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PPG INDUSTRIES, INC. CHEMICAL DIVISION - U.S. P. 0. BOX 1000 LAKE CHARLES, LA. 70602
September 8, 1980
Mr. Paul Kelley Petrocon, Inc. P. 0. Box 3971 Beaumont, TX 77704
SUBJECT: Reliability Study
Dear Paul:
Enclosed are Lamar White's calculations for pressure and temperature limits on the furnace tubes. Also included are the curves and data supplied by Huntington Alloy for INCQLOY alloy 800 H.
Please compare these numbers with yours. If there are still some questions, please give me a call.
Very truly yours,
WLO/bjm cc: S. L. White File: 4.47
Walter L. Oglesby
SL 012158
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SL 012166
INCOLOY alloy BOOH
SL 012167
CONFIDENTIAL*.
subiect to Protective Or-aer .
* UtU Judicial District Court
Rupture strength of the alloy is shown by the data plotted in Figure 20. Rupture-strength values for some specific temperatures and times are listed in Table 22.
ASME boiler and pressure vessel code
INCOLOY alloy 800H is approved under the Boiler and Pressure Vessel Code of the American Society of Mechanical Engineers. The alloy is approved under Section I (Power Boilers), Section III (Nuclear Vessels), and Section VIII (Pressure Vessels). Section I coverage is provided by Code Case 1325; Section III design values are contained in Code Case 1592.
Design stresses specified for alloy 800H by Section I and Section VIII. Division 1. of the Code (1977 edition) are listed in Table 23. Stress-intensity values for Class 1 components of nuclear vessels
Table 22 - Representative Rupture-Strength Values for INCOLOY alloy 800H
Stress to Produce Rupture in
Temperature 10,000 h 30,000 h 50.000 h 100,000 h
F C psi MPa psi MPa psi MPa psi MPa
1200 650 17,500 121 15.000 103 14,000 ,97 1300 705 11,000 76 9,500 66 8,800 61
1400 760 7,300 50 6,300 43 5,800 40
1500 815 5,200 36 4,400 30 4,100 28 1600 870 3,500 24 3,000 21 2.800 19 1700 925 1,900 13 1.600 11 1,400 10
1800 980 1,200 8.3 1,000 6.9 900 6.2
13,000 90 8,000 55
5,300 37 3,700 26 2,500 17 1,200 8.3
800 5,5
Table 23-INCOLOY alloy 800H Design Stresses from ASME Boiler and Pressure Vessel Code.
Section I and Division 1 of Section VIII
Maximum Metal
Temperature
F C
100 38 200 93 300 149 400 204 500 260 600 316 650 343 700 371 750 399 800 427 850 454 900 482 950 510 1000 538 1050 566 1100 593 1150 621 1200 649 1250 677 1300 704 1350 732 1400 760 1450 788 1500 816
Maximum Allowable Stress in Tension
Standard
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psi MPa psi MPa"'
16,200 111.6 16,200 111,6
15.400
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111.6
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99.9 16.200 111 6
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93.0 16,200 111 6
12.900
88.9 16,000 1103
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11,900
82.0 16,000 110.3
11.700
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78 6 15,400 106,1
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9,800 67.5 11.200 77 2-
87UU 57.9 8.400 57 9
6,900 47.5 6,900 47 5
5,400 37.2 5,400 37.2
4,500 31,0 4,500 31 0
3,600 24,8 3.600 24 8
3,000 20.6 3.000 20 6
2.500 172 2.500 172
These higher stress values ol up to 90% ol yield strength al temperature may he used where slightly greater deformation is acceolable The stresses may result in dimensional changes due to permanent strain and are not recommended lor aoplrcations such as Hanges ol gasketed loinls.
Figure 20. Typical rupture strength of INCOLOY alloy 800H
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Low-cycle fatigue strength of alloy 800H at room temperature and M00F (760C) is shown in Figure 16.14 Low-cycle fatigue data for alloys 800 and 800H are compared at 1000F (538C) and 1200F (649C) in Figures 17 and 18.
Physical constants and thermal properties
Mechanical properties
Creep and rupture properties
The outstanding characteristic of INCOLOY alloy 800H is its high creep and rupture strength. The alloy's carbon content and annealing treatment are designed to produce optimum creep-rupture proper ties in material having the standard INCOLOY alloy 800 composition. Figure 19 shows creep strength of alloy 800H at various temperatures.
UK 10'
10* 10' to*
Cycles to Failure
Figure 17. low-cycle fatigue strengths of INCOLOY alloys 800 and 800H at 1000F (540C).
10' 10' 10' 10* 10'
Cycles lo Failure
Figure 16. low-cycle fatigue strength of INCOLOY alloy 800H Bending strain was used for alloy 800; axial strain was used lor alloy 800H.
10' 10' 10* 10* 10'
Cycles lo Failure
Figure 18, low-cycle fatigue strengths of INCOLOY alloys 800 and 800H at 1200F (650C).
Figure 19. Typical creep strength of INCOLOY alloy 800H
SL 012168
AMERICAN NATIONAL STANDARD .'chemical PLANT AND PETROLEUM REFINERY PIPING
ANSI B31.3-1976 302.2.2
ponents shall be furnished in nominal thicknesses. Unless limited elsewhere in this Code, such com ponents may be rated tor the same allowable pres sures as seamless pipe of the same nominal thickness, as determined in 304.1 for material having the same allowable stress.
Piping components such as pipe, for which allow able stresses have been developed in accordance with 302.3, but which do not have established pressure ratings may be rated by rules for pressure design in 304, modified as applicable by other provisions of this Code.
302.2.3 Normal Operating Conditions Normal operating conditions are those in which the design pressure and design temperature apply. In selecting components the following limitations apply: (a) The rated pressure of components at the design temperature shall be equal to or greater than the design pressure. (b) For components without ratings the design pressure shall not produce a stress exceeding the allowable stress for the material at design temperature.
302.2.4 Allowances for Variations from Normal Operating Conditions
Variations in the temperature or pressure, or both, from normal operating conditions are characteristic of certain services. If the duration of these variations is greater than permitted by (a) and (b) below, as in cyclic operations, the most severe combination of pressure and temperature shall be regarded as normal operation. If these variations are infrequent and of short duration, however, the pressure-temperature ratings or the allowable stresses of the piping com ponents may be exceeded as indicated in (a) and (b) below. Application of pressures exceeding pressuretemperature ratings of valves may under certain condi tions cause a loss of seat tightness or difficulty of operation. Such application is the owner's responsi bility. These allowances shall not be applied to: 1) materials whose allowable stresses have not been reduced as specified in Note 3 in 302.3.2(b), nor 2) cast iron or similar non-ductile materials.
(a) if the increased operating condition will not last more than 10 hours at any one time and will not total mor^ than 100 hours per year, it is permissible to exceed the pressure rating or the allowable stress at the temperature existing in the increased operating condition by up to 33 percent.
(b) if the increased operating condition will not last more than 50 hours at any one time and will not total more than 500 hours per year, it is permissible to exceed the pressure rating or the allowable stress at the temperature existing in the increased operating condition by up to 20 percent.
302.2.5 Ratings at Junction of Different Services When two services that operate at different pres sure-temperature conditions are connected, the valve segregating the two services shall be rated for the more severe service condition. If the valve will oper ate at a reduced temperature due to its remoteness from a high temperature header or piece of equip ment, this valve (and any mating flanges) may be rated at the reduced temperature provided it can withstand the hydrostatic tests required on each side of the valve. Piping on either side of the valve, how ever, shall be designed for the conditions of the service to which it is connected.
302.3 Allowable Stresses and Other Stress Limits for Metallic Components
302.3.1 General Appendix A contains allowable stresses (SE) in tension for metals and design stresses (5) for bolting materials which shall be used in design calculations unless modified by other provisions of this Code. For materials not subject to a specified quality or joint factor (E), the allowable stresses in Appendix A are numerically equal to basic allowable stresses (5) determined in accordance with the bases stated in 302.3.2(b). For certain castings, a casting quality factor (E) has been applied as defined in 302.3.3. For components containing longitudinal or spiral welds, a joint factor (E) has been applied as defined in 302.3.4. For steels of structural grade, a quality factor (E) of 0.92 has been applied. For bolting materials, the design stresses in Appendix A were determined in accordance with the bases stated in 302.3.2(a). The tabulated allowable and design stresses are grouped by material and product form, and are listed for stated temperatures up. to the limit provided for the material in 323.2.1. Straight line interpolation between temperatures is permissible. The temperature intended is the design temperature. (a) Shear and Bearing: Allowable stresses in shear shall be 0.80 times the basic allowable stress in ten sion derived from tabulated values in Appendix A in accordance with Note 16. Allowable stress in bearing shall be 1.60 times the basic allowable stress in tension. (b) Compression: Allowable stresses in compres sion shall be no greater than the basic allowable stresses in tension as tabulated in Appendix A. Con sideration shall be given to structural stability.
302.3.2 Bases for Allowable Stresses The bases for establishing design stress values for bolting materials and allowable stress values for other materials in this Code are as follows:
11 _
SL 012169
AMERICAN NATIONAL STANDARD CHEMICAL PLANT AND PETROLEUM REPINERY PIPING
ANSI B31.3-1976 302.3.2
(a) Uniting Materials: Design stress values at temperature for bolting materials shall not exceed the lowest of the following:
(1) 1/4 of the specified minimum tensile strength at room temperature. (If the bolting material is heat treated, see Note 1.)
(2) 1/4 of the "tensile strength at tempera ture." (Sec Note 2.) ' (3) 5/8 of the specified minimum yield strength at room temperature. (If the bolting material is heat treated, see Note 1.)
(4) 5/8 of the "yield strength at temperature." (See Note 2.)
(5) 100 percent of the average stress for a creep rate of 0.01 percent per 1000 hours.
(6) 67 percent of the average stress for rupture at the end of 100.000 hours.
(7) 80 percent of minimum stress for rupture at the end of 100,000 hours.
(b) Other Materials: Basic allowable stress values at temperature for materials other than bolting materials shall not exceed the lowest of the following:
(1) 1/3 of the specified minimum tensile strength at room temperature.
(2) 1/3 of the "tensile strength at tempera ture." (See Note 2.)
(3) 2/3 of the specified minimum yield strength at room temperature.
(4) 2/3 of the "yield strength at temperature" (see Note 2), except that for austenitic stainless steels and for certain of the nickel alloys, this factor may be as large as 90 percent (see Note 3) of the "yield strength at Temperature" (but never more than 2/3 of the specified minimum yield strength at room temperature).
(5) 100 percent of the average stress for a creep rate of 0.01 percent per 1000 hours.
(6) 67 percent of the average stress for rupture at the end of 100,000 hours.
(7) 80 percent of the minimum stress for rupture at the end of 100,000 hours.
Note 1: For heat treated bolting materials the design stress shall be further limited to the lower of 1/5 of the specified minimum tensile strength at room temperature or 1/4 of the specified minimum yield strength at room tempera ture.
Note 2: For an unlisted material, the "tensile (or yield) strength at temperature" shall be derived by multiplying the average expected tensile (or yield) strength at temperature by the ratio of the specified minimum tensile (or yield) strength at room temperature to the average (expected) tensile (or yield) strength at room temperature.
Note 3: The use of these stress values (approaching 90 percent of yield strength at temperature) is not recommended for flanges or gasketed joints or other applications where slight amounts of deformation can cause leakage or malfunction. Where possiblity of such deformation is present, an allowable stress value of either 75 percent of the allowable stress listed in Appendix A or 2/3 of yield strength value as published in ASME Section VIII, Division 2 should be used.
302.3.3 Casting Quality Factor (E) (a) General: The casting quality factors (H) defined herein shall be used for cast components not having pressure-temperature ratings established by standards listed in Appendix E, Table 1. Allowable stresses (5E) for cast materials listed in Appendix A contain appropriate factors, as noted. (b) Easic Quality Factors: Static castings which conform to basic requirements of the material specifi cation and have received a visual examination in accordance with MSS SP-55 shall be assigned a basic casting quality factor (E) of 0.80. Centrifugal cast ings which conform to specification requirements only to the extent of chemical analysis, tensile, hydrostatic and flattening tests and visual examina tion shall be assigned a basic casting quality factor of 0.80. (c) Increased Quality Factors: Casting quality factors may be increased when supplementary ex aminations are performed on each casting. Table 302.3.3C states the increased casting quality factors (E) which may be used for various combinations of supplemenatry examination. Quality factors higher than those shown in Table 302.3.3C do not result from combining tests 2a and 2b, or 3a and 3b. In no case shall the quality factor exceed 1.00. Several of the specifications listed in Appendix A require machining of all surfaces and/or one or more of these supplementary examinations. In such cases, the appropriate increased quality factor is shown in the stress table and has been incorporated in the tabulated allowable stress for such materials.
Table 302.3.3C Increased Casting Quality Factors (E)
Supplementary Examination
Factor,
in Accordance with Notc(s)
1................................................................................................0.85
2a or 2b.......................................................................................0.85
3a or 3b.......................................................................................0.95
1 and 2(a or b)..........................................................................0.90
1 and 3(a or b).......................................................................... 1.00
2(a or b) and 3(a or b)............................................................. 1.00
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T^TR# Ci, S URGS TX 60 ~ ) > *Z 6
US~ FA/Sr/zYG sr<* TT 60-$S3~
r-3/o T-3ZO
C RUDE P8-JF0A S TOfifiGE P8-ZQ& product storage
D -3/0 &! pfty TfiRK STORfiGF
D - 3Z0 #Z DA/
STORAGE
c.s. C.S' CF C.S-
T-330
VflCUUM SysTFM SOL/XRf SpG C.S.
AST, OOO /6EjOOo
sr^o o jSTs'GO
/3 30 9-S 9. S'
/6 33 /*
. s-f .s-l
<**'%!&'. tacr
oqu^b3ec^t t0Jviaa,ll-DUisict
SL 012171
PROCESS NOP- I/O
P- IZO P- 130 P-140
P-ISO
EQUIPMENT NAME
PS-CP LOP IDE FEED FREE A ED A FEED EDO FLASH RECEIVER PB-EDA WAS/4 FEED EDA FLASH VACUUM.
^ PUMP
N\ PTE. (URL
C . 5.
<? U If ME/VT
GfM
Nor mEi
Q. 3
(2.S. C. -S. Hflsrit-of
-X
.& a. ?
/ /
C.3.
=
LIS 7~
AP Psi
70 /93 N
DENS try WG2U. @> Fto*f 6. ?/
KfNSMR T)<L.
aH p
1/73 CoS iTl/ - C.s.
170
ua
xo /oo Z(0 0
Nat l*>0
n. 3S-
7. 3 jT S.N7
.gs/DO
,o ? *2o
/,0
jsr \N. fi.c
P-ZIO P-22.0 P-230 P-240 P- 25,0 P-2E0 P-270 P- 2 SO P-2PO
SOLVENT FEED BUTANOL FEED CAUSTIC FEED EDA -WATER Pda RECOVEAy WAS T WATER EDA- CAUSTIC ClRCtUAT/0N S TFong Cftu&ne, Noonion EDA Recovers/ vacuum
C-3.
c.>s.
C.J. HflsnuY c.s.
C. >5. N/C/Cjt^
AUCkSL C-S .
I.Sl.syA
./
./3 'SIP*-
.33
*/
/ /
/r
/
3^ 13# 7-3
3S* /oo# 6. n
-3\T S~3
30 ? 7
?3?
so 0 7.3 S'
/o S/P 7 3y
No 7^0 /3.3^
c20 Si // /3.s"
SO 60 . *s.8S'
.Ns , 1ST .X
,N ./ .07
t-jf .01
CONFIDENTIAL: Subject to Protective Order
JUth Judicial District Court No. 91-1145
SL 012172
PROCESS NO.
qiH PMENT NfiM
mURlflL
const
near
OUT.V m sn/H
H1
-//o
-/ZO
- ISO
P Q-Cf//OR(0 PR h/0 fR ZOfi- FJLftSHZP PRS //SRTZH
)#-FZHSHER Coypp3R
C.ss.
HPSTllo/ Off fiftoCeZs.
C .S .
A5"0 <& 0
6>3
US' /* 7
JO
pRTSS UfitT
SHELL
OP/03.
T USE"
OP/GS
tp fAP
oSPH/Eoj&LsL OT/>U/03JSE
S.T0M R^qm/fZD V///R
COAI/Hf A/ T~S
:3+l4iA*i!&Z+*~*iS%' KAHwwhyy
/3L<^f<S-G
/7s/3*-
;#/ PH
3S"o/Voo 3 00/3s-0 /13
3 fs/y&o 3su/ yoo
70
0/ ?s-
,8/ fT 3 6 /36
33s-/sso
--
$ <3 Pf* <2 7~*S R /JOP**? P/A'P
- Z/O - ZZO - Z30
- Z.HO
WPS H W/9 TJfif ZCOA/6AU2/TR 0/9 ~ W/f TR PRH/9 T/? WfisMt W# rep Hep re R
0# Recovepy coA/eez/sen.
C.S.
cs.
N t o/9 PR0CS33
C.3.
Vf VJ HIS.
JfJ
13/ 33
VAR
7A
ri. 1 /-o
/SO//7S' / os'/xoe
S~ / 7S' SO/99T SO/7S'
0 / 7S' / /~o
3.60/3 oO 3S"o/3O0 3 6S~/j/0 0 3lS~&/3oO 3 &r/Vo o AJV/-30 o
S~8* ~p O
/oo//SO 3.30/3 '7'f' --
10 & Pm c rw
- 3/0 - 3ZO
- 330 e - 3V>
PRODUCT srR/PPeR F/EC CAHo/miL C.S.
PRODUCT STR/PPR R80/lR
cs.
PRODUCT STRtPPZR Co/UOzmsfcP
C-S.
PROQUCT COoiZR
cs
/3 6
300 /3* ia.o
V8J /36 3s~o ja.e'
JSO^so !2J^W9S'
&/')' S/7
42//so W/f0
4-/ 7S'
3io/z3SSsv/tycO
//O//st>
I/O //S~0
3So/3 OS3o*/3<r& 3-/9 /3 OO /7ti /200
3^6
HCPm Ctm/
iS.GPm c rvP
SL 012173
* i4E*
Biefcrict Court
N0*. 91-1143
FROG ESS, /VO-
EQUUPMEMT MAMET
V-/oa
CCl4 EJ.rtSt/ DRUM
v- no
SOA ftEpCTcR A /
i/-/zo V-/30
ftfl<-T0A &Z SPA E-lAs/V RSC^/ysR
MATERIAL diameter EONS-T
rnm.....m....m. pwpw^l.nj j ,,Kgpwl14
Anci/r
PRESSURE
OPrt#f//K DE&f&tf
TBMP O pEfifiT/t/C
J
DESt&S
G/fi&s Xtt/P
/
S' S.SS
33
/SO
30 0
<3 t?<r'
GI//S3. L/SfD
^4
-$" 3'
.3S~ 3
J3 .S'
/so so/s/s
3 00
3 7S"
\/-2JO !/-zzo /-Z30
K- zH-o
amass' ss/paatoA S0A PSCt>/SRy ACC-UM/ATOp WAS# WATS* sYSfortfiro/? sA<T coTc^StRrto A
C.4. C.S, At Aa,
/- 3/0 Rftooutr srs/sss/t PCc.^jnLPnA c.s.
i Si Si
3
(S'
30
S'
7
SO /
3jl/l4+1
OS' so s*/sr
/7 0 TisO 3LEO
ZEO 3<P0 3 00
& 'T 3
a fs/A.
so/EE
s?/r
3.SO
c - //O a - z/o
SO A (/AC uurt fi/?S/ S0A R SCOTSAy C0/.l4/rf/M PRooi/cr sta/ppaA
////STCJLko/ <3
Mi C.s.
SS 3
9 * V (fis/cu par ^ 30 C0*. A EltfZ&i o-
SO//ry m
S<2/Sts
3SO 3 SO 3 00
A/OO 3a O 3 SO
ijLjywBP'M. ngj^TfrrtiwwMlWi
C-OMMEA/TS
frfc/rsrto
^///e
usAcs
i e n?#ys , jy"
0 1
u>
o
SL 012174
PROCESS.
NO.
RQUI P Mfits' NtfMf
P-- 310 PRODUCT STRIPPER Fee a
P-320 PRODUCT STR/PPFR fSOTTD/A
P-330 AQUEOUS PHASE-
P-246 SOLVE NT RTCycL E
P-3S0 PRODUCT STRIPPER VACUUM
?-3iO PRODUCT Dffy TANK P-370 product loadms
P-380 VACUUM STAL
C -S'. c. s c. -s. c. s.
C~s-
c.s Cs. cs.
P3*
a
,23
S 3lSO
a i
}QO /oo Hi (o 00 Ss
AP DBA/S/XD
s~o w it 30 /DO $P ZO V > 3S' 96
9. A 63/ 8.z 6. 7/
K//VEM tf 7/C " & H. A i//J C OS / 7l!/
3 0 i.O ? ts~ / .// t . iS'
30 SO m S3 so
?. a ? a 7a
s yj" /S'
7 . s'
3^^
cour t
SL 012175
Process. HO
nAmT
M-/
Epft ft0C TO ft mixed
V- I/O
M-Z
EOfl ftTfiCTO/t V- UO
M/Aed
1/-Z/0 DfiWE
Up
}
fo jesriMn-re ! /o
JZS~
CONFIDENTIAL:
e<:k
Protective Order
l4tl\ iudiei&i. District Court
wa, ^-1145
SL 012176