (EN)• Materials and material-testing according to ASTM, or to equivalent EN• NACE• Pressure Equipment Directive (PED) 2014/68/EC,• MGS-S-REF-M-1.0 General requirements for static equipment• MGS-S-REF-M-6.1 and MGS-S-REF-M-6.1.4.4 Requirements of inspection

and checking

2. CONSTRUCTION REQUIREMENTS

2.1 Requirements of designing

2.1.1 In principle plate heat exchangers are considered as pressure vessels, therefore the rules, standards etc. valid for pressure vessels shall be taken into consideration concern-ing design, manufacturing and installation and putting into operation of such kind of equip-ment.


Rev 1.00.00 5/5

2.1.2 The following reserves have to be kept at calculations (in lack of other values on the data sheet):

• reserve of the heat transfer surface: 10-30 %, • minimal hydrodynamic reserve (differential pressure): 20 %, • possible surface extension reserve of the frame in case non welded construc-

tion: 30 %.

2.2 Prescriptions to manufacturing Sealed or welded construction will be manufactured, based on the medium specified on the data sheet and on the operational parameters. 3. QUALITIES OF MATERIALS

3.1 Structural material

3.2 In general

Construction materials shall be designed (chosen) in line with operation conditions and medium chemical properties. . 3.3 SUPERVISION AND CONTROL OF MANUFACTURING MOL Group is authorised to control all phases of manufacturing of the heat exchangers according to MGS-S-REF-M-6.1 and MGS-S-REF-M-6.1.4.4.

3.4 Radiographic test All welded joining shall have radiography test, according to EN standards or ASME Code VIII-1, or AD-Merkblätter 2000 - HP series, if no more comprehensive tests are prescribed on the designs. Complete radiographic test is required in case of intoxicant or highly in-flammable and explosion risk mediums.

3.5 Crack detection In case of equipment that have to be 100 % radiography tested, where the seams can not be radiographic tested, there magnetic or penetration crack detection have to be executed, as agreed with the MOL Group.



MOL Group


1. Static Equipment

3. Heat Exchangers

3. Air Coolers

MGS – S – REF – M –1.3.3

Rev. 1.00.00


TECHNICAL SPECIFICATIONS - MECHANICAL Release: Rev. 1.00.00 Static Equipments Date: 20.03.2012 Air Coolers Page/Pages: 2/11


Release list


0.00.00 31.12.2005 Basic release


MGS-S-REF-M-LI


Rev. 1.00.00 3/11

Contents 1. General description .................................................................................................... 4

1.1 Scope ...................................................................................................................... 4 1.2 Alternative designs .................................................................................................. 4 1.3 Conflicting requirements.......................................................................................... 4 1.4 Definition of terms ................................................................................................... 4 1.5 Referenced publications .......................................................................................... 4

2. Requirements for design ............................................................................................ 4 2.1 General aspects ...................................................................................................... 4 2.2 Design pressure and temperature ........................................................................... 6 2.3 Chamber covers ...................................................................................................... 6 2.4 Tube bundle ............................................................................................................ 7 2.5 Steel structure ......................................................................................................... 7 2.6 Fans ........................................................................................................................ 8 2.7 Materials.................................................................................................................. 8

3. Manufacturing requirements....................................................................................... 8 4. Inspection, acceptance............................................................................................... 9 5. Installation .................................................................................................................. 9

5.2 Cleaning of tubes .................................................................................................. 10 Appendix - additional rules valid for Slovnaft refinery:....................................................... 11


Rev. 1.00.004/11


1.1 Scope This description deals with engineering design, structural materials, fabrication, inspection and testing of air-cooled heat exchangers, containing the minimum requirements thereof. The air-coolers shall be specified according to the EN ISO 13706 (API 661) standard.

1.2 Alternative designs If the Vendor offers an alternative design deviating from the project specification or from the inquiry documents but equivalent with that, it can be accepted by a written consent of MOL Group.

1.3 Conflicting requirements If any contradiction exists between this specification and the content of the delivery contract, then the contract is dominant.

1.4 Definition of terms For purposes of these specifications, the term definitions used in EN ISO 13706 (API 661) standards are accepted.

1.5 Referenced publications a) Safety Regulations for Pressure-Containing Vessels (local law)b) Pressure Equipment Directive PED (2014/68/EC)c) Machinery Directive (2006/42/EC)d) ATEX Directive (94/9/EC) and (99/92/EC)e) EN ISO 13706 (API 661) Air-Cooled Heat Exchanger for General Refinery Servicef) MGS-S-REF-M-1.0 General requirementsg) MGS-S-REF-M-6.1 and MGS-S-REF-M-6.1.4.5 Requirements of inspection and

checking

2. Requirements for design

2.1 General aspects

2.1.1 In principle air coolers are considered as pressure vessels, therefore the rules, standards etc. valid for pressure vessels shall be taken into consideration concerning design, manufacturing and installation and putting into operation of such kind of equipment.

2.1.2 The air-cooled heat exchangers are supported by a welded and pre-fabricated steel structure assembled from mounting elements at the site of the installation.

It is the responsibility of the vendor to investigate all operating conditions, temperature differentials, or temperature shocks specified in the requisition to determine that his proposed design is adequate.

All bays shall be structurally independent, unless otherwise specified in the individual material requisition.


Rev. 1.00.00 5/11

2.1.3 Into the horizontal frame openings of the steel structure are fitted the diffusers. The cooling elements are accommodated above the diffusers, fixed by screws. The fans are fixed with screws to the bottom ring of the diffusers, mountable from the foundation level. The motor and the drive elements are accessible from the same level.

2.1.4 If in a plant several air-cooled heat exchangers are used, they shall be uniformed to the possible greatest extent in order to make the finned tube bundle interchangeable. Drive motors of the fans shall be of explosion-proof and drip water protected design.

2.1.5 Design the air cooler with double-flow, i.e. to build-in the input and output fittings for each flow, is required.

2.1.6 Integral construction in which fins are formed by extrusion from aluminium outer tube that is mechanical bonded to an inner tube or liner is required.

2.1.7 Fan-bearing lubricating to be designed as the remote central lubrication from the operating personnel work-place (reason: the lubrication should be carried out during operation of the air-coolers, without their shut-down, covers removal, and without building scaffoldings).

2.1.8 Venting and drain valves (there must be two valves for venting and drain) of the air-coolers shall be designed with flanges.

2.1.9 The louvers shall be installed on all air-coolers and shall be adjustable manually.

2.1.10 Maximum allowable noise level is 80 dB at a distance of 1 m from the equipment.

2.1.11 Connecting material (screws, nuts) must be in accordance with the metric system.

2.1.12 Counter flanges including the seals, bolts, nuts and washer shall be a part of delivery.

2.1.13 Connecting flanges shall be designed according to ANSI or EN.

2.1.14 Inlet and outlet nozzles shall be designed on the same side.

2.1.15 The asbestos free sealing material must be applied.

2.1.16 Local pressure and temperature gauges shall equip each air-cooler.

2.1.17 We recommend using of spiral wound gaskets with inner and outer centre ring.

2.1.18 The Molycoat paste shall be applied on all screw connections used on air-coolers.

2.1.19 For un-insulated parts of chamber shall be applied personal protection for operators not to contact with them.

2.1.20 All piping materials shall be supplied with mill certificates in accordance with EN 10204 3.1.

2.1.21 The air cooling fans shall feature as follows: a) Direct driven propeller (without driving gear) shall be used only under 22 kW motor


Rev. 1.00.00 6/11

power. b) Forced draught air cooler shall be used only. c) Near to the fans at the site a disabling switch shall be installed for machine

protection and maintenance purposes. d) To detect vibration of the fans, a vibration switch shall be installed at the fans,

each. e) Each bay, which may consist of several tube bundles, shall be formed by two or

three fan units, one of which shall be provided with frequency regulator. f) The rotor shall be dynamically balanced. g) The propeller blades shall be made of antistatic material. h) The tube bundles shall constitute a self-contained unit. i) Lateral motion of the tube bundle shall not exceed 6 mm in both directions or 13

mm in one direction. j) The tubes shall be supported on both sides. The minimum supporting length shall

be 1.83 m from centre to centre. k) Tubes of single-pass condensers and all steam tracing (heating) coils shall be

installed with 10 mm/m slope. l) The air supply shall be so designed as to pass over the entire tube bundle,

reducing the air leak and recirculation to minimum. In general no air gap larger than 10 mm may exist.

2.2 Design pressure and temperature

2.2.1 Application of air coolers a) The outlet-inlet range of the medium to be cooled is not wide and the exit

temperature can be relatively high. b) Adequate technological medium to be heated is not available. c) The medium to be cooled is relative, of low heat content. d) The investment costs are higher than that of the water-coolers but their operating

costs are essentially lower. e) It is expedient to use them primarily for condensation or, product cooling.

2.2.2 Unless otherwise specified, the design temperature may not be lower than temperature of the inlet medium + 30 °C.

2.2.3 Unless otherwise specified, the design pressure shall be the inlet pressure + 10 % thereof or, the pressure of the inlet medium + 1.7 bar (g), which is higher.

2.2.4 If no corrosion allowance is specified, then in case of carbon steel or low-alloy steel minimum 3 mm shall be taken into account. This applies to both sides of the partition plates and nozzles.

2.2.5 The depth of grooves of partition plates of the pass can be the maximum corrosion allowance.

2.3 Chamber covers

2.3.1 Shall be so designed as to form streaming surface minimum as stream cross section of the tubes.


Rev. 1.00.00 7/11

2.3.2 Thickness of the partition plates shall be minimum 12 mm for carbon steel and low-alloy steel and 6 mm for alloyed steel.

2.3.3 In case of dismountable chamber cover the structure shall be so designed that no dismounting of the piping is necessary for dismounting of the cover.

2.3.4 The flanges of the nozzles shall be of welding neck type and the thickness of the neck shall be identical with the wall thickness of the nozzle. Minimum nozlze size: DN 40.

2.3.5 The chamber shall be of removable cover plate or removable bonnet type design. For high pressure application plug headers shall be considered. The bonnets shall be of flanged design, provided with concealed seal.

2.4 Tube bundle

2.4.1 The tube size for air coolers shall be: O.D. 25 - 40 mm BWG (min) No. 13

2.4.2 Length of the tube bundle shall be 6000 mm or 9000 mm.

2.4.3 Connecting of the air-coolers must be designed so that it must be possible to remove the air-coolers without cutting the pipes.

2.4.4 For tube bundles and air coolers, seamless tubes shall be used.

2.4.5 Connections tubes/tube-sheet should be provided with seal welds as well.

2.4.6 Tubes to tube sheet joints shall be of

expanded type (grooved tube sheet) with seal welds or welded only to the tube sheets.

The selection can be made after MOL Group’s consent.

2.5 Steel structure

2.5.1 It is expedient to fix the anchoring bolts assuring the steel structure, after erection of the structure.

2.5.2 If the foundation is built in final form prior to the installation with bolts, then the anchoring bolts shall be located with use of a template corresponding to legs of the supporting structure, with ± 1.5 mm tolerance.

2.5.3 The vendor shall provide all platforms and ladders required above the unit column base level.

2.5.4 The steel structure shall be delivered in state prefabricated to the possible maximum. The structure shall be so designed that the motor is located at minimum 2200 mm from the operator's level.

2.5.5 Unless otherwise specified, the louvers of the air cooler shall be manually adjusted.


Rev. 1.00.00 8/11

2.5.6 Supporting structures shall consist of the following parts: a) supporting legs; b) access platforms covered by steel gratings from the head side of the air coolers,

kick-off plates and handrails; c) the top pipe of the handrail shall be painted by yellow and black stripes. Length of

each to be 30 cm; d) the bottom and top bar of the ladder protecting cage shall be painted by yellow

and black stripes. Length of each to be 7cm; e) ladders with the protecting cage and the self close protecting barrier installed at

the top of the ladder; f) any opening in platforms etc., staircases and railings shall be protected against

accidental drop of tools, bolts by the use of kick plates; g) supporting structure of the air-coolers must be hot zinc galvanised. The minimum

thickness of the zinc layer must be hot dip galvanised 450 g/m2 minimum;

2.6 Fans

2.6.1 The fans shall be of electrically driven design. The tube bundle shall be accommodated over the fan, in the forced-draft branch. The requirements relating to the electric motors are defined in the MGS-S-REF-E-4.10 electric specification. Guarantees

1. The vendor shall guarantee the exchanger to perform as specified at design conditions.

2. The vendor shall guarantee the noise and vibration level will not exceed that specified.

3. The vendor shall guarantee the exchanger against improper design and defective workmanship and materials.

2.7 Materials

2.7.1 For the production only killed steel may be used.

2.7.2 Material of the fin: aluminium.

2.7.3 In case of welded chambers the material of the partition plate shall coincide with material of the chamber.

2.7.4 The fan blade can be made of aluminium alloy or plastic.

2.7.5 The louvers shall be of galvanized design, with possibility for adjustment on the operator's walkway.

3. Manufacturing requirements

3.1 For fabrication only materials of quality as specified in the plans and verified by quality certificate may be used.

3.2 Operational reliability of the equipment can be ensured with a careful installation of the tube fastenings and sealing surfaces. To this end, adherence to the following is


Rev. 1.00.00 9/11

required:

3.3 The chamber-end, flush-machined side of the tube bundle walls and the holes of the tube fixations shall be prepared to metal-clean, degreased state, prior to assembling. On the hole or on the tube end no visible axial-direction scratches may exist.

3.4 Rolling-in of the tubes shall be in such sequence that the deformation of the tube bundle wall is kept at minimum. Instead of smooth tube bundle wall grooved tube bundle wall shall be applied.

3.5 Should a gap endangering the sealing occur in consequence of deformation between the tube bundle wall and the cover, then the surface of the tube bundle wall can be re-machined down to maximum 2 mm depth.

3.6 In the factory the air cooler shall be complete assembled, trial running shall be performed with vibration measuring, then, if justified by the dimensions, disassembled to units for shipment.

4. Inspection, acceptance

4.1 Generally, air coolers are considered as pressure vessels, therefore the directives, laws, standards etc. valid for pressure vessels shall be taken into consideration concerning inspection, installation and putting into operation of such kind of equipment (e. g. PED 2014/68/EC, regional laws).

4.2 For such equipment, which comes under competence of these rules, the requirements of MGS-S-REF-M-1.0 shall be met.

4.3 Each finned tube shall be checked for soundness of the fins. In case of deformation repairing is permitted. Damaged pipes with irreparable fining may not be installed.

4.4 At the site of the installation all appliances shall be checked for undamaged state.

4.5 Acceptance of the equipment shall be made on basis of the MGS-S-REF-M-6.1 and MGS-S-REF-M-6.1.4.5 standard specification relating to the requirements of inspection and checking.

4.6 Tightness test of the tube bundle and the cover shall be carried out by air at 175 kPa pressure, according to API 661 standard.

5. Installation

5.1.1 For winterization purpose the selection of the following solution shall be made to apply after occurring MOL Group’s consent:

Heating pipe coil (pipe tracing) can be installed under the tube bundle,All sides of the air coolers around the supporting legs shall be provided with manuallyadjustable louvers.With internal recirculation acc. to EN Std.


Rev. 1.00.00 10/11

5.2 Cleaning of tubes

5.2.1 Cleaning of the finned tubes shall be made with use of high-pressure water jet or steam shaver. The electric motor shall be protected from this by individual fixed or temporary protection.

5.2.2 Possibility for removal of the electric motors (route, handcart for lift off and remove of motor) shall be provided.


Rev. 1.00.00 11/11

Appendix - additional rules valid for Slovnaft refinery:

A. If the air cooler comes under competence of PED 2014/68/EC, the air cooler hydro testing shall be carried out in accordance with the requirements of PED (or STN EN

13445). A.1. Note (PED Guidelines - Guideline 2/4): Air coolers come not under competence of PED 2014/68/EC if, and only if, the 3 following conditions are met:

1. air is the secondary fluid;2. they are used in refrigeration systems, in air conditioning systems or in heat pumps;3. the piping aspects are predominant.Piping heat exchangers which do not meet the requirements of this exception are not to be classified according to the last sentence of Article 1, paragraph 2.1.2 (PED) as piping. They are to be classified as vessels.


MOL Group


1. Static Equipment

4. Storage Tanks (aboveground)

1. Atmospheric Tanks

MGS – S – REF – M – 1.4.1

Rev. 1.00.01



MGS-S-REF-M- 1.4.1 Refining & Marketing TECHNICAL SPECIFICATIONS - MECHANICAL Release: Rev. 1.00.01 Static Equipments Date: 01.06.2014 Atmospheric Tanks Page/Pages: 2/11

Release list


0.00.00 31.12.2005 Basic release


MGS-S-REF-M-LI



SLOVNAFT a.s. MGS-S-REF--M-1.4.1 Refining & Marketing

Contents

1.1 Validity ..................................................................................................................... 4 1.2 Alternative solutions ................................................................................................ 4 1.3 Contradictory prescriptions ...................................................................................... 4 1.4 Terminology ............................................................................................................. 4 1.5 Referred legislation rules, standards, prescriptions ................................................. 4 2.1 Requirements of designing ...................................................................................... 5 2.2 Detail Construction Requirements ........................................................................... 5 3.1 Substitutions ............................................................................................................ 6 4.1 Rolling, Forming ...................................................................................................... 6 4.2 Beveling ................................................................................................................... 6 4.3 Welding ................................................................................................................... 7 4.4 Welding prescriptions .............................................................................................. 7 5.1 Technical Supervision, Control of Manufacturing .................................................... 8 5.2 Instructions for Audits .............................................................................................. 8 6.1 Taking over of the tank is executed as prescribed respectively in the in the Contract, and on the data sheet taking into consideration of MGS-S-REF-M-6.1.4.6. ..... 9 Appendix - additional rules valid for Slovnaft refinery……………………………………....10

Rev 1.00.01 3/11


1. GENERAL DESCRIPTION

1.1 Validity

1.1.1 This specification, together with the relevant other prescriptions contains the main requirements of designing, manufacturing, control of aboveground storage tanks. The tanks are designed for storing of liquids at pressure near the atmospheric pressure, and are closed by fix or floating roof or by combination of them (aluminum domes and internal floating covers/decks).

1.2 Alternative solutions

1.2.1 When the Manufacturer offers an alternative designing solution, different from the specification of the project, or from the requirements of the offer, which however represents equivalent design value, it may only be considered as accepted, by the written consent of MOL Group.

1.3 Contradictory prescriptions

1.3.1 In case of any contradiction between this specification and the project, and the content of the Contract for delivery, the directions of the Contracts shall be followed.

1.4 Terminology

1.4.1 The terminology applied in the local legislation rules and standards and in the prescriptions of API 650 is accepted in this specification

1.5 Referred legislation rules, standards, prescriptions

1.5.1 The minimum requirements that all pieces of equipment have to fulfil are the latest versions of the standards, prescriptions listed below, in case there are no other requirements in the given specification. If the two requirements overlap each other, the more stringent one shall be applied. If the Manufacturer wants to divert from these prescriptions, the suggested solution, certified by calculations, experimental measurements or by other examinations, can also be realized with the written consent of the MOL Group.

1.5.2 MOL Group will underline the norm that shall be applied during manufacturing of the tank/equipment. The selected norm shall consequentially be followed. One may only deviate from this, if accepted by MOL Group.

a) Local valid legislation rules; b) Local technical standards stipulated for tank design, manufacturing and operating; c) API Standard 650: Storing of Welded Steel Tanks; d) API 2000 Venting Atmospheric and Low-Pressure Storage Tanks e) EN 14015: Specification for the design and manufacture of site built, vertical,

cylindrical, flat-bottomed, above ground, welded, steel tanks for the storage of liquids at ambient temperature and above

f) ASTM, or equivalent norms, (EN) material qualities and material tests. g) MGS-S-REF-M-6.1.4.6 Requirements of inspection and checking

Rev 1.00.01 4/11


2. CONSTRUCTION REQUIREMENTS

2.1 Requirements of designing Design and selection are performed by the Contractor/Manufacturer, according to the data of the Data-sheet.

2.1.1 Corrosion

2.1.1.1 The corrosion reserve is to be considered as: overall allowances on the shell, nozzles, man holes, and on the inner sides of the blank flanges, but it may not be less than 1 mm; in case of other structures not less, than 0,5 mm.

2.1.1.2 Protection against corrosion shall be made according to MOL specifications MGS-S-REF-M-6.2.

2.2 Detail Construction Requirements

2.2.1 Tank Body

2.2.1.1 The shell and the bottom are manufactured on site from prefabricated properly spaced sheets, made at the Manufacturer. Tolerances of sheets are indicated on designs. The roof structure and the external collar shall also be composed and assembled on site.

2.2.1.2 The nozzles shall be installed into the sheets of the lower and the upper mantle. These can be welded at the Manufacturer and, if prescribed, heat treated together with the steel sheets.

2.2.2 Outer Steel Structures

2.2.2.1 These (circular stairway, - handrail, - walkway) shall be constructed as prescribed by the MOL Group. The bolster plates joining to the shell are of identical material quality to that of the tank, shall be welded on site. The fixing seams must not cover the tank-seams. The distance between the two types of seams has to be minimum 100 mm.

2.2.3 Nozzles, flanges, sealing

2.2.3.1 Measurement of nozzles will be API 650 or/and according to the requirements of Client.

2.2.3.2 EN 1092, or ANSI type, welding neck flanges have priority when selecting flanges. The interpenetrations of pipes and the weld edges must so be formed that, the openings do not exceed 0-3 mm after setting the pipes. In cases of wider openings, these not correctly formed places have to be signed and corrected by welding, grinding.

2.2.3.3 All technological joints must be of flange type. The roughness of flange surfaces has to be shown on the drawings.

2.2.3.4 The nozzles shall be long enough to ensure that the normal rivet-screws can be removed from the flanges on their equipment side, in case of insulation, too. When setting the flanges, attention has to be paid the orientation of the flange holes, and to keeping the angles of the pipes’ axes to the angles of the casing elements, as indicated on the design

Rev 1.00.01 5/11


drawings.

2.2.3.5 The manholes have to be equipped with cover turning structure, if the weights of the blind flanges are more than 25 kg.

3. QUALITIES OF MATERIALS

Quality of structural materials shall answer to the indicated ones of the datasheet. Materials shall be selected according to Section 2 of API 650 and shall be in line with EN 14015 depending on the wall thicknesses and the temperatures of the walls. The tank body, and the parts welded to it (flanges, nozzles, reinforcing plates) are taken over by specialists. These have to be provided with identification numbers, and positioned by batch-number map. In lack of other prescriptions, the conformities of strength materials have to be certified according to 3.1 documentation of EN 10204. Other materials’ qualities are as prescribed under 2.2 of EN 10204.

3.1 Substitutions

3.1.1 The conforming substituting materials can be the relevant PED conform, harmonized EN material qualities.

3.1.2 Approval of MOL Group is needed for using other materials, instead of the prescribed ASTM, or EN ones.

4. MANUFACTURING REQUIREMENTS

4.1 Rolling, Forming

4.1.1 Maximal deviations from the arch are: a) ± 7mm in longitudinal direction on the axe-line, measured by 2000 mm long

template, ± 1 mm in the 500 – 500 mm margin belts, and ± 7mm on the inner section of the sheet, measured crosswise by 2000 mm long template,

b) ± 1mm along the edges, measured by 2000 mm long template.

4.1.2 The control measurements shall be performed when forming, and the results registered on measurement documentation forms.

4.2 Beveling

4.2.1 Hands made flame cuts can be performed only close to the nozzles joints, with appropriate allowances, and only if the edges are finished grinded.

4.2.2 The ready made edges have to be visual checked, whether there are no scaly parts, cracking, more serious damages on the edge surface.

4.2.3 The welding edges shall be or magnetic or liquid-penetration crack detection tested in cases of any thicknesses of alloy steel, of more than 30 mm thick high-strength steel (yield point is higher than 350 N/mm2), and in cases of carbon steels over 50 mm wall thickness.

Rev 1.00.01 6/11


4.2.4 Reparation of material deficiencies may only be made with the consent of designer. Edges shall be formed according to ASME part IX. or AD 2000-Merkblatt.

4.2.5 If the edge-formed sheets are to be stored for a longer period of time on open air, the edges have to be protected by removable foil, or by neutral paint that does not influence the welding.

4.3 Welding

4.3.1 The welding procedures, technologies, and equipment have to be certified according to ASME Code IX, or to AD-Merkblatter 2000, and EN norms. In other cases the consent of MOL Group is required.

4.3.2 Welding may only be performed by welders qualified according to EN 287-1.

4.3.3 The qualification of welders with the exact denomination shall be worded according to the EN 287-1. The qualification certificate has to satisfy the requirements of “B” appendix of EN 287-1, and the Manufacturer’s welding process specification (WPS) the “C” appendix of EN 287-1.

4.3.4 The persons doing non-destructive tests have to be qualified according to EN 473.

4.3.5 The welding instructions, the approval of the welding technology, and the welding tests have to be performed according to the series of norms EN 288 / 1., 2., 3. Each welded joint different from the other has to have previously its WPS elaborated according to EN 288 - 2. This welding technology must be approved by a process test executed as stated in the norm EN 288-3, and the approval shall be documented by Welding Process Approval Report (WPAR), as determined by the standard.

4.3.6 The procedures applied for testing the specimens’ welding and the extent of tests must be determined as written in the point 7. and table 1. of the norm EN 288-3. The approval report has to be certified by the supervising authority and/or by the organization appointed by the authority. The WPS shall be elaborated based on the approved welding technology. The material of the welding electrode shall be determined during elaborating the welding process.

4.4 Welding prescriptions

4.4.1 Allowed displacement of the edges to be welded may be max. 2 mm. A difference greater than this has to be matched by 1:4 ratio works off. The outer and inner surfaces of the welds have to remain controllable.

4.4.2 The inner surface of the shell must be shaped and joint to ensure the same level position at the welds. The inner diameter is valid, in case the shell plates differed in thickness.

4.4.3 Carbon steel parts may not directly joint to other elements of equipment of great alloy content.

4.4.4 Joining seams of nozzles shall be made of full penetration melting, to avoid slot corrosion on the root side.

Rev 1.00.01 7/11


4.4.5 Before starting manufacturing, the Manufacturer has to send the welding technology to the MOL Group for approval.

4.4.6 Weld cutting is required in the welding process of Manufacturer; this cutting has to be made deep down to the base metal. After carbon-arc welding and grinded root cutting, the weld on the root side, starting at one end shall be preceded continually to finishing.

4.4.7 The prescribed destructive work samples, for the coupling welds of the tank have to be executed on 500 mm run out sheet of the same material and prepared on the same way.

4.4.8 If possible, all welds of nozzles, smaller joints, and of their supports should be thoroughly melted welds. If possible the under plate belts have to be removed.

4.4.9 The sealing surfaces of all flanges and the threaded joints shall be supplied with protection against oxidation. It is prohibited to weld after occasional stress relieving thermal treatment.

4.4.10 The edges of reinforcing plates being in contact with the loaded parts of the equipment shall be welded by perfectly closing welds, to protect the shell against atmospheric corrosion. 6 mm diameter holes shall be drilled into the reinforcing plates for tightness test. These holes have to be filled up by smear or plastic tapped, after the test. The welds must be cleared from slag, impurity, oil, paint, and other contaminations, before controlling the structure and the water test. The manufacturing aids, as fixtures, consoles, etc. welded to the tank have to be removed without damaging the base material, and the places of these have to be controlled by crack detection.

5. SUPERVISION AND AUDIT OF MANUFACTURING

5.1 Technical Supervision, Control of Manufacturing

5.1.1 A technical supervision procedure shall be elaborated by manufacturer, where all steps of manufacturing are included (starting from approval of designs to hand over).

5.1.2 The technical supervision may be performed by a third party, independent from the Manufacturer. MOL Group is authorized to control all phases of manufacturing and assembling.

5.1.3 Controls shall be made according to the API 650 and the specified directions, as required.

5.1.4 Requirements of inspection and checking to be followed by Manufacturer shall met the MOL Group standard specification MGS-S-REF-M-6.1.4.6.

5.2 Instructions for Audits All welded joining shall partially be radiography tested, according to API 650, or National Authority Regulation, except, if no more comprehensive radiographic tests are prescribed on the designs.

Rev 1.00.01 8/11


5.2.1 Radiographic Test

5.2.1.1 The radiographic tests shall be performed in the extent as prescribed by the relevant standard and design.

5.2.1.2 The Manufacturer has to prepare an evaluation report on the places (welds’ pictures) where radiographic tests had been performed.

5.2.2 Crack Detection

5.2.2.1 Welds that can not be radiographic tested, shall be controlled by magnetic or penetration crack detection, as coordinated and agreed with MOL Group.

5.2.3 Liquid Penetration Test

5.2.3.1 All seams made on site have to be tested. The nozzles joint seams and the welds not radiography tested all shall be tested by liquid penetration, according to the prescriptions of API 650.

5.2.4 Vacuum Test

5.2.4.1 The tightness of the weld shall be vacuum tested at locations approachable from one direction only.

5.2.5 Tightness Pressure Test

5.2.5.1 The ready assembled equipment has to be water pressure tested (fill up with water). The execution of this process is determined by the Manufacturer, and it is written in the design documentation. The water temperature may not be less then + 5 0C.

5.2.5.2 The heating and other systems will be tested on the prescribed pressure.

5.2.5.3 Water pressure tests must be executed before heat insulation and painting.

5.2.5.4 The fixing collars and reinforcing plates shall be tightness tested, by 0.5 bar pressure air.

5.2.5.5 The execution and the result of the water pressure test is certified by the Manufacturer’s and the MOL Group’s controller.

5.2.5.6 Specialized works (final paintings, heat insulation, etc.) can be made after successful water test.

5.2.5.7 Sinking test is also made when the water test is performed.

6. TAKING OVER

6.1 Taking over of the tank is executed as prescribed respectively in the in the Contract, and on the data sheet taking into consideration of MGS-S-REF-M-6.1.4.6. Appendix - additional rules valid for Slovnaft refinery: A. Referred legislation rules, standards, prescriptions

Rev 1.00.01 9/11


A.1. Legislation rules:

- Public notice No. 410/2012 Coll.- Regulation considering sources of air pollution, emission limits, technical and general requirements related to the operating of facilities, the list of pollutants, the classification of air polluting sources and the provisions for diluting polluting materials;

- Law No. 364/2004 Law about water protection - Public Notice No.100/2005 Coll. Regulation of Ministry for Environment

considering storage of dangerous substances. - Public Notice No. 96/2004 Coll. Regulation considering fire protection - Public Notice No. 508/2009 Coll. Concerning occupational safety and health at

work, safety of pressure, lifting, electrical and gas technical equipments and on expert competence

A.2. The Slovak standards:

- STN EN 14015 Specification for the design and manufacture of site built, vertical, cylindrical, flat-bottomed, above ground, welded, steel tanks for the storage of liquids at ambient temperature and above.

- STN 65 0201 Flammable liquids. Plants and storage rooms; - STN 75 3415 Water protection against petroleum substances.

Plants for handling of petroleum matters and their storage;

- STN 92 0800 Fire safety of buildings. Flammable liquids. - 031/BTP/TI for design, manufacturing and testingof new and

existing pressure equipment (vessels) - 032/BTP/TI for operating and maintenance of existing

pressure equipment (piping) - PROD_1_SN 7 Storge tanks inspection carrying out.

B. Additional requirements for storage tanks

B.1. The storage tanks shall be equipped by hydraulic closure in the cases when the stored medium has specific properties (is sticky or creates sediments, has corrosion effect, polymerizes, the freezing point is over 0 °C, etc.)

B.2. The storage tanks, where exists the precondition of gas using for their technological piping blowing through from technological point of view, such storage tanks shall be equipped by roof flaps.

B.3. The check valve shall be installed at inlet piping as prevention of medium spill (when it is usually very long piping).

Rev 1.00.01 10/11


B.4. Technical condition of the tanks (shell, bottoms, etc..) shall be tested. In the case of impossibility to carry out the tests according to relevant rules described in the legislation and/or relevant technical standards (e. g. external checking of tank shell impossibility) the Vendor shall ensure relevant Authority's (and/or Authorized Legal Person) written approval, confirming the procedure how the tank technical condition shall be tested during the period, required by local code. The Vendor shall prepare the draft of such procedure, which will be commented by Buyer. The relevant Authority's (and/or Authorized legal Person) written approval shall be incorporated into the tank’s technical documentation. The necessary details shall be included in the tank’s technical documentation.

Rev 1.00.01 11/11

Documents

TECHNICAL SPECIFICATIONS - Slovnaft