GIS 46-010 Specification for Pressure Vessels

© BP p.l.c. Security classification: BP Internal

Global Projects Organisation

Specification for Pressure Vessels

B01 Rev

Issued for Use Mike T Brown Reason for Issue Author Refresh Cycle Code (years) N/A Retention Code (years) N/A This document is copyright and shall not be reproduced without the permission of BP

10 Oct 2013 Michael Ho Date Checked Expiry Date N/A Delete Date N/A

10 Oct 2013 Date

Mike T Brown Approved

10 Oct 2013 Date

Rev

GPO-EN-SPE-46010

B01

Group Instruction for Supply

GIS 46-010 Specification for Pressure Vessels

GPO-EN-SPE-46010 © BP p.l.c.

Page 2 of 2

Rev: B01 BP Internal


Table of Contents Page 1

Scope .................................................................................................................................... 7

2

Normative references............................................................................................................. 7

3

Terms and definitions........................................................................................................... 10

4

Symbols and abbreviations .................................................................................................. 12

5

Order of precedence ............................................................................................................ 14

6

Supplier’s responsibilities..................................................................................................... 14

7

Design requirements............................................................................................................ 15 7.1 General..................................................................................................................... 15 7.2 Design loads and load combinations......................................................................... 16 7.3 Wind loading ............................................................................................................. 16 7.4 Seismic loading......................................................................................................... 17 7.5 Snow loading ............................................................................................................ 17 7.6 Motion induced loads ................................................................................................ 17 7.7 Cyclic loading............................................................................................................ 17 7.8 Local loading............................................................................................................. 18 7.9 Wind-induced vibration of vertical vessels................................................................. 18 7.10 Transportation loads ................................................................................................. 19 7.11 Lifting loads............................................................................................................... 19 7.12 Design calculations ................................................................................................... 20 7.13 Shock loading ........................................................................................................... 20

8

Materials requirements ........................................................................................................ 20 8.1 General..................................................................................................................... 20 8.2 Certificates of compliance ......................................................................................... 21 8.3 Certified material test reports .................................................................................... 21

9

Vessel components.............................................................................................................. 21 9.1 Vessel shells and transitions..................................................................................... 21 9.2 Formed heads........................................................................................................... 21 9.3 Connections, nozzles, and manways ........................................................................ 22 9.4 Flanges..................................................................................................................... 25 9.5 Blind flanges and bolted flat heads ........................................................................... 27 9.6 Swing bolt closures ................................................................................................... 27 9.7 Quick-actuating closures........................................................................................... 27 Copyright © 2013 BP International Ltd. All rights reserved. This document and any data or information generated from its use are classified, as a minimum, BP Internal. Distribution is intended for BP authorised recipients only. The information contained in this document is subject to the terms and conditions of the agreement or contract under which this document was supplied to the recipient's organisation. None of the information contained in this document shall be disclosed outside the recipient's own organisation, unless the terms of such agreement or contract expressly allow, or unless disclosure is required by law.

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GPO-EN-SPE-46010 10 October 2013


9.8 9.9 9.10 9.11 9.12 9.13 9.14

Supports ................................................................................................................... 27 Anchor bolts.............................................................................................................. 30 Internal attachments ................................................................................................. 31 External attachments ................................................................................................ 32 Removable internals ................................................................................................. 38 External jackets ........................................................................................................ 41 Nameplates............................................................................................................... 42

10

Spares ................................................................................................................................. 42

11

Fabrication requirements ..................................................................................................... 42 11.1 General..................................................................................................................... 42 11.2 Tolerances ................................................................................................................ 43 11.3 Joints ........................................................................................................................ 43 11.4 Welding..................................................................................................................... 44 11.5 Temporary welded attachments ................................................................................ 47

12

Examination requirements ................................................................................................... 47 12.1 General..................................................................................................................... 47 12.2 Preparation ............................................................................................................... 48 12.3 Examination of materials........................................................................................... 48 12.4 Surface examination of welds ................................................................................... 49 12.5 Volumetric examination of welds............................................................................... 49 12.6 Hardness testing ....................................................................................................... 50 12.7 Repair of welding defects.......................................................................................... 50 12.8 Positive materials identification (PMI)........................................................................ 51 12.9 Production control test plates.................................................................................... 51

13

Inspection requirements....................................................................................................... 51

14

Post weld heat treatment ..................................................................................................... 51

15

Pressure test........................................................................................................................ 52 15.1 General..................................................................................................................... 52 15.2 Hydrostatic test ......................................................................................................... 53 15.3 Pneumatic test .......................................................................................................... 54

16

Cleaning, surface preparation, painting, and marking .......................................................... 54 16.1 Cleaning ................................................................................................................... 54 16.2 Surface preparation painting and non-metallic lining ................................................. 55 16.3 Marking..................................................................................................................... 56

17

Preparation for shipment...................................................................................................... 57 17.1 General..................................................................................................................... 57 17.2 Preparations for the vessel ....................................................................................... 58 17.3 Preparations for spares and crated parts .................................................................. 58 17.4 Securing and padding ............................................................................................... 59 17.5 Material safety data sheets ....................................................................................... 59

18

Documentation..................................................................................................................... 59 18.1 Proposal documentation ........................................................................................... 59 18.2 During design and fabrication ................................................................................... 60 Page 3 of 96



18.3

Final documentation.................................................................................................. 61

19

Quality management............................................................................................................ 63

20

Inspection, test and certification ........................................................................................... 63 20.1 Inspection and test plan ............................................................................................ 63 20.2 Inspection access ..................................................................................................... 63 20.3 Quality assurance ..................................................................................................... 63

21

Packing, preservation, marking and shipping ....................................................................... 64

22

Supplier deliverables............................................................................................................ 64

Annex A (Normative) Supplementary requirements for special services ....................................... 65 A.1

General................................................................................................................................ 65

A.2

Anhydrous ammonia service................................................................................................ 65

A.3

Butane storage .................................................................................................................... 65

A.4

Amine service ...................................................................................................................... 65

A.5

Caustic service .................................................................................................................... 65

A.6

Cyanides service ................................................................................................................. 65

A.7

Cyclic service....................................................................................................................... 66

A.8

Hydrofluoric acid .................................................................................................................. 66

A.9

Hydrogen service................................................................................................................. 66

A.10 Cryogenic service ................................................................................................................ 67 A.11 Propane storage .................................................................................................................. 67 A.12 Sour water, wet H2S, or wet sour service ............................................................................. 67 Annex B (Normative) Supplementary requirements for chrome-moly vessels ............................... 71 B.1

General................................................................................................................................ 71

B.2

Fabrication........................................................................................................................... 72

B.3

Examination requirements ................................................................................................... 72

B.4

1,25Cr-0,5Mo vessels (including Vanadium enhanced) ....................................................... 72

B.5

2.25Cr-1Mo vessels (including Vanadium enhanced) .......................................................... 72

Annex C (Normative) Supplementary requirements for stainless steel vessels ............................. 74 C.1

Fabrication........................................................................................................................... 74

C.2

Welding................................................................................................................................ 74

C.3

Examination requirements ................................................................................................... 74

C.4

Cleaning and surface preparation ........................................................................................ 75

Annex D (Normative) Supplementary requirements for clad plate or weld-overlay construction .... 76 D.1

Design ................................................................................................................................. 76

D.2

Clad plate material............................................................................................................... 78

D.3

Cladding re-instatement....................................................................................................... 78

D.4

Weld overlay ........................................................................................................................ 79

D.5

Welding procedures ............................................................................................................. 80 Page 4 of 96



D.6

Internal attachments ............................................................................................................ 81

D.7

Examination of weld overlay and clad re-instatement........................................................... 81 D.7.1 UT examination......................................................................................................... 81 D.7.2 PT examination......................................................................................................... 82 D.7.3 Chemical analysis ..................................................................................................... 82

Annex E (Normative) Supplementary requirements for DHT and IPWHT...................................... 83 E.1

Dehydrogenation heat treatment.......................................................................................... 83

E.2

Intermediate post weld heat treatment ................................................................................. 83

Annex F (Normative) Allowable piping loads on nozzles ............................................................... 85 Annex G (Normative) Ladders and platforms ................................................................................ 93 G.1. General................................................................................................................................ 93 G.2. Layout.................................................................................................................................. 93 G.3 Platforms ............................................................................................................................. 93 G.4. Ladders, ladder cages, and safety gates.............................................................................. 96 G.5. Handrailing .......................................................................................................................... 96

List of Tables Table 1 - Minimum transportation acceleration loadings................................................................ 19 Table 2 - Minimum thickness of nozzles........................................................................................ 23 Table 3 - Quality levels for straight beam examinations from flat surfaces .................................... 26 Table 4 - Skirt vents ...................................................................................................................... 29 Table 5 - Dimensions of light lifting lugs ........................................................................................ 35 Table 6 - Dimensions of heavy lifting lugs ..................................................................................... 36 Table 7 - Tailing lug dimensions.................................................................................................... 37 Table 8 - Mist eliminator dimensions ............................................................................................. 41 Table 9 - Flatness tolerances of gasket contact surface................................................................ 43 Table F.1 - Pipe size forces .......................................................................................................... 86 Table F.2 - De-rating factor ........................................................................................................... 86 Table F.3 - Allowable piping loads on nozzles............................................................................... 87 Table G.1 - Minimum platform clearances..................................................................................... 95

List of Figures Figure 1 - Skirts on vertical vessels less than 50 mm (2 in) thick or in non-cyclic service .............. 28 Figure 2 - Skirts on vessels ≥ 50 mm (2 in) thick or in cyclic service ............................................. 28 Figure 3 - Opening for skirt access or for piping............................................................................ 29 Figure 4 - Opening for a skirt vent................................................................................................. 29 Figure 5 - Design of light lifting lug ................................................................................................ 35 Figure 6 - Design of heavy lifting lug ............................................................................................. 36 Page 5 of 96



Figure 7 - Design of tailing lug....................................................................................................... 37 Figure 8 - Mist eliminator used for the full diameter of a vessel ..................................................... 38 Figure 9 - Mist eliminator for an enclosed internal cylinder............................................................ 39 Figure 10 - Mist eliminator for a reduced diameter ........................................................................ 39 Figure 11 - Mist eliminator attachment details ............................................................................... 40 Figure 12 - Mist eliminator support details..................................................................................... 41 Figure 13 - Surface Contours........................................................................................................ 56 Figure 14 - Internal attachments ................................................................................................... 56 Figure D.1 - Typical clad nozzle attachment to shell ..................................................................... 76 Figure D.2 - Attachment of lightly loaded attachment to a clad vessel........................................... 76 Figure D.3 - Attachment of a moderately loaded attachment to a clad vessel ............................... 77 Figure D.4 - Method for cladding a raised face flange ................................................................... 77 Figure D.5 - Method for cladding a ring type joint flange ............................................................... 77 Figure D.6 - Cladding re-instatement at a vessel seam ................................................................. 79 Figure G.1 - Typical column platform and ladder elevations.......................................................... 94 Figure G.2 - Minimum clearances in platform design .................................................................... 95 Figure G.3 - Typical platform at the top of a vessel ....................................................................... 96

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1

Scope a.

b.

2

This Specification provides requirements for the design, materials, fabrication, inspection, testing, documentation, and preparation for shipment of pressure vessels designed, fabricated, and certified in conformance to one of the following standards: 1.

ASME Boiler and Pressure Vessel Code, Section VIII, Division 1.

2.

ASME Boiler and Pressure Vessel Code, Section VIII, Division 2.

3.

BSI PD 5500 Specification for Unfired Fusion Welded Pressure Vessels.

4.

EN 13445 Unfired Pressure Vessels.

This specification also provides recommended design requirements for standard vessel details which may be used if desired by the vessel manufacturer or if specified to be used on the engineering datasheet in the direct purchase of pressure vessels. The use of other standard details, such as those provided by the engineering contractor or industry organisations, is not precluded.

Normative references The following documents are referenced in one or more requirements in this document. For dated references, only the version cited applies. For undated references, the latest version of the referenced document (including any amendments) applies. Company Documents GIS 06-602 GIS 18-012 GIS 18-013 GIS 36-025 GIS 36-102 GIS 36-103 GIS 42-300 GIS 42-301 GIS 46-040 GP 36-26

Specification for Coating and Painting of Supplier Equipment Specification for Procurement, Storage, and Control of Welding Consumables Specification for Weld Overlay, Integral Cladding, and Limited Loose Lining of Pressure Vessels and Other Components Requirements for Sour Service Materials for Upstream Oil and Gas Production Systems Specification for Hardness Testing, Post Weld Heat Treatment, Stress Relief, and Pickling for Pressure Vessels, Piping, and Other Components Specification for Positive Materials Identification (PMI) for Pressure Vessels, Piping, and other Components Specification for Flange Bolts Specification for Gaskets Specification for Internals for Columns Materials for Sour Service in Refining and Marketing Operations

American Petroleum Institute (API) API Specification 5L API Specification Q1 API RP 934-A

Specification for Line Pipe. Specification for Quality Programs for the Petroleum, Petrochemical and Natural Gas Industry Materials and Fabrication of 2 1/4Cr-1Mo, 2 1/4Cr-1Mo-1/4V, 3Cr-1Mo, and 3Cr-1Mo-1/4V Steel Heavy Wall Pressure Vessels for High-temperature, High-pressure Hydrogen Service

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API RP 934-C

API RP 934-E

Materials and Fabrication of 1 1/4Cr-1/2Mo Steel Heavy Wall Pressure Vessels for High-pressure Hydrogen Service Operating at or below 825ºF (441 ºC) Closed Recommended Practice for Materials and Fabrication of 1 1/4 CR-1/2 Mo Steel Pressure Vessels for Service above 825ºF (440ºC)

American Society of Mechanical Engineers (ASME) ASME SA-263 Standard Specification for Stainless Chromium Steel-Clad Plate ASME SA-264 Standard Specification for Stainless Chromium Nickel Steel Clad Plate ASME SA-265 Standard Specification for Nickel and Nickel Base Alloy Clad Steel Plate ASME SA-435/SA-435M Straight-Beam Ultrasonic Examination of Steel Plates ASME SA-516/SA-516M Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderate and Lower Temperature Service ASME SA-541/SA-541M Quenched and Tempered Carbon and Alloy Steel Forgings for Pressure Vessel Components. ASME SA-578/SA-578M Standard Specification for Straight-Beam Ultrasonic Examination of Rolled Steel Plates for Special Applications ASME SA-745/SA-745M Ultrasonic Examination of Austenitic Steel Forgings ASME SA-770/SA-770M Through-Thickness Tension Testing of Steel Plates for Special Applications ASME SA-841/SA-841M Steel Plates for Pressure Vessels, Produced by Thermo-Mechanical Control Process (TMCP) ASME B16.5 Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard ASME B16.47 Large Diameter Steel Flanges: NPS 26 through NPS 60 Metric/Inch Standard ASME B31.3 Process Piping ASME PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint Assembly ASME PCC-2 Repair of Pressure Equipment and Piping ASME BPVC VIII-1 ASME Boiler and Pressure Vessel Code (BPVC), Section VIII, Division 1: Rules for Construction of Pressure Vessels ASME BPVC VIII-2 ASME Boiler and Pressure Vessel Code (BPVC), Section VIII, Division 2: Alternative Rules American Society for Testing and Materials (ASTM) ASTM A380 ASTM A578 ASTM E112 ASTM E165

Standard Practice for Cleaning, Descaling and Passivation of Stainless Steel Parts, Equipment, and Systems Standard Specification for Straight-Beam Ultrasonic Examination of Rolled Steel Plates for Special Applications Standard Test Methods for Determining Average Grain Size Standard Practice for Liquid Penetrant Examination for General Industry

American Society of Civil Engineers (ASCE) ASCE 7

Minimum Design Loads of Buildings and Other Structures

American Welding Society (AWS) AWS A4.2

Standard Procedures for Calibrating Magnetic Instruments to Measure the Delta Ferrite Content of Austenitic and Duplex Austenitic-Ferritic Stainless Steel Weld Metal Page 8 of 96



AWS A2.4

Standard Symbols for Welding, Brazing, and Non-destructive Examination

British Standards Institute (BSI) BSI BS EN 1991-1-4 + A1 NA UK National Annex to Eurocode 1 - Actions on structures Part 1-4: General actions - Wind actions - AMD 1 BSI PD 5500 Specification for Unfired Fusion Welded Pressure Vessels European Standards (EN) EN 1991-1-4 + A1 EN 10028-3 EN 10028-5 EN 10028-6 EN 10160 EN 10164 EN 10228-1 EN 10228-2 EN 10228-3 EN 10228-4 EN 13445

Eurocode 1 - Actions on structures Part 1-4: General actions - Wind actions Flat products made of steels for pressure purposes Part 3: Weldable fine grain steels, Normalised Flat products made of steels for pressure purposes Part 5: Weldable fine grain steels, Thermomechanically rolled Flat products made of steels for pressure purposes. Weldable fine grain steels, quenched and tempered Ultrasonic testing of steel flat product of thickness equal or greater than 6 mm (reflection method) Steel products with improved deformation properties perpendicular to the surface of the product. Technical delivery conditions Non-destructive testing of steel forgings. Magnetic particle inspection Non-destructive testing of steel forgings. Penetrant testing Non-destructive testing of steel forgings. Ultrasonic testing of ferritic or martensitic steel forgings Non-destructive testing of steel forgings. Ultrasonic testing of austenitic and austenitic-ferritic stainless steel forgings Unfired pressure vessels

International Organisation for Standardisation (ISO) ISO 8249 ISO 8573-1 ISO 9001 ISO 15156-1

ISO 15156-2

ISO 15156-3

Welding - Determination of Ferrite Number (FN) in austenitic and duplex ferritic-austenitic Cr-Ni stainless steel weld metals Compressed air - Part 1: Contaminants and purity classes Quality Management System - Requirements Petroleum and natural gas industries - Materials for use in H2S-containing environments in oil and gas production - Part 1: General principles for selection of cracking-resistant materials Petroleum and natural gas industries - Materials for use in H2S-containing environments in oil and gas production - Part 2: Cracking-resistant carbon and low-alloy steels and the use of cast irons Petroleum and natural gas industries - Materials for use in H2S-containing environments in oil and gas production - Part 3: Cracking-resistant CRAs (corrosion-resistant alloys) and other alloys

National Association of Corrosion Engineers (NACE) NACE MR0103 NACE MR0175

Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining Environments Petroleum, Petrochemical and Natural Gas Industries – Materials for Use in H2S-containing Environments in Oil and Gas Production (ISO 15156) Page 9 of 96



NACE SP0472

Methods and Controls to Prevent In-Service Environmental Cracking of Carbon Steel Weldments in Corrosive Petroleum Refining Environments NACE TM0284 Evaluation of Pipeline and Pressure Vessel Steels for Resistance to Hydrogen-Induced Cracking NACE TM0177 Laboratory Testing of Metals for Resistance to Sulfide Stress Cracking and Stress Corrosion Cracking in H2S Environments SSPC SP 5/NACE No. 1 White Metal Blast Cleaning Other References Joseph Vellozzi, Ph.D

Brownell and Young Zick, L.P

Dynamic Response of Tall Flexible Structures to Wind Loading., Department of Commerce, National Bureau of Standards, Building Science Series Number 32, 1966 Process Equipment Design, Wiley & Sons Publishers, 1959 Stresses in Large Horizontal Cylindrical Pressure Vessels on Two Saddle Supports, Pressure Vessels and Piping: Design and Analysis, A Decade of Progress. Vol. 2, 1972

Process Industry Practices (PIP) PIP STE05501 PIP STF05501 PIP STF05520 PIP STF05521 PIP STF05530 PIP STE05535 PIP STF05535 PIP VEFV1100 PIP VEFV1100M

Fixed Ladders and Cages Design Guide Fixed Ladders and Cages Fabrication Details Details for Pipe Railing for Walking and Working Surfaces Details for Angle Railings for Walking and Working Surfaces Grating Fabrication Details Vessel Circular Platform Detail Guidelines Vessel Circular Platform Details Vessel/S&T Heat Exchanger Standard Details (U.S. Customary Units) Vessel/S&T Heat Exchanger Standard Details (Metric Units)

Welding Research Council (WRC) WRC Bulletin 297 WRC Bulletin 368 WRC Bulletin 537

3

Local Stresses in Cylindrical Shells Due to External Loadings on Nozzles Stresses in Intersecting Cylinders Subjected to Pressure Precision Equations and Enhanced Diagrams for Local Stresses In Spherical and Cylindrical Shells Due To External Loadings For Implementation of WRC Bulletin 107

Terms and definitions For the purpose of this Specification, the following terms and definitions apply: ASME Code ASME Boiler and Pressure Vessel Code. Certificates of compliance A document by which the material manufacturer (or seller to the extent that the Code allows) certifies that the material represented has been produced and tested in conformance to the requirements of the basic material specification shown on the certificate.

Page 10 of 96



Certified material test report A document, or documents, on which are recorded the results of tests, examinations, repairs, or treatments required by the material specification. Cladding re-instatement The process in which areas at joints, nozzles and attachments, that have had cladding removed to permit welding of the base material, are re-clad by weld overlay. Company BP p.l.c., an associate or subsidiary, or other organisation acting as owner, purchaser, or customer as designated in the Purchase Order. Company responsible engineer Company engineer responsible for the technical requirements of the item. Cyclic service A service in which fatigue becomes significant due to the cyclic nature of mechanical and (or) thermal loads. Fabrication plan A detailed description of the processes and sequence of the processes to be used to fabricate the pressure vessel. Ferritic steel Steel where the predominant phase is ferrite, such as Carbon, Carbon Manganese, and low alloy steels. Inspection and test plan A detailed matrix of quality assurance and inspection activities to be performed. The format of the document includes provisions to indicate monitoring and witness points. Manufacturer An entity performing welding of a pressure vessel or pressure vessel parts. May or may not be the Supplier. Quality assurance Planned and systematic actions required to provide confidence that a product or service satisfies given requirements for quality. Quality control plan The manufacturer’s job specific documented plan for ensuring that all specified technical requirements shall be followed. Quality control system The manufacturer’s documented system for ensuring that all applicable code requirements for the manufacturing process, including material handling and identification, design, fabrication, inspection and testing, are followed. Quality plan A document setting out the specific quality practices, resources and sequence of activities for a particular product, service or Purchase Order.

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Reinforcing plate Reinforcing element as used in ASME Code, compensation plate as used in BSI PD 5500, or reinforcing plate as used in EN 13445. Supplier Entity entering into a Purchase Order with Company to provide materials, goods, supplies, equipment, or plant and includes the successors and (or) permitted assigns of such entity. Weldment Weld, HAZ, and adjacent parent metal.

4

Symbols and abbreviations For the purpose of this Specification, the following symbols and abbreviations apply: ASS

Austenitic stainless steel.

CMCL

Corrugated metal with covering layers.

CMTR

Certified material test report.

DHT

Dehydrogenation heat treatment.

DN

Nominal pipe diameter.

FCAW

Flux cored arc welding.

FEA

Finite element analysis.

FN

Ferrite number (per Welding Research Council Bulletin Number 342).

GMAW

Gas metal arc welding.

GTAW

Tungsten inert gas welding.

HAZ

Heat affected zone.

HIC

Hydrogen-induced cracking.

HRB

Rockwell hardness number, B scale, tested with a steel ball.

HBW

Brinell hardness measured by tungsten carbide ball (also referred to as HB and BHN).

Hv10

Vickers hardness measured with a 10 kgf indenter (also referred to as HV).

IPWHT

Intermediate post-weld heat treatment (also known as ISR Intermediate stress relief).

ITP

Inspection and test plan.

LWN

Long welding neck.

MAP

Maximum allowable pressure.

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MAWP

Maximum allowable working pressure.

MSDS

Material safety data sheets.

MDMT

Minimum design metal temperature.

MT

Magnetic particle testing.

NDE

Non-destructive examination.

NPS

Nominal pipe size.

PCN

Personnel Certification in Non-Destructive Testing.

PMI

Positive material identification.

PQR

Procedure qualification record.

PT

Liquid or dye penetrant testing.

PWHT

Post-weld heat treatment.

PWHTmin

Shortest time for which the vessel may be heat treated to meet code requirements.

PWHTmax

Longest time for which the vessel may be heat treated.

QA

Quality assurance.

Q+T

Quenched and tempered.

RT

Radiographic testing.

RTV

Room temperature vulcanising.

SAW

Submerged arc welding.

SMAW

Shielded metal arc welding.

SOHIC

Stress orientated hydrogen induced cracking.

SZC

Soft zone cracking.

TMCP

Thermo-mechanical control process.

TOFD

Time of flight diffraction.

UT

Ultrasonic testing.

WFMT

Wet fluorescent magnetic particle testing.

WPQ

Welder or welding operator performance qualification.

WPS

Welding procedure specification.

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5

Order of precedence a.

6

The order of precedence of the codes and standards quoted in the specifications shall be: 1.

International and local statutory regulations.

2.

Project data sheets.

3.

Project specifications.

4.

This Specification.

5.

Referenced Company documents.

6.

Referenced national and international codes.

b.

Areas of apparent conflict between documents shall be brought to the attention of Company for resolution.

c.

In the event of a conflict between this document and a relevant law or regulation, the relevant law or regulation shall be followed. If the document creates a higher obligation, it shall be followed as long as this also achieves full compliance with the law or regulation.

d.

Design, engineering, procurement, and construction for equipment shall comply with the statutory laws and regulations of the final location of the asset. Refer to documents identified in the Purchase Order for a list of these regulations.

e.

For projects where the final location of the asset is in the EU: 1.

Products supplied shall be confirmed to comply with applicable EU directives.

2.

A Declaration of Conformity shall be provided.

3.

The CE mark shall be affixed to the pressure vessel nameplate.

4.

Components supplied shall be listed together with the EU directives with which they comply and the rationale by which compliance has been achieved.

5.

A Technical File in compliance with applicable EU directives shall be compiled and retained for a period of 10 years.

Supplier’s responsibilities a.

The mechanical design, provision of materials, fabrication, inspection, testing, and quality of workmanship of pressure vessels which shall be provided in conformance to this Specification and the following: 1.

Comply with local jurisdictional requirements.

2.

The required design code shall be as specified on the data sheets.

3.

Pressure equipment directive when specified on the data sheets.

4.

Other codes and standards referenced in this Specification.

5.

Additional requirements listed on the data sheets.

b.

Vessels shall conform to the specified design code, including the application of code stamp or certificate of conformity.

c.

Vessels designed in conformance to the ASME Code shall be registered with the National Board.

d.

Design of a vessel or a vessel component furnished by Company shall not relieve the Supplier of their responsibility to conform to the requirements of this Specification and other Purchase Order documents.

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7 7.1

e.

Company’s review and agreement of Supplier documentation shall not relieve the Supplier of their responsibility to conform to the requirements of this Specification and other Purchase Order documents.

f.

Company shall be allowed shop access for inspecting materials and activities during vessel fabrication for conformance to this Specification. Work or materials not conforming shall be cause for rejection.

g.

Data sheets, drawings, quality control records, and other items which assist in determining the acceptability of a vessel for inspection shall be made available to Company.

h.

Release for shipment by Company inspector shall not relieve the Supplier of their responsibility to conform to the requirements of this Specification and Purchase Order documents.

i.

The Supplier shall be responsible for assuring that subcontracted fabrication work is in conformance to this Specification and Purchase Order documents, however no portion of vessel construction, such as plate forming, welding, heat treatment, non-destructive examination, painting, shall be subcontracted without prior written agreement from Company.

Design requirements General a.

Vessel design shall be in conformance to the applicable design code, this Specification, and all Purchase Order documents.

b.

Computer calculations shall show input and output data, clearly state assumptions made, and specify program name and version number.

c.

The maximum design temperature rating shall be increased to the highest temperature permitted in conformance to the Code without affecting the minimum required thickness of the shell or heads and without changing the pressure class of the flanges.

d.

A vessel may be designed and stamped for more than one condition of pressure and coincident metal temperature.

e.

Unless otherwise specified on the data sheets, vessels shall be assumed to operate completely filled with process fluid having a minimum specific gravity of 1,0.

f.

MAWP shall be calculated based on actual construction unless otherwise specified on data sheets.

g.

For vessels constructed to ASME BPVC VIII-1, the coincident ratio used for calculating the MDMT of the vessel shall not be less than 1,0.

h.

The supplementary requirements for special services shall conform to Annex A of this Specification if specified on data sheet.

i.

Standard details provided by Supplier are not precluded, but details in this Specification shall be used and fabricated as shown if specified on data sheets.

j.

Document numbers PIP VEFV1100 and PIP VEFV1100M contain standard drawings, prefixed ‘PIP VEFV’ in U.S. customary units and metric units respectively. This Specification will reference metric standard drawing numbers only but it shall be interpreted as also referring to the metric standard drawing (with suffix M) and equivalent standard drawing in U.S. customary units (without suffix M).

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7.2

Design loads and load combinations

7.2.1

Design load classifications and definitions The following definitions shall apply for the load case combinations specified in 7.2.2:

7.2.2

a.

Dead load (L1) is the installed weight of the vessel, including internals, catalyst or packing, refractory lining, platforms, insulation fireproofing, piping, and other permanent attachments. This does not include the weight of process liquid or catalyst contents.

b.

Operating live load (L2) is the weight catalyst plus the weight of process liquid at the design liquid level, including that on trays.

c.

Pressure load (L3) is the MAWP (internal or external at the coincident temperature) considering the pressure variations through the vessel.

d.

Thermal load (L4) is the load caused by the restraint of thermal expansion and interaction of vessel and its supports.

e.

Test load (L5) is the weight of test water.

f.

Wind load (L6) shall be determined in conformance to 7.3.

g.

Seismic load (L7) shall be determined in conformance to 7.4.

h.

Piping and superimposed equipment loads (L8) are loads caused by piping (based on Annex F loadings), and loads caused by superimposed equipment. See 9.3.6.

Load conditions Vessels and their supports shall satisfy all of the following load conditions: a.

Erected condition with full wind load (L1 + L6).

b.

Design condition with wind load (L1 + L2 + L3 + L4 + L6 + L8). 1.

c.

Design condition with seismic load (L1 + L2 + L3 + L4 + L7 + L8). 1.

d.

e.

7.3

Both full and zero pressure loads (L3) shall be included for check of maximum longitudinal tensile and compressive stress. Both full and zero pressure loads (L3) shall be included for check of maximum longitudinal tensile and compressive stress.

Future (corroded) pressure test (L1+ test pressure + L5 + 0,25*L6). 1.

Vessels shall be designed to permit application of a full hydraulic test in their operating positions and 25% design wind load.

2.

The general primary membrane tensile stress under this load condition in the corroded condition shall not be greater than either of the following: a)

For hydrostatic testing, 90% of the specified minimum yield strength at 38°C (100°F), in both circumferential and longitudinal directions.

b)

For pneumatic testing, 80% of the specified minimum yield strength at 38°C (100°F), in both circumferential and longitudinal directions.

Lift condition 1.

See data sheets and 7.11.

2.

Erection load shall be total erection weight of vessel multiplied by an impact factor as specified in data sheet.

Wind loading a.

Unless otherwise specified on the data sheets: Page 16 of 96



1.

7.5

a)

Importance factor shall be Category III.

b)

Velocity pressure exposure coefficient and gust response factors shall be Exposure C for inland and coastal installations and Exposure D for offshore installations.

2.

For EU sites, wind loading shall conform to EN 1991-1-4 + A1.

3.

For sites in the UK, wind loading shall conform to EN 1991-1-4 + A1, used in conjunction with BSI BS EN 1991-1-4 + A1 NA.

4.

Wind load for other locations shall conform to data sheets and comply with local regulatory requirements.

b.

Allowable deflection at any location on a vertical vessel in the corroded condition shall not exceed 150 mm per 30 m (6 in per 100 feet) of vessel height.

c.

Projected area of vessel accessories such as platforms, ladders, piping, and other equipment attached to the vessel shall be included in the wind load calculation.

d.

Vessels fitted with spoilers:

e. 7.4

For US sites, wind load shall conform to ASCE 7 and governing local jurisdictional requirements. The following shall be used in calculations:

1.

Column projected area shall be calculated using the projected diameter taken at the outside edge of the spoilers multiplied by the height of the section under consideration.

2.

Column projected area normal to wind and corresponding force coefficient, for the column height shall be used in the design of vessel and supporting structure to calculate the overturning load.

Wind induced moment and shear forces at the base of the vessel shall be specified on Supplier drawings.

Seismic loading a.

Unless otherwise specified on the data sheets, seismic loads shall be determined in conformance to ASCE 7 and governing local jurisdictional regulations.

b.

Pressure vessel, supporting structures and foundation bolts shall be evaluated using the allowable stress design method.

c.

Vertical columns shall be considered as “cantilevered column systems” if they are anchored to a foundation at grade.

d.

Seismic induced moment and shear forces at the base of the vessel shall be specified on Supplier drawings.

Snow loading Unless otherwise specified on the data sheets, the snow load shall be determined in conformance to ASCE 7 and governing local jurisdictional regulations.

7.6

Motion induced loads The motion induced loads listed on the data sheets shall be applied to all load cases listed in 7.2.

7.7

Cyclic loading a.

The rules in ASME BPVC VIII-2, Paragraph 4.1.1.4, shall be used as a basis for establishing further action if a data sheet specifies a vessel is in cyclic service.

Page 17 of 96



b. 7.8

Local loading a.

b.

7.9

A fatigue analysis shall be performed for agitator mounting nozzles and their attachment to the vessel.

Local stresses in vessel shell, heads and nozzles shall be evaluated using either WRC Bulletin 297, 537 and 368 procedures, BSI PD 5500 annex G, or other local stress analysis procedures agreed by Company based on: 1.

The allowable imposed loads and moments on nozzles specified in Annex F of this Specification.

2.

The loads and moments imposed on attachments from piping and platforms.

For loads evaluated using WRC Bulletins 297, 537 and 368: 1.

The allowable stresses for local nozzle loads and pressure at design temperature shall be 1,5S for local primary membrane stress and 3S for primary membrane plus secondary bending stress at nozzles.

2.

The allowable stresses for attachment local loads at ambient temperature shall be 1,0S and 1,5S respectively.

c.

S is the Code allowable or design stress.

d.

For local loads evaluated in conformance to BSI PD 5500 annex G, the allowable stresses at ambient and design temperature shall conform to the code.

Wind-induced vibration of vertical vessels a.

Vessels with a height to diameter ratio of either the entire vessel or the top third of the vessel is greater than or equal of 15 shall be evaluated for dynamic behaviour from wind excitation as described in Dynamic Response of Tall Flexible Structures to Wind Loading or by other similar proven evaluation methodology.

b.

Critical wind velocities shall be determined for every change in vessel outer diameter.

c.

Vessel critical wind velocities (first and second modes) shall be less than 7 m/s (15 mph) or greater than 27 m/s (60 mph).

d.

For a vessel with critical wind velocities between 7 m/s (15 mph) and 27 m/s (60 mph): 1.

A means of either preventing vortex formation (e.g., by spoilers, piping, ladders, or platforms) or vibration dampening shall be provided.

2.

Wind spoilers shall be added to the vessel in conformance to one of the following methods if it is established that a vessel may vibrate and the attachments of the vessel cannot be changed to put the vessel in a range where vibration cannot occur. The method used to deter wind-induced vibration shall be agreed by Company. a)

b)

Helical spoilers 1)

A three-start system of spoilers in a helical pattern shall be provided on top third of the vessel.

2)

Exposed width of the spoilers beyond insulation shall be 0,09D and a pitch of 0,5D, where D is the diameter of the top third of the vessel.

3)

Spoiler system may be interrupted to provide clearance at vessel appendages.

Short vertical spoilers 1)

A three-start system of short vertical spoilers arranged in a helical pattern shall be provided on the top-third of the vessel.

Page 18 of 96



7.10

2)

Exposed width beyond insulation of the spoilers shall be 0,09D and the height of one helical wrap between 0,5D and 0,11D.

3)

A minimum of eight spoilers shall be provided over the pitch distance (i.e., each complete helical wrap) and a minimum of 1,5 helical wraps over the top-third of the vessel.

4)

Spoiler system may be interrupted to provide clearance at vessel appendages.

Transportation loads a.

Vessels subject to transportation loadings shall be analysed for the following conditions: 1.

Bending between supports.

2.

General primary membrane tensile stress.

3.

Bending and compressive stress at supports and fixture attachment points.

b.

Calculated general primary membrane tensile stress shall not exceed that listed in 7.11e.

c.

Vessels shall be analysed for actual vertical, lateral, and longitudinal loadings.

d.

Minimum acceleration loadings for different modes of transportation shall be as shown in Table 1.

e.

Vessel shall be designed for the most severe vertical, lateral, and longitudinal loading condition if erection loadings are greater than the transportation loadings. Table 1 - Minimum transportation acceleration loadings Transportation Mode

Downward

Vertical acceleration Upward

Lateral acceleration

Longitudinal acceleration

Truck (highway speeds)

1,7∙g

0,5∙g

0,3∙g

1,8∙g

Truck (<11,1 m/s (25 mph) or multi-wheel transporter)

1,3∙g

0,2∙g

0,2∙g

0,2∙g

Rail

2∙g

2∙g

2∙g

3∙g

Inland barge

1∙g

0,2∙g

0,75∙g

0,4∙g

Oceangoing ship or barge

2∙g

2∙g

0,75∙g

0,4∙g

Notes: 1. If multiple modes of transportation are used, the most severe condition shall be used for evaluation. 2. 1,0∙g is a load equal to the shipping weight of the vessel.

7.11

Lifting loads a.

Lift weight shall include the weight of all components, such as trays, ladders, platforms, insulation, additional piping with insulation.

b.

An impact factor, as specified on the data sheet, shall be applied to the lift weight for the design of lifting devices and vessel shell bending calculations.

c.

Local stresses in the vessel shell, head, skirt and base rings from lifting lugs and trunnions loads shall be determined using WRC Bulletins 297 or 537,BSI PD 5500 annex G, or other accepted local stress analysis procedures agreed with Company. Allowable stress values shall be as specified in 7.8b or 7.8d.

d.

Shear stresses for fillet welds on the lifting attachments to vessel shell or head shall not be greater than 0,55 times the Code-allowable stress at 38ºC (100ºF) for the material selected.

e.

Lifting stress calculations shall be performed for vertical vessels with height-to-diameter ratios greater than 8 and lift weight exceeding 11 300 kgf (25 000 pounds) as follows: Page 19 of 96



7.12

7.13

1.

Bending stresses in the vessel shell and skirt from the loadings imposed during the lift from horizontal to vertical position.

2.

Calculated general primary membrane tensile stress shall not be greater than 80% of the material’s specified minimum yield strength at 38ºC (100ºF).

3.

Calculated compressive stress shall not be greater than 1,2 times the allowable compressive stress.

Design calculations a.

Calculations satisfying the pressure vessel code of construction requirements shall be performed using COMPRESS, PVElite, or Finglow software packages.

b.

Design calculation reports, including finite element analysis reports, shall be submitted for review and agreement by Company.

c.

The following vessel components shall be subject to analysis and the results submitted for review and agreement by Company: 1.

Thermal and stress analysis of vessel and skirt attachment region, if specified on data sheets.

2.

Localised stress analysis of internal and external attachments to the shell.

3.

Localised stress analysis of nozzles subject to piping loads.

4.

Thermal analysis of nozzles, skirt, and appurtenances for thermal gradients induced into shell, if specified on data sheets. a)

Information from this analysis shall be used to determine the need for a fatigue evaluation.

b)

Results of the thermal analysis exempting a vessel from fatigue evaluation shall be included in the calculations.

d.

For pressure vessels designed to ASME BPVC VIII-1, if a rule for the design of a vessel or vessel component subject to pressure does not exist in ASME BPVC VIII-1 then, in conformance to ASME BPVC VIII-1 Paragraph U-2(g), the design shall be evaluated by rules of ASME BPVC VIII-2.

e.

Calculations evaluated to EN 13445-3 Annex B shall be submitted for review and agreement by Company.

Shock loading Vessels shall be checked for dynamic effects if the data sheet indicates the possibility of the process applying a shock loading such as a slug flow which results in an increased force on the vessel shell or internals.

8 8.1

Materials requirements General a.

Pressure vessel materials shall be as specified on data sheets.

b.

Materials shall conform to the following additional requirements in this Specification when specified on data sheets:1.

Annex B-supplementary requirements for chrome-moly vessels.

2.

Annex C-supplementary requirements for stainless steel vessels.

3.

Annex D-supplementary requirements for clad plate or weld overlay construction.

Page 20 of 96



8.2

8.3

9

c.

Materials shall be new and unused.

d.

Material substitutions shall not be made without Company agreement.

e.

Steel plates shall be made in an open-hearth, basic-oxygen, or electric-arc furnace.

f.

Charpy V-notch impact tests for carbon and low alloy steel plates shall conform to design code unless specified otherwise in Purchase Order.

g.

Records of Charpy V-notch impact tests for steel plates shall record the percent shear fracture and the lateral expansion for each specimen.

h.

Impact test values shall be reported in the CMTR.

i.

Materials shall be stamped with low stress (round bottom) stamps.

Certificates of compliance a.

Records of compliance with the requirements of material specifications shall be maintained.

b.

Certificates of compliance shall include reports or test results required by the material specification or Purchase Order.

Certified material test reports a.

Supplementary or special requirements, in addition to the requirements of the material specification, as required by the Purchase Order shall be included on the CMTR.

b.

The specification of the material being represented, year of issue and material heat number shall be included on the CMTR.

c.

All such documents shall identify the applicable material specification and shall be identified to the material represented.

Vessel components The following clauses contain design, fabrication, and examination requirements for components of pressure vessels as specified on the data sheets.

9.1

Vessel shells and transitions a.

Shells shall be fabricated from rolled plate, pipe or forgings.

b.

Transitions shall be made with knuckle and flare if any of the following conditions apply:

c.

1.

Vessel is in cyclic or hydrogen service.

2.

Section is subject to a major support reaction (for example, skirt-to-cone attachment).

3.

Transition thickness or attached shell thickness is over 30 mm (1,25 in).

4.

All loadings per ASME BPVC VIII-1 Appendix 1-5 or 1-8, whichever is applicable, are not available.

Minimum thickness of shells and transitions shall not be less than 6 mm (1/4 in).plus the greater of corrosion allowance and the forming allowance.

9.2

Formed heads

9.2.1

General a.

Heads shall be supplied as one of the following as specified on the data sheets: 1.

Hemispherical.

Page 21 of 96



9.2.2

9.2.3

2.

2:1 Semi-elliptical.

3.

ASME flanged and dished.

4.

Toriconical.

b.

Dished head construction shall preferably be seamless.

c.

Minimum thickness of heads shall not be less than 6 mm (1/4 in).plus the greater of corrosion allowance and the forming allowance.

d.

Heads and head nozzles supporting agitators shall be reinforced to withstand the agitator dynamic loadings in conformance to requirements of 9.3.6a and 9.3.6b.

e.

Head design shall be agreed with the agitator manufacturer and Company before the head is ordered.

f.

Carbon steel and C-Mn steels, cold-formed heads shall be normalised or stress-relieved prior to welding to the shell.

Joints in formed heads a.

Joints in formed heads shall be full penetration.

b.

Joints in formed heads shall be fully radiographed before forming.

c.

Joints in formed heads shall be ground flush with the plate surfaces before forming.

d.

Spin hole which remains after forming and final construction shall be repaired with a metal plate butt-welded in place and given full volumetric examination.

e.

After forming, all joints in formed head shall receive 100% surface examination on both sides.

Intermediate heads a.

Intermediate heads shall: 1.

Be designed with a corrosion allowance applied to both sides.

2.

Be fitted so that the internal head OD equals the shell ID.

3.

Have a continuous fillet weld from the end of the head plate to shell.

4.

Have the attachment welds magnetic particle or liquid penetrant examined.

9.3

Connections, nozzles, and manways

9.3.1

General a.

b. 9.3.2

Connections shall not be made with: 1.

Threaded coupling.

2.

Socket weld fitting.

3.

Single fillet welds.

4.

Tapped or threaded openings.

Nozzles shall be flanged unless otherwise specified on the data sheets.

Design a.

MAWP shall not be limited by nozzle reinforcement or nozzle neck thickness.

b.

MAP shall not be limited by nozzle reinforcement or nozzle neck thickness.

Page 22 of 96



9.3.3

c.

Nozzles with internal projections shall not include the internal projection in reinforcement calculations.

d.

Nozzles in dished heads shall be positioned such that the nozzle, reinforcing pads, and attachment welds are not within the knuckle region of the dished head.

Construction details a.

Nozzles shall be set-in type.

b.

Nozzle to parent component weld shall be full penetration.

c.

Nozzles DN 300 (NPS 12) and larger shall be made from forgings, rolled plate, or seamless pipe.

d.

Nozzles smaller than DN 300 (NPS 12) shall be constructed using forgings or seamless pipe.

e.

Nozzles DN 50 (NPS 2) or smaller shall be constructed using either: 1.

LWN or heavier forgings if the forging length is 400 mm (16 in) or less.

2.

Welding stub welded to seamless pipe if the nozzle length is greater than 400 mm (16 in).

f.

Flange rating of connections DN 50 (NPS 2) or smaller shall be minimum class 300.

g.

Rolled plate used as nozzle necks shall have full volumetric examination prior to attachment to other components. Acceptance criteria shall be in conformance to the design code for full NDE.

h.

Minimum pipe schedule used for nozzles shall be as shown in Table 2 or applicable design code, whichever is greater. Table 2 - Minimum thickness of nozzles Material

Size DN (NPS)

Minimum pipe schedule (1)

Carbon steel and low alloy, clad steels

50 (2)

Schedule 160

High alloy and non-ferrous materials

Larger than 50 (2)

Schedule XS

50 (2)

Schedule 80S

Larger than 50 (2)

Schedule STD

Note: 1. Pipe wall thickness designations per ASME B36.10M.

9.3.4

i.

Nozzles not directly connected to internals shall be flush with the inside surface of the vessel wall.

j.

Nozzle with an internal projection shall have a fillet weld at the inside corner.

k.

Inside edges of manways and nozzle neck shall be rounded to 3 mm (1/8 in) minimum radius unless requirements in 16.2i.3 apply.

Reinforcing pads a.

Reinforcing pads shall be external to the vessel.

b.

Reinforcing pads shall not be used on internal heads.

c.

Reinforcing pads shall not be used if any of the following conditions apply: 1.

Operating temperature exceeds 300°C (572°F).

2.

Operating partial pressure of hydrogen exceeds 7 bar(a) (100 psia) and operating temperature exceeds 230°C (450°F).

Page 23 of 96



9.3.5

Design is for non-intrusive inspection.

4.

Parent wall thickness exceeds 50 mm (2 in).

5.

Ferritic vessels if operating temperature is lower than -50°C (-58°F).

6.

Cyclic service.

d.

Reinforcing pad thickness shall not exceed the parent wall thickness to which the nozzle is attached.

e.

Reinforcing pads shall be full penetration welded to the nozzle.

f.

Design of multi-segmental reinforcing pad elements shall conform to ASME BPVC VIII-1 Paragraph UG-37(h).

g.

Each pad segment shall have one American Standard Taper Pipe Thread (NPT) 1/4 inch (6 mm) telltale hole for testing purposes. Each hole shall be left open during welding of pad and PWHT and located near the lowest point of a pad with the vessel in its operating position to permit drainage.

h.

See 15.1f for testing of reinforcing pads.

i.

Reinforcing pads that are not circular shall have rounded corners of 75 mm (3 in) minimum radius.

Nozzle external projection a.

9.3.6

3.

Minimum projection from the outside of the vessel wall or external insulation to the nozzle face shall be: 1.

Nozzles less than or equal to DN 200 (NPS 8): 200 mm (8 in).

2.

Nozzles larger than DN 200 (NPS 8): 250 mm (10 in).

b.

The dimension from the face of the nozzle to the vessel centreline or reference line shall be rounded up to the next greater 10 mm (1/2 in) increment.

c.

Projection of flanged nozzles with external piping attached shall permit removal of bolting from either side without removal of insulation.

d.

Nozzles shall be extended to ensure flanges and bolting are outside vessel insulation.

e.

Projections of nozzles and manways shall be established by applying the following: 1.

Clearance shall be provided for removing flange stud bolts from between the flange and vessel and for accessing flange stud nuts.

2.

Clearance shall be provided for flange studs and nuts if nozzles penetrate insulation or platforms.

Nozzle loading a.

Nozzles supporting agitators, pumps, or other mechanical equipment shall be evaluated to withstand the mechanical loadings specified by the equipment manufacturer and piping loads derived from Table F.3 in Annex F. Nozzle reinforcement as determined by nozzle reinforcement calculations shall be used in the evaluation.

b.

If, following evaluation, the vessel shell or head is overstressed, Supplier shall not increase reinforcement on nozzle but shall submit the calculations for review by Company responsible engineer.

c.

Dynamic loading shall be evaluated for an infinite number of stress reversals using the applicable stress concentration factor as follows: 1.

5 for as welded attachment welds.

Page 24 of 96



2.

3,5 for contoured and blend ground nozzle attachment welds.

d.

Nozzles supporting pressure relief devices shall be evaluated to withstand the thrust reaction by using piping loads derived from Table F.3 in Annex F. Nozzle reinforcement as determined by nozzle reinforcement calculations shall be used in the evaluation and shall conform to requirements of 9.3.6b.

e.

Gussets shall not be used to strengthen, stiffen, or reinforce nozzles, unless demonstrated by calculations to be designed for the specified cyclic life and thermal condition, and the dimensional requirements, such as tolerances, of the device as furnished by the device manufacturer are considered.

9.4

Flanges

9.4.1

General a.

Flanges welded on a nozzle shall be weld neck type unless otherwise specified on data sheets.

b.

Dimensions and pressure-temperature ratings of standard flanges for nozzles and manways DN 600 (NPS 24) and smaller shall conform to ASME B16.5.

c.

Dimensions and pressure-temperature ratings of standard flanges for nozzles and manways larger than DN 600 (NPS 24) shall conform to ASME B16.47 to the series specified on data sheets.

d.

Vessel shell flanges and head flanges with covers not conforming to sizes in ASME B16.5 or ASME B16.47 shall be weld neck type and designed in conformance to the design code.

e.

The following shall apply if studded nozzle pads are used: 1.

Studded pad holes and studs shall be machined in conformance to drawing number PIP VEFV1129M.

2.

Indicator type studs for studded pads shall be in conformance to ASME PCC-1 Figures 1 and 2.

3.

Studded pads shall be checked to ensure the full thread depth holes conforms to specified design code.

f.

Bolt holes in all fixed flanges and studded pads shall straddle the natural centrelines.

g.

For vessels supported on a skirt, the flanges of nozzles in bottom head shall be located outside the skirt.

h.

Except for standard flanges conforming to ASME B16.5 and B16.47, all carbon, low-alloy, and high-alloy steel forgings greater than 75 mm (3 in) thick shall be examined ultrasonically in conformance to ASME SA-745/SA-745M and the following: 1.

Quality levels for straight beam examinations from flat surfaces shall conform to Table 3.

2.

Quality level for straight beam examinations from curved surfaces shall be QL-5.

3.

Quality level for all angle beam examinations shall be QA-1. Notch depth shall conform to QA-1 or 6 mm (0,25 in), whichever is less.

Page 25 of 96



Table 3 - Quality levels for straight beam examinations from flat surfaces

9.4.2

9.4.3

Quality level

75 (3) < t ≤ 200 (8) 200 (8) < t ≤ 300 (12) t > 300 (12)

QL-2 QL-3 QL-4

Flange facing and surface finish a.

Splice welds on gasket contact surfaces of a lap ring or flange shall not be used.

b.

Flanges shall have one of the following configurations: 1.

Raised face.

2.

Ring type joint.

3.

A construction that provides outer confinement to the gasket if specified on data sheets.

c.

The height of a raised face shall be in conformance to ASME B16.5 or ASME B16.47 unless otherwise specified on the data sheets.

d.

Except for flanges conforming to ASME B16.5 and ASME B16.47, the gasket contact surface flatness tolerance for flanges and shop-fabricated lap rings shall conform to the following: 1.

0,150 mm (0,006 in) total indicator reading in both the radial and circumferential directions.

2.

The total circumferential tolerance shall not occur in less than 20 degrees arc.

3.

Measurement shall be made using a dial indicator after all other operations, including fabrication and heat treatment of flange or lap ring, and attachment to the shell or nozzle neck, affecting flatness tolerance have been completed.

e.

Flange facings shall be machined in conformance to ASME B16.5 and ASME B16.47.

f.

Flange facings shall be protected from damage during fabrication, heat treatment, and shipping.

Flange bolting a.

9.4.4

Forging thickness (t) mm (in)

Flanged joints shall be designed to enable the use of hydraulic bolt tensioners on the following: 1.

Joints with nominal bolt diameter 50 mm (2 in) and over.

2.

Duties where the nominal bolt diameter is 40 mm (1,5 in) and over, and the flanges are either on hydrogen service or are PN 110 (Class 600) or over.

3.

If specified on the data sheets for nominal bolt diameter 25 mm (1 in) and over.

b.

Bolts for bolt tensioning shall be extended by the length of one nut and provided with a cap for protection during service.

c.

Nozzles adjacent to shell girth flanges or horizontal vessel saddles shall be located with clearance such that bolt tightening equipment can be used on the girth flange bolts.

d.

Flange bolting, including coating requirements, shall be as specified on data sheets and conform to GIS 42-300.

Gaskets a.

Gaskets shall be as specified on data sheets and conform to GIS 42-301. Page 26 of 96



9.5

9.6

b.

Pressure and leak test gaskets shall conform to 15.1j.

c.

Spare gaskets shall conform to 10b.1.

Blind flanges and bolted flat heads a.

Except for blind flanges conforming to ASME B16.5 and B16.47, rolled plate for flat covers and blind flanges greater than 75 mm (3 in) thick shall be examined in conformance to ASME SA-578/SA-578M acceptance standard - Level B after cutting to final size.

b.

Nozzles shall not be welded to blind flanges conforming to ASME B16.5 or ASME B16.47 and weld neck reducing flanges shall be used unless the applicable ASME blind flange standard specifically allows such an opening while keeping the pressure and temperature rating.

c.

Vessel manways and flanges fitted with blind flanges shall be supplied with bolting and gaskets.

Swing bolt closures Swing bolts shall be of one-piece construction without welding. Hinge pins shall be solid and of the same material as the swing bolts.

9.7

Quick-actuating closures a.

Quick-actuating closures shall be designed per ASME BPVC VIII-1 Paragraph UG-35.2 or ASME BPVC VIII-2 Paragraph 4.8 and Annex 4.B.

b.

Procedures for the operation or maintenance of quick-actuating closure shall be submitted for review and agreement by Company.

9.8

Supports

9.8.1

Skirts a.

Vertical vessels shall be self-supporting without guys or braces.

b.

Unless otherwise specified on data sheets skirt supports shall conform to one of the following standard drawings: 1.

PIP VEFV1107M - Type A skirt base plate with gussets only

2.

PIP VEFV1108M - Type B with cap plate and gussets

3.

PIP VEFV1109M - Type C with cap plate and offset gussets

4.

PIP VEFV1110M - Type D with top ring and gusset

c.

A hot box shall be provided at the junction between the skirt and shell for vessels with a design temperature of 345°C (650°F) and above.

d.

Material at the top of the skirt for vertical vessels constructed from materials other than carbon steel shall be the same material specification and grade as the vessel plate to which it is attached for a length at least equal to the greater of the following: 1.

2,5 * √(skirt radius * skirt thickness).

2.

600 mm (24 in).

Page 27 of 96



Figure 1 - Skirts on vertical vessels less than 50 mm (2 in) thick or in non-cyclic service

Figure 2 - Skirts on vessels ≥ 50 mm (2 in) thick or in cyclic service

Forging Option

Weld Buildup Option Shell

Shell

Head Head / skirt forging

Weld buildup (with ultrasonic examination) Upper skirt section (same material as vessel shell) Lower skirt section (Carbon steel)

e.

Skirts on vessels 2 m (6 ft) diameter or less shall have at least one access opening. Vessels over 2 m (6 ft) diameter and skirt heights over 2,5 m (8 ft), two access openings shall be provided in the skirt.

f.

Minimum skirt access opening shall be 600 mm (24 in) diameter or 450 mm x 900 mm (18 in x 36 in) obround.

g.

Openings for skirt access and piping shall conform to Figure 3. Additional strengthening may be provided by increasing the thickness of sleeve.

h.

Unless specified otherwise on data sheets, a minimum of two 50 mm (2 in) radius semi-circular drain holes 180 degrees apart shall be located at the vessel skirt to base ring attachment weld. The drain holes shall be staggered 90 degrees from the skirt vent holes. In applications where the inside of the skirt will be open or grated, the drain opening shall be omitted.

i.

Skirt openings for piping shall have a 13 mm (1/2 in) maximum clearance between the pipe outside diameter, including insulation, and skirt opening if inside of skirt is not fireproofed.

j.

Openings for pipe vents shall conform to Figure 4.

k.

Refer to Table 4 for quantities of skirt vents.

Page 28 of 96



Figure 3 - Opening for skirt access or for piping 6mm (1/4 in) 6mm (1/4 in) SLEEVE

MINIMUM SLEEVE THICKNESS OF t sk

76mm (3 in) MIN 76mm (3 in) MIN t sk

BASE RING

ACCESS OPENING OR PIPE Where tsk is skirt thickness

Figure 4 - Opening for a skirt vent

6mm (1/4 in)

OD 114.3mm T8.8mm (NPS 4 SCH. 80) PIPE SLEEVE 76mm (3 in) MIN 76mm (3 in) MIN

Table 4 - Skirt vents Vessel Diameter at Skirt Attachment

9.8.2

Number of

mm

in

Skirt Vents

< 900

< 36

2

> 900 to 1 500

> 36 to 60

4

> 1 500 to 2 400

> 60 to 96

6

> 2 400 to 4 500

> 96 to 180

8

> 4 500

> 180

12

Legs or column supports a.

Leg supports shall not bear on the knuckle or crown of formed heads but conform to one of the following standard drawings unless otherwise specified on data sheets: 1.

PIP VEFV1112M - Angle type leg without pad

2.

PIP VEFV1113M - Angle type with reinforcing pad

b.

Leg-type supports shall not be used on vessels greater than 1 524 mm (5 ft) diameter or 6 100 mm (20 ft) tan. to tan.

c.

Structural calculations shall be provided to verify adequacy of leg design.

d.

Stress analysis of legs on spheres shall be submitted for review and agreement by Company.

Page 29 of 96



9.8.3

Saddles a.

Unless otherwise specified on data sheets welded saddles shall conform to one of the following standard drawings: 1.

PIP VEFV1104M - Small horizontal vessel saddle supports

2.

PIP VEFV1105M - Horizontal vessel saddles supported on concrete

3.

PIP VEFV1106M - Horizontal vessel saddles supported on structural steel

b.

Horizontal vessels shall be investigated for buckling and local stresses. The method of L.P. Zick may be used for this investigation.

c.

Horizontal vessels shall be supported on two saddles only.

d.

Slots shall be provided for the anchor bolts in one saddle to allow for thermal expansion.

e.

The saddle support that is “fixed” and the support that is “sliding” (slotted) shall be indicated on the fabrication drawings.

f.

Saddles shall be continuously welded to the shell.

9.9

Anchor bolts

9.9.1

General

9.9.2

9.9.3

a.

Calculations determining quantity and size of anchor bolts shall be based on referenced PIP standard details, and specified on fabrication drawings.

b.

Supply of anchor bolts is not in Supplier’s scope of supply.

c.

Anchor bolts shall not be less than 19 mm (3/4 in) diameter.

d.

Unless data sheets specify high-strength anchor bolts the following shall apply: 1.

Anchor bolts (such as carbon steel, ASTM F1554-36, etc.) shall have an allowable stress of 138 MPa (20 000 psi) based on the tensile stress area of the threaded portion.

2.

Maximum anchor bolt diameter shall be 76 mm (3 in).

e.

Design loadings for anchor bolts embedded in concrete shall be determined by either the simplified method (i.e., neutral axis of bolt pattern at centreline of vessel) or the shifted neutral axis method in conformance to Process Equipment Design.

f.

Unless otherwise specified on data sheets, the design concrete bearing stress shall be 11,4 MPa (1 658 psi) for vessels on concrete foundations.

High-strength anchor bolts a.

High strength anchor bolts may be used only if specified on the data sheets.

b.

Unless otherwise specified on the data sheets, high-strength anchor bolts (such as ASTM F1554-105) shall have an allowable stress of 207 MPa (50 000 psi).

Vertical vessel anchor bolts a.

Anchor bolts shall straddle normal centrelines.

b.

Anchor bolt configuration shall provide radial clearance for a bolt tensioning device.

c.

The number of anchor bolts shall be a multiple of four (4).

d.

All parts of the base ring support system (base ring, chairs, compression ring, gussets, skirt, etc.) shall accommodate a pretension force on the anchor bolts equal to 75% of the allowable anchor bolt stress.

Page 30 of 96



9.10

Internal attachments

9.10.1

General a.

Internal attachments welded to shells and heads shall be located to permit full visual inspection of attachment and attachment weld.

b.

Welding of internal attachments to the pressure boundary shall be continuous on all surfaces to eliminate corrosion pockets.

c.

Internal attachments welded directly to the pressure vessel envelope shall be fabricated from the same material as the vessel.

d.

Internal attachments shall be naturally draining.

e.

Size of welds shall include the corrosion allowance specified for vessel.

f.

Weld spatter on downcomer bolting bars shall be removed to ensure a flush seal with downcomer.

g.

If the downcomer does not form a continuous seal with the bolting bars, the downcomer shall be reassembled with gasket supplied by tray Manufacturer.

h.

Baffles, partitions, and supporting beams shall be designed to accommodate thermal expansion of vessel shell. Internals, such as mist pads, shall be bolted to support attachments, not directly welded to shell.

i.

Minimum thickness of welded internal attachments shall be 5 mm (3/16 in) plus corrosion allowance for each wetted side.

j.

Minimum fillet weld size shall be 5 mm (3/16 in) in the corroded condition.

k.

Seams and corner joints shall be sealed.

l.

Internal attachments shall be designed and installed to satisfy one of the following requirements:

m. 9.10.2

9.10.3

1.

The distance between the weld-toe of the attachment is not within 50 mm (2 in) of a pressure boundary weld toe.

2.

The portion of the pressure boundary weld that is covered by the attachment shall be ground flush and given 100% volumetric examination before internal attachment is made.

3.

The attachment shall be coped or notched to clear all weld area and each weld-toe by at least 25 mm (1 in).

The stresses in the attachment and attachment weld shall be checked to ensure they are within allowable limits of the code of construction.

Manway grab rungs a.

Manways in vessels shall be supplemented with rungs attached to the inside of the vessel shell if other internal fixtures do not afford safe footing and handholds for persons entering or leaving the vessel.

b.

Internal ladder rungs for vertical and horizontal vessels shall conform to drawing number PIP VEFV1125M unless otherwise specified on data sheets.

c.

Ladder rungs may be extended upwards from the grab rung on vertical vessels if specified on data sheets.

Vortex Breakers Vortex breakers shall conform to drawing number PIP VEFV1124M unless otherwise specified on data sheets. Page 31 of 96



9.11

External attachments

9.11.1

General

9.11.2

a.

External attachments welded to shells and heads shall be located to permit full visual inspection of attachment and attachment weld.

b.

Ladders, platforms and clips shall conform to Annex G unless otherwise specified on data sheets.

c.

Pipe segments shall not be directly attached to a pressure boundary and used as supports for ladders, platforms, piping, etc.

d.

Welding of external attachments to the pressure boundary shall be continuous on all surfaces to eliminate corrosion pockets.

e.

All components welded directly to the pressure vessel envelope shall be fabricated from the same material as the vessel.

f.

External attachments shall be designed and constructed to prevent the channelling and hold up of rainwater.

g.

Minimum thickness of welded external attachments shall be 5 mm (3/16 in).

h.

Minimum fillet weld size shall be 5 mm (3/16 in).

i.

Seams and corner joints shall be sealed.

j.

External attachments shall be designed and installed to satisfy one of the following requirements: 1.

The distance between the weld-toe of the attachment is not within 50 mm (2 in) of a pressure boundary weld toe.

2.

The portion of the pressure boundary weld that is covered by the attachment shall be ground flush and given 100% volumetric examination for the length of the overlap plus at least 50 mm (2 in) on each side before the attachment is made.

3.

The attachment shall be coped or notched to clear all weld area and each weld-toe by at least 25 mm (1 in).

k.

Stresses in the attachment and attachment weld shall be checked to ensure they are within the allowable limits of the code of construction.

l.

Galvanised clips or attachments shall not be welded to a vessel.

Insulation supports a.

Insulation supports shall comprise flat rings, rods, or lengths of angle attached to vertical vessels in conformance to drawing number PIP VEFV1123M.pages 1, 2 and 5, unless otherwise specified on data sheets.

b.

Vertical vessel shell insulation shall be supported by one of the following methods: 1.

Support rings which shall conform to the following details and locations shown in drawing number PIP VEFV1123M: a)

Type 2 or 3 intermediate ring supports in conformance to detail “J”.

b)

Support rings for vessels with skirts located below the bottom tangent line in conformance to details “E”, “G” or “H”.

c)

Ring spacing shall be between 3 000 mm (10 ft) and a maximum of 3 700 mm (12 ft) with the exception of upper support ring which shall be a maximum of 2 400 mm (8 ft) from top tangent line.

Page 32 of 96



9.11.3

9.11.4

9.11.5

c.

Top heads of vessels insulation shall be supported by a floating ring and type 1 support ring fitted to the vessel in conformance to details “A” and “J” of drawing number PIP VEFV1123M.

d.

Insulation for bottom heads of vertical vessels shall be supported by one of the following methods: 1.

A floating ring and anchor ring fitted to vessels with skirts in conformance to details “E”, “G” or “H” of drawing number PIP VEFV1123M.

2.

A floating ring and type 1 support ring fitted to vessels without skirts in conformance to detail “J” of drawing number PIP VEFV1123M.

e.

Rings welded to vertical shell or skirt shall be discontinuous or perforated to prevent the accumulation of moisture.

f.

Insulation for heads on horizontal vessels shall be supported by a floating ring and anchor ring fitted to the vessel in conformance to details on page 2 of drawing number PIP VEFV1122M.

g.

Horizontal vessels with shells 2 450 mm (96 in) diameter or larger shall have longitudinal supports fitted in conformance to drawing number PIP VEFV1122M.

Fireproofing supports a.

Fireproofing supports shall be provided and installed on skirts and saddles if concrete fireproofing is specified on the data sheets.

b.

Fireproofing supports for concrete fireproofing shall conform to details in drawing number PIP VEFV1123M.

Nameplate brackets a.

Unless otherwise specified on data sheets vessel nameplate brackets shall conform to drawing number PIP VEFV1101M.

b.

Nameplate brackets shall be located near a manway and shall not be obstructed if the manway is open.

c.

For insulated vessels: 1.

Two nameplate brackets shall be provided.

2.

Design code required nameplate shall be installed on a bracket designed to be totally encased under the vessel insulation.

3.

An additional nameplate bracket and duplicate nameplate shall be attached to the vessel support, not pressure vessel shell, and project beyond the insulation or fireproofing material.

Manway davits and hinges a.

Manways shall be provided with davits or hinges which conform to the following standard drawings unless otherwise specified on data sheets: 1.

PIP VEFV1116M - Vessel manway hinge

2.

PIP VEFV1117M - Vessel vertical manway davits

3.

PIP VEFV1118M - Vessel horizontal manway davits

b.

Davit and hinge dimensions for manway sizes and (or) flange ratings not listed shall be determined and design included in calculations for review and agreement by Company.

c.

Selection of davits or hinges shall be as specified on the data sheets.

Page 33 of 96



9.11.6

d.

Manways orientated at an angle other than 0 degrees or 90 degrees from the horizontal plane shall be designed with a hinge which opens in the horizontal plane.

e.

Stops shall be provided to prevent damage to vessel shell or insulation from the over-rotation of the manway hinge or davit.

f.

Eyebolts used in manway davit designs shall be one-piece forgings.

Vacuum stiffening rings a.

Vacuum stiffening rings shall be designed as a flat bar type and made from plate matching the vessel plate material specification and grade.

b.

Vacuum stiffening rings shall be continuous fillet welded on the top and bottom of the ring.

c.

Vessels subject to thermal cycling, such as coke drums, shall not use vacuum stiffening rings.

9.11.7

Lifting attachments

9.11.7.1

Vertical vessels a.

Two lifting lugs or trunnions shall be provided on vertical vessels to facilitate handling during transport and erection at site.

b.

Typical designs of lifting lug are shown in Figure 5 and Figure 6 with dimensions in Table 5 and Table 6. These designs assume that a spreader beam is used keeping loads normal to the plane of the lugs to a minimum.

c.

Calculations for the design of lifting lugs, trunnions, and other lifting devices shall be submitted for review and agreement. Calculations shall include the following: 1.

Lifting lug hole diameter D shall be 1,05 x shackle pin diameter.

2.

Bearing stress area shall be 0,75 x pin diameter x (lug + bearing plate thicknesses).

d.

Lifting trunnions shall be fitted if calculations show that vessel is overstressed during lift with lifting lugs located at top of vessel.

e.

See 7.11 for design of lifting devices.

f.

Attachment of lifting lugs shall be such that water cannot be trapped between the vessel and lifting lug.

g.

Portion of lifting lug above tangent line shall be flat. Portion below tangent line shall fit to curvature of vessel.

h.

Weld seams under lifting lugs shall be ground flush.

i.

Length of the lifting lug shall be such that the vessel may be fully insulated prior to the lift.

j.

Lifting lug may be attached to a lifting flange on thick-walled vessels with a formed head and a top, centre nozzle if specified on the data sheets.

k.

1.

Calculations of the stresses in the nozzle neck and head shall be submitted for review and agreement. See 7.8b

2.

Lifting flange shall be provided with full bolting.

3.

Lifting lug shall be inserted through the lifting flange and fillet welded on both sides of the lifting flange.

Stress analysis shall identify the angle which results in the maximum stress at each lifting point during the lift from horizontal to vertical.

Page 34 of 96



Figure 5 - Design of light lifting lug B A

D

B/

2

R1.5mm (1/16 in)

C

H

LUG REMOVAL LINE

TANGENT LINE 2A RADIUS ALL CORNERS J

WELD SEAM

F

G

FIELD NOTE: FOR INSULATED VESSELS, CUT OFF LUG AS SHOWN AFTER ERECTION. {APPROX. 25mm (1 in) PROJECTION}

OMIT 13mm (1/2") OR WELD TO PROVIDE DRAIN

Table 5 - Dimensions of light lifting lugs Max vessel erect wt. kg (lbs)

Thickness of Plate mm (in) A

4 500 (10 000)

13 (1/2)

Width mm (in)

Length mm (in)

Dia. of Holes mm (in)

B

C

D

150 (6)

400 (16)

9 000 (20 000)

16 (5/8)

190 (7 1/2)

450 (18)

13 500 (30 000)

20 (3/4)

215 (8 1/2)

500 (20)

18 000 (40 000)

25 (1)

230 (9)

500 (20)

See 9.11.7.1.c.1

Page 35 of 96

Height of side weld mm (in)

Weld leg size mm (in)

T.L to top of lug mm (in)

T.L to bottom of lug mm (in)

F

G

H

J

75 (3)

9 (3/8)

250 (10)

150 (6)

130 (5)

9 (3/8)

250 (10)

200 (8)

130 (5)

12 (1/2)

300 (12)

200 (8)

130 (5)

16 (5/8)

300 (12)

200 (8)



Figure 6 - Design of heavy lifting lug B A

D

H

2 B/

A

R1.5mm (1/16 in)

C

K

LUG REMOVAL LINES

2 E/

TANGENT LINE A RADIUS ALL CORNERS

WELD SEAM

F

J

E

G

OMIT 13mm (1/2 in) OF WELD TO PROVIDE DRAIN 2 PLACES

Table 6 - Dimensions of heavy lifting lugs Notch Brace to T.L to Bottom Width of height Weld top of bottom of of brace notch and side leg size lug lug to T.L. weld

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

mm (in)

A

B

C

D

E

F

G

H

J

K

22 750 (50 000)

25 (1)

225 (9)

460+K (18+K)

75 (3)

125 (5)

16 (5/8)

225 (9)

225 (9)

45 000 (100 000)

40 (1 1/2)

300 (12)

585+K (23+K)

100 (4)

125 (5)

22 (7/8)

300 (12)

275 (11)

90 000 (200 000)

50 (2)

400 (16)

760+K (30+K)

150 (6)

200 (8)

32 (1 1/4)

400 (16)

350 (14)

136 000 (300 000)

65 (2 1/2)

500 (20)

915+K (36+K)

175 (7)

250 (10)

38 (1 1/2)

500 (20)

400 (16)

181 500 (400 000)

75 (3)

600 (24)

1095+K (43+K)

200 (8)

300 (12)

44 (1 3/4)

600 (24)

475 (19)

Max vessel erect wt. kg (lbs)

9.11.7.2

Width

mm (in)

See 9.11.7.1.c.1

Length

Dia. of holes

Thickness of plate

By Supplier

Tailing lugs a.

A typical design of tailing lug is shown in Figure 7 with dimensions in Table 7.

b.

Calculations for the design of tailing lugs, including quantities shall be submitted for review and agreement. Requirements specified in 9.11.7.1c.1 and 9.11.7.1c.2 shall be incorporated. Page 36 of 96



c.

Tailing lug load shall be determined assuming vessel is lifted from horizontal unless otherwise agreed.

d.

Tailing lug material shall be the same as the vessel skirt

e.

A skirt stiffening spider shall be provided as required. Figure 7 - Design of tailing lug C/L VESSEL

C B/2

TOP PLATE

B

SKIRT

A BUTT WELD

D

A

A

G

BASE PLATE SECTION A-A

L 25mm (1 in) PLATE x Ø305mm (12 in) BOTH SIDES

PLAN

10mm (3/8 in) BEARING PLATE

Table 7 - Tailing lug dimensions

Max. load per lug kg (lbs)

Thickness of plate mm (in) A

22 750 (50 000)

30 (1 1/8)

45 000 (100 000)

50 (1 7/8)

67 750 (150 000)

60 (2 3/8)

Length mm (in)

Dia. of holes mm (in)

B

C

D

150 (6)

300 (12)

10 (3/8)

200 (8)

400 (16)

16 (5/8)

230 (9)

430 (17)

Width mm (in)

See 9.11.7.1.c.1

Weld leg size mm (in)

Lug spacing mm (in)

G

L

16 (5/8)

90 000 (200 000)

65 (2 1/2)

300 (12)

500 (20)

117 000 (260 000)

70 (2 3/4)

340 (13 1/2)

550 (21 1/2)

16 (5/8)

135 000 (300 000)

75 (3)

355 (14)

560 (22)

16 (5/8)

9.11.7.3

16 (5/8)

By Supplier see 9.11.7.2.b

Horizontal vessels a.

Horizontal vessels shall be provided with lifting lugs welded to the shell if specified on the data sheets.

b.

Calculations for the design of lifting lugs shall be submitted for review and agreement. Requirements specified in 9.11.7.1c.1 and 9.11.7.1c.2 shall be incorporated.

Page 37 of 96



9.11.8

9.12

9.12.1

Earthing (grounding) bosses a.

Vessel shall be supplied with two 40 mm (1 1/2 in) diameter x 50 mm (2 in) minimum length earthing (grounding) bosses each complete with M12 x 30 mm (1/2 in x 1 1/8 in) brass bolt, flat washer, and phosphor bronze lock washer. Length of earthing (grounding) bosses may be increased to enable them to protrude fireproofing on supports.

b.

Earthing (grounding) boss material shall be of same quality of supports and attached to the supports with 6 mm (1/4 in) continuous fillet weld.

Removable internals a.

All portions of the vessel, including removable internals, shall be completely self-draining.

b.

Removable internals shall be designed or sectioned to pass through vessel manways.

c.

Agitator baffles shall pass through the agitator mounting flange.

d.

Weight of individual parts of components that are normally disassembled such as tray decks, downcomers, distributor piping, baffles, minor beams, etc. shall not exceed 25 kg (55 lbs) including attached vapour-liquid contacting devices.

e.

Flanges for internal non-pressure piping may be slip-on or fabricated from plate to the dimensions of ASME B16.5 Class 150 unless otherwise specified on data sheets.

f.

Trays and other column internals shall conform to GIS 46-040.

g.

All fasteners shall be positively locked by nut and full size locknut or cotter pin. All fasteners shall be threaded full length.

Mist eliminators a.

Mist eliminators shall be of the sandwich type consisting of entrainment mesh, retained between welded grid supports as shown in Figure 10.to Figure 12 and Table 8. Mesh, grids, bolting, detailed in Figures are in mist eliminator supplier scope but are shown for clarity.

b.

The screen assembly shall be attached to the support beams at a minimum of four (4) points per panel with M12 (1/2 in) minimum diameter J-bolts with locknuts.

c.

A pressure drop of 3,5 kPa (0,5 psi) shall be used for vessel support and mist eliminator grid design unless otherwise specified. Figure 8 - Mist eliminator used for the full diameter of a vessel

DETAIL A

DETAIL C. (SEE DETAIL D FOR END CONNECTION TO SHELL)

Page 38 of 96



Figure 9 - Mist eliminator for an enclosed internal cylinder

DETAIL A OR DETAIL E


CYLINDER ENCLOSED Figure 10 - Mist eliminator for a reduced diameter

DETAIL F DETAIL A OR DETAIL E

Page 39 of 96




Figure 11 - Mist eliminator attachment details

19mm (3/4 in) MFG. CLEARANCE (REF)

GRID MESH BLANKET GRID

SEE DETAIL B FOR SUPPORT RING

A 19mm (3/4 in) T

19mm (3/4 in)

1/2 in J BOLTS WITH HEX NUTS. TWO (2) REQUIRED AT EACH END OF DEMISTER SECTION

C/L Ø16mm (5/8 in) EQUALLY SPACED ON 140mm (5 1/2 in) APPROX CENTRES

W W

DETAIL A

C/L

DETAIL B

GRID MESH BLANKET GRID

12mm (1/2 in)

1/2 in J BOLTS WITH HEX NUTS. TWO (2) REQUIRED AT EACH END OF DEMISTER SECTION 19mm (3/4 in) 19mm (3/4 in)

32mm (1 1/4 in) 45mm (1 3/4 in)

C/L Ø16mm (5/8 in) EQUALLY SPACED ON 140mm (5 1/2 in) APPROX CENTRES

DETAIL C

TRIM FLANGE TOP & BOTTOM AS REQUIRED

C/L TWO (2) Ø14mm (9/16 in) HOLES IN CLIP AND 14mm x 19mm (9/16 in x 3/4 in) SLOTTED HOLES IN BEAM FOR 1/2 in BOLTS. (TYP EACH END)

DETAIL D

Page 40 of 96



Figure 12 - Mist eliminator support details SEE VESSEL DRAWING FOR THICKNESS

SECTIONAL DEMISTER.USE 25mm x 6mm (1 in x 1/4 in) WITH TWO (2) CLIPS PER RING SECTION. CLIPS TO BE WELDED TO RING. RING TO BE PROVIDED WITH Ø16mm (5/8)) HOLES ON 140mm (5 1/2 in) APPROX. CENTRES.

CLIP ANGLE: 38mm x 38mm x 6mm x 38mm LONG. (1 1/2 in x 1 1/2 in x 1/4 in x 1 1/2 in LONG)

ONE PIECE DEMISTER. USE FOUR (4) CLIPS ONLY WITH Ø16mm (5/8 in) HOLE IN CLIP.

Ø16mm (5/8 in) HOLES FOR 1/2 in BOLTS DETAIL E A 13mm (1/2 in)

T

SEE VESSEL DRAWING FOR THICKNESS

C/L

Ø16mm (5/8 in) HOLES EQUALLY SPACED ON 150mm (6 in) APPROX. CENTRES FOR 1/2 in BOLTS

W W DETAIL F

Table 8 - Mist eliminator dimensions Demister Nominal Diameter

Ring

Beams

A

No. Required

Carbon Steel

Flange

Web

Up to 450 mm (18 in)

2

0

_______

_______

_______

451 mm to 1800 mm (>18 in to 72 in)

2

0

_______

_______

_______

1801 mm to 3600 mm (>72 in to 144 in)

2

1

IPE 200 (WF 6 X 12)

100 mm x 6 mm (4 in x 1/4 in)

150 mm x 6 mm (6 in x 1/4 in)

3601 mm to 5400 mm (>144 in to 216 in)

3

2

IPE 200 (WF 6 X 12)

100 mm x 10 mm (4 in x 3/8 in)

150 mm x 10 mm (6 in x 3/8 in)

Over 5400 mm (216 in)

3

Stainless Steel

Special Design. See Vessel Drawing

Notes: 1. T = 3 mm (I/8 in) plus twice corrosion allowance with 6 mm (1/4 in) minimum thickness. 2. W = T/2 plus corrosion allowance with 5 mm (3/16 in) minimum fillet weld.

9.13

External jackets Design of half-pipe or pipe section jackets shall conform to one of the following: a.

ASME BPVC VIII-1 Appendix EE.

b.

ASME BPVC VIII-2 Paragraph 4.11.6. Page 41 of 96



c. 9.14

Half-pipe and pipe section jacket attachment welds to shells and (or) heads shall be full penetration, full strength welds and 100% PT examined.

Nameplates a.

Unless otherwise specified on data sheets, nameplates shall be type 316L stainless steel with the data stamped or engraved with minimum height 4 mm (3/16 in) lettering.

b.

Nameplate shall show at least the following information: 1.

Purchase Order number.

2.

Item number.

3.

Date of manufacture.

4.

Order placed by.

5.

Supplier name.

6.

Supplier serial number.

7.

Design code and its date.

8.

Maximum pressure rating and at coincident temperature.

9.

Minimum design temperature and coincident pressure.

10. Extent of volumetric weld NDE, inspection category or equivalent descriptor. 11. PWHT. 12. Test pressure new. 13. Test pressure corroded. 14. Total weight empty. 15. Required code or statutory markings. 16. Company equipment tag number or a Works Identification Number (of nine digits).

10

11 11.1

Spares a.

Spares shall be provided as specified on the data sheets.

b.

Minimum spares shall be provided as follows: 1.

Two sets of spare service gaskets shall be furnished for vessel girth, manway, and blinded flanges.

2.

An additional 10% (minimum quantity 2) for each size of bolting, and nuts shall be provided.

Fabrication requirements General a.

Machining shall be performed after welding or heat treatment if such operations change machined surface characteristics or geometry such as flange face flatness.

b.

Stainless steel, high nickel alloy, titanium, or zirconium surfaces shall be mechanically cleaned with stainless steel brushes, stainless steel grit, glass beads, or other high quality abrasive provided their use does not contaminate the material surfaces.

Page 42 of 96



c.

Welder’s and welding operator’s symbols and reference lines may be stamped on the material, in conformance to the design code, provided that a round-nose stamp is employed and the symbol is located a minimum of 25 mm (1 in) from the edge of the weld.

d.

The following materials shall not be used to mark on or coat vessels: 1.

Marking inks that contain halogens.

2.

Lubricants.

3.

Crayons.

4.

Adhesives.

5.

Tapes (e.g. duct tape).

6.

Coatings to prevent adhesion of weld spatter.

7.

Paints containing sulphur.

8.

Chlorine compounds that decompose to hydrogen chloride.

9.

Carbon.

10. Harmful metal or metal salts (e.g., zinc, lead, or copper). e. 11.2

All tools used for machining shall be dedicated for use on specific CRA material. Carbon steel tools or other steel tools dedicated to different materials shall not be used.

Tolerances a.

Tolerances shall be in conformance to drawing number PIP VEFV1102M sheets 1 and 2.

b.

Tolerances shall be specified on the fabrication drawings in either the main dimensions or as an additional tolerance drawing.

c.

Allowable flatness tolerances of gasket contact surfaces of flanged shell girth joints, after PWHT if required, shall be as shown in Table 9 for the designated service condition. Table 9 - Flatness tolerances of gasket contact surface Vessel diameter mm (in) < 380 (15) > 380 (15) to 760 (30) > 760 (30) to 1 140 (45) > 1 140 (45)

Allowable tolerance mm (in) (1) Normal service

Special service (2)

0,8 (0,03) 0,8 (0,03) 0,8 (0,03) 0,8 (0,03)

0,08 (0,003) 0,150 (0,006) 0,225 (0,009) 0,300 (0,012)

Notes: 1. Total tolerance on peripheral gasket contact surface shall not occur on less than a 0,35 radian (20 degree) arc. 2. Design temperatures greater than 454°C (850°F), or a flange rating greater than ISO PN 110 (ASME Class 600).

11.3

Joints

11.3.1

General a.

Location of all longitudinal and circumferential joints shall be shown on the fabrication drawings.

b.

If two sections of unequal thickness are butt welded together, the inside (process face) shall be flush.

c.

Weld joints shall be prepared by machining, grinding, or thermal cutting. Page 43 of 96



11.3.3

If thermal cutting is performed, the joint surfaces shall be ground to sound metal prior to welding.

2.

Preheat requirements for thermal cutting shall be the same as specified in the WPS.

d.

Except as permitted in 11.3.1e, longitudinal joints shall be located to clear nozzle openings, nozzle attachment welds, and reinforcing pad attachment welds by at least 50 mm (2 in), measured weld toe to weld toe.

e.

The following shall apply if a nozzle opening, nozzle attachment weld, reinforcing plate, or reinforcement plate weld is located on a longitudinal or circumferential weld.

f.

11.3.2

1.

1.

It shall be demonstrated to Company that plates cannot be re-orientated or relocated in instances where the required weld toe clearance is not achieved.

2.

Alignment of the butted plates under the reinforcement plate shall be flush.

3.

Longitudinal or circumferential weld shall be ground flush and given 100% volumetric and surface examination for a length equal to three times the diameter of the opening before attachment of pad.

4.

Location of the nozzle and weld seam shall be agreed by Company.

Welds subject to severe forming, where ratio of thickness to local radius is greater than 5%, shall have full volumetric examination before forming and full surface examination after forming.

Longitudinal joints a.

Longitudinal seams shall not fall within the tray-downcomer area of trays or behind other large obstruction that prevents inspection of the welds.

b.

Longitudinal joints shall be offset between courses by at least five times the plate thickness, or 150 mm (6 in), whichever is greater.

c.

Longitudinal joints shall be located to maximise access for internal visual inspection, consistent with the presence of the internals.

d.

Longitudinal joints in horizontal vessels shall not be located: 1.

Under the saddle or saddle wear plate.

2.

Within 50 mm (2 in) of the saddle or saddle wear plate attachment welds.

3.

Within 15 degrees of the horn of the saddle or saddle wear plate.

Circumferential joints a.

Circumferential joints shall be located at least 50 mm (2 in) above or below the tray ring attachment welds.

b.

Circumferential joints shall be located at least 50 mm (2 in) away from horizontal vessel saddle or saddle wear plate attachment welds.

11.4

Welding

11.4.1

General a.

Butt joints shall be full penetrations.

b.

For butt joints inaccessible from the inside, a method for obtaining a full penetration and full fusion weld from one side shall be submitted for Company review and agreement.

c.

Butt joints shall not use permanent backing strips.

Page 44 of 96



d.

All welds, including internals, non-pressure parts and attachments, temporary attachments and shipping attachments, shall be made by welders, welding operators, and welding procedures qualified under the provisions of the pressure vessel code and agreed by Company.

e.

The following documents shall be provided to Company for review and agreement before the start of fabrication: Welding procedure specification.

2.

Procedure qualification record.

3.

Welder performance qualification.

4.

Detailed weld map.

5.

Welding procedures.

6.

Fabrication drawings.

f.

The detailed weld map shall include, as a minimum, a sketch of all weld joints, welding symbols used in conformance to AWS A2.4, and associated weld procedure numbers.

g.

Arc strikes shall be conditioned to eliminate surface stress concentrations.

h.

Defects found from arc strikes shall be removed and the surface shall be repaired and re-examined.

i.

Significant weld repairs shall be subject to agreement by Company.

j.

Removable start-up and run-off tabs may be used for longitudinal welds. The tab materials shall be of the same material specification and grade as the base metal.

k.

Unless specifically agreed by Company, use of weld materials with strengths higher than that of low-hydrogen weld materials for any welding processes shall not be permitted.

l.

Welding consumables shall:

m. 11.4.2

1.

1.

Be the same nominal composition as the parent metal.

2.

Not contain addition of alloys via the flux, other than that required to make up for losses (e.g., in the arc).

3.

Filler wire shall conform to GIS 18-012.

4.

Have material properties such as, tensile strength or yield strength, equal to or greater than the minimum requirements for the base metal at ambient and design temperature.

A local DHT shall be performed for butt-welds and corner joint welds (i.e., ASME weld category A, B, and C) that are 50 mm (2 in) and greater in thickness (See Annex E).

Welding processes a.

The following welding processes shall not be used: 1.

Self-shielded flux-cored arc (FCAW).

2.

Welding process agreed by Company for a different Purchase Order, but not submitted or agreed for the subject Purchase Order and item.

b.

Manual shielded metal arc with covered electrode (SMAW) of carbon and low alloy steels shall be made using low hydrogen electrodes.

c.

Semi-automatically submerged arc (SAW) may be used.

d.

Gas metal arc using solid wire (GMAW) may be used. 1.

The type of metal transfer (short-circuiting arc, globular or spray transfer) shall be specified on the WPS under electrical characteristics. Page 45 of 96



11.4.4

The process is applicable to carbon steel and weld overlay if a satisfactory level of dilution is demonstrated.

3.

GMAW using a short-circuiting arc shall only be used for depositing metal that is subsequently removed.

4.

Field welding is subject to Company agreement.

e.

Gas tungsten arc, manual or automatic (GTAW) may be used.

f.

Gas shielded flux-cored arc (FCAW) may be used.

g. 11.4.3

2.

1.

The type of metal transfer shall be specified on the WPS. Globular or spray is permitted but using a short-circuiting arc is prohibited.

2.

Rutile wire may be used for welding carbon and low alloy steels and stainless steel. FCAW shall not be used for other alloys.

3.

Basic cored wires may only be used for the deposition of fill passes in butt welds in the 1G and 1GR position.

4.

For welds subject to PWHT and requiring impact testing, the FCAW brand name for rutile wires shall be an essential variable.

5.

Fillet welding procedures in 1F and 2F positions shall be separately qualified for leg length greater than 6 mm (1/4 in).

The use of metal cored wires is subject to specific agreement by Company.

Weld procedure and welder qualification a.

Changes to the agreed WPS or PQR shall also be submitted for review and agreement by Company.

b.

The WPQ shall be made available for review upon request.

c.

Repair procedures shall be submitted for review and agreement if the repairs could be detrimental to the material (either in terms of mechanical performance of corrosion performance in service) or delivery of the vessel.

d.

Unless otherwise agreed, the position of the impact test specimens for tests of weld metal and HAZ shall be: 1.

Weld metal centreline.

2.

Fusion line.

3.

Fusion line plus 2 mm (1/16 in).

4.

Fusion line plus 5 mm (1/4 in).

Dissimilar welds between austenitic stainless steels and ferritic steels a.

Welds joining austenitic stainless steels to ferritic steels shall be made with filler metal as follows: 1.

2.

For services not exceeding 340°C (650°F), one of the following shall be used: a)

ASME SFA-5.4 classification E309L.

b)

SFA-5.9 classification ER309L.

c)

The filler metals given in 11.4.4a.2 below.

For services exceeding 340°C (650°F), one of the following shall be used: a)

ASME SFA-5.14 classification ER NiCr-3.

b)

ASME SFA-5.11 classification E NiCrFe-3 or E NiCrFe-2. Page 46 of 96



11.5

12 12.1

c)

Another filler metal as specified on the data sheets.

d)

Company agreement is required for dissimilar welds in services exceeding 340°C (650°F).

b.

Preheat shall be based on the ferritic material.

c.

The first layer of weld overlay deposits shall be made using the preheat required for the base plate.

d.

Subsequent weld layers may use the preheat required for the alloy deposits.

e.

Proposals for dissimilar welds that require a PWHT shall be submitted to Company for review and approval

Temporary welded attachments a.

Attachment point of spiders, braces, or other temporary attachments shall be of the same material alloy as the point on the vessel to which it is attached.

b.

Temporary welds shall conform to 11.4.1d.

c.

Temporary clips, brackets and other fabrication aids shall be removed flush with vessel without damage to base metals. 1.

Gouges from cutting tools shall be welded with an agreed procedure and ground flush to a finish in conformance to the pressure vessel welding code.

2.

Areas where attachments have been removed shall be subjected to examination by PT/MT, in addition to visual examination, to ensure no cracks have been generated.

3.

Temporary attachment removal and repairs shall be performed prior to PWHT and hydrotest.

4.

Peening shall not be used.

Examination requirements General a.

The extent of examination and special documentation, in addition to the minimum requirements of the design code, shall be as specified in the Purchase Order documents.

b.

All specified NDE shall be performed in conformance to the design code.

c.

For specific welded pressure joint examination requirements, see the data sheets.

d.

The minimum degree of examination of welded butt joints shall be spot radiography.

e.

Accessible surfaces of completed corner joint welds shall be examined by MT, PT, UT, or other non-destructive methods in conformance to Company’s Purchase Order documents.

f.

Welded joints that are inaccessible after assembly shall be examined by PT or MT in conformance to the following instructions, and repaired as required before painting, assembly, and testing:

g.

1.

After back-chipping to sound metal, the root pass and its opposite side shall be examined.

2.

After any required machining or grinding, the finished surfaces of the weld shall be examined, and all indications on the finished weld surfaces shall be repaired by grinding or welding before pressure testing.

Imperfections shown to be unacceptable during examination shall be repaired and then, as a minimum, the repair shall be examined by the same method, to the same extent, and by the same acceptance criteria that revealed the condition. Page 47 of 96



h.

The following items shall be examined by MT or PT: 1.

2.

3.

The following surfaces of butt-type joints greater than 50 mm (2 in) thick: a)

The surface of sound metal after back-chipping or gouging root pass to metal surface.

b)

All accessible surfaces of completed weld.

The following surfaces of non-butt type joints, including surfaces in nozzles and manways, if the vessel section or head is designed using a joint efficiency of 1.00: a)

The surface of sound metal after back-chipping or gouging root pass to metal surface.

b)

All accessible surfaces of completed weld.

The cut edge of openings in vessel walls greater than 13 mm (1/2 in) thick into which nozzles and manways are attached with a full penetration weld through the nozzle or manway wall. a)

4.

i. 12.2

12.3

Examination shall be performed before nozzle attachment, and a re-examination performed after attachment if accessible.

All accessible surfaces of completed welds for the following: a)

Internal and external welds if the thickness of the pressure part is greater than 50 mm (2 in).

b)

Welds attaching vertical vessel supports.

c)

Welds attaching vessel lifting lugs.

d)

Welds attaching manway davits.

Fracture mechanics assessment of weld flaws shall not be used to justify weld defects not permitted by the design code.

Preparation a.

The NDE schedule and NDE procedures shall be submitted to Company for review and agreement.

b.

Personnel concerned with inspection, interpretation, and NDE shall be qualified to at least PCN Level 2 or ASNT Level 2 if the qualification has been obtained through examination by an independent organisation. Evidence of the qualification shall be available to Company for verification.

c.

Company reserves the right to test and monitor the performance of any NDE operator and to exclude any that are deemed unsatisfactory.

d.

Calibration certificates for NDE equipment shall be available for inspection at all times.

e.

Before fabrication, materials shall be visually inspected for defects on accessible surfaces.

f.

Heads and shell sections that are annealed or normalised shall be free of mill scale prior to inspection.

g.

Materials for marking, painting, or inspection on stainless or nickel based alloys shall not contain chlorine, bromine, or other halogens, sulphur, zinc, or low melting point metals.

Examination of materials a.

Plates of thickness 50 mm (2 in) and above shall be subject to UT check for laminations.

b.

Forgings of thickness 50 mm (2 in) and above shall be subject to a 100% UT check for subsurface defects. Page 48 of 96



12.4

Surface examination of welds a.

Extent of surface examinations, location selection, acceptance criteria, repair method, and re-examination required in this Specification shall be performed in conformance to the specified design code.

b.

Welds shall be free from surface breaking defects.

c.

Pressure welds in ferritic materials, not subject to RT or UT, shall be examined by MT at back-chipped surface and at finished weld surface.

d.

Skirt attachment welds of ferritic materials shall be examined by MT.

e.

On ferritic vessels subject to PWHT, the shell to nozzle welds on nozzles greater than DN 200 (NPS 8) shall be subject to MT after PWHT.

f.

Magnetic particle inspection techniques liable to damage the vessel by arcing shall not be permitted.

g.

After hydrotest, the following surface examinations shall be made: 1.

MT on external welds and the location of temporary welds.

2.

Internal welded surfaces and HAZs, including pressure boundary welds, internal attachment welds, and the location of temporary welds may be inspected by WFMT after PWHT and hydrostatic test if specified on the data sheets. Indications revealed by WFMT shall be removed.

3.

Areas requiring repairs shall be given PWHT after welding, equipment shall be hydrostatically re-tested and repaired area shall be re-inspected by WFMT.

4.

Surface preparation for WFMT inspection shall be accomplished by:

5.

12.5

a)

Blasting to SSPC SP 5/NACE No. 1 (white metal) with fresh aluminium oxide or coal slag grit.

b)

If agreed, power wire brushing or grinding to a clean metal surface for limited areas not accessible for sand-blasting.

For small pressure vessels if internal inspection after hydrostatic testing is impractical, the following shall apply: a)

Welds identified for WFMT shall be inspected by WFMT prior to making final closure seam.

b)

Inaccessible welds shall be inspected by UT from outside surface after hydrostatic testing.

Volumetric examination of welds a.

Extent of volumetric examinations, location selection, acceptance criteria, repair method, and re-examination required in this Specification shall be performed in conformance to the specified design code.

b.

Volumetric examination of welds shall use the following recordable NDT methods.

c.

1.

X-ray source.

2.

Radio isotope gamma ray source (with restrictions listed in 12.5c).

3.

Digital RT.

4.

TOFD UT equipped with creeping wave probe(s).

5.

Phased array UT.

Gamma ray shall be subject to the following restrictions. Isotopes not listed below shall not be used. Page 49 of 96



12.7

Iridium-192 shall only be used for thicknesses of 5 mm (3/16 in) up to and including 38 mm (1,5 in).

2.

Cobalt-60 shall only be used for thicknesses greater than 38 mm (1 1/2 in) up to and including 50 mm (2 in).

3.

Selenium-75 shall only be used for thickness of 5 mm (3/16 in) up to and including 30 mm (1,125 in). The source design shall be thermally stable and non-activating.

4.

Elemental selenium shall not be used.

5.

The RT film density shall be between 2,5 and 3,5 inclusive.

6.

The RT film shall be high definition film.

7.

A radiation survey meter in good working condition and calibrated for the types and energies of gamma radiation being used shall be available at the work location.

d.

For thickness greater than 50 mm (2 in), recordable UT methods such as TOFD UT equipped with creeping wave probe(s) or phase array UT shall be used.

e.

If PWHT is performed, all volumetric examinations for record shall be done after any PWHT.

f.

For vessels constructed to ASME Section VIII:

g.

12.6

1.

1.

Ferritic plates below 50 mm (2 in) thick shall be UT inspected, if required or specified, in conformance to ASME SA-578/SA-578M, including Supplementary Requirements S1, S2, S3, and S4. Acceptance Level C shall be used.

2.

Ferritic plates of thickness 50 mm (2 in) and above shall be UT inspected, if required or specified, in conformance to ASME SA-435/SA-435M.

3.

Ferritic forgings shall be UT inspected, if required or specified, in conformance to ASME SA-541/SA-541M including Supplementary Requirement S2.

For vessels constructed to BSI PD 5500: 1.

UT inspection of plate shall be in conformance to EN 10160. The required quality classes shall be S1 for the through thickness check (on 100 mm grid) and E1 for the edge check, unless otherwise specified by Company.

2.

Forgings shall be MT tested to EN 10228-1 and the required quality class shall be class 3 unless otherwise specified by Company.

3.

Forgings and pipe shall be UT tested per EN 10228-3. The required quality class shall be class 3 unless otherwise specified by Company.

Hardness testing a.

Hardness testing shall conform to GIS 36-102.

b.

The hardness of weld metal and the heat affected zones for carbon-steel, C-Mn and low alloy steels as measured on the vessel shall not exceed 200 HBW, unless otherwise specified on data sheets.

c.

The maximum requirements for other materials (other than carbon-steel, C-Mn and low alloy steel) shall conform to Table 2-8 of ASME section II part A.

d.

The upstream hardness requirements shall conform to NACE MR0175/ISO 15156-2 and 3.

e.

The downstream hardness requirements shall conform to NACE MR0103 and NACE SP0472.

Repair of welding defects a.

Repairs of weld defects shall be considered major if one of the following exists: Page 50 of 96



12.8

12.9

1.

The defect size exceeds 9 mm (3/8 in) in depth.

2.

The defect size exceeds one-half the wall thickness of the component.

3.

The defect resulted in leakage during a pressure test.

b.

Weld repairs shall receive surface examination.

c.

Major weld repairs shall receive full volumetric examination.

Positive materials identification (PMI) a.

PMI shall conform to GIS 36-103.

b.

PMI shall be performed to the extent specified on the data sheets and other documents in Purchase Order.

c.

The PMI procedure shall be submitted for review and agreement.

Production control test plates Production control test plates shall be supplied if specified on data sheets or required by the design code.

13

14

Inspection requirements a.

Company’s inspection requirements, including, review, witness, inspection, hold points, and inspection documentation are furnished on the Purchase Order quality requirements or other quality related documents included in the Purchase Order.

b.

Company’s inspector shall be notified and given the option of inspecting major components or services at their point of manufacture.

c.

Company’s quality surveillance and notification requirements shall be included in all suborders.

d.

Certified drawings shall be available for use by Company’s inspector at the point of manufacture.

e.

Inspections shall be performed for conformance to Company’s Purchase Order documents.

f.

The performance of quality surveillance by Company’s inspector shall not relieve the Supplier or manufacturer of responsibility for conforming to the requirements of the Purchase Order documents.

Post weld heat treatment a.

Unless otherwise agreed by Company, alternative PWHT requirements of ASME BPVC VIII-1 Table UCS 56.1 or ASME BPVC VIII-2 Table 6.16 shall not be used.

b.

Unless otherwise specified on the data sheets, PWHT of test specimens shall include one extra PWHT cycle for potential future field repair.

c.

PWHT shall be performed after all welding, weld repairs, and non-destructive examination is completed before and after pressure testing.

d.

Furnaces used for PWHT shall be constructed to prevent flame impingement on the vessel.

e.

A PWHT procedure shall be submitted to Company for approval and shall include as a minimum: 1.

Furnace description.

Page 51 of 96



15 15.1

2.

Loading pattern.

3.

Details and locations of supports and bracing.

4.

Thermocouple locations.

5.

Heating and cooling rates.

6.

Soak time and temperatures.

f.

All PWHT shall be recorded and documented by temperature and time charts.

g.

Except as specified in Annex C clause C.1b, pressure parts made of austenitic stainless steel, if hot formed, shall be solution annealed between 1 010°C (1 850°F) and 1 120°C (2 050°F) followed by rapid cooling through the sensitization range.

h.

Vessels shall not come into contact with galvanised components during PWHT.

i.

On ferritic vessels subject to PWHT, the shell to nozzle welds on nozzles greater than DN 200 (NPS 8) shall be subject to MT after PWHT.

j.

Local PWHT procedures shall be submitted to Company for review and approval.

k.

Vessels shall be PWHT in one section unless prior agreement has been reached with Company.

Pressure test General a.

Unless otherwise specified on data sheets, the test pressure shall be based on the MAP (new and cold).

b.

Prior to the pressure test, the inside and outside of the vessel shall be thoroughly cleaned, free from slag, scale, dirt, grit, weld splatter, pieces of metal, paint and oil. Welds shall be free of slag, oil, grease, paint, and other foreign substances that might prevent interpretation of the required tests.

c.

Vessels shall not be painted or controlled shot peened before the pressure test, with the following exceptions: 1.

Surfaces that are to be painted, but are inaccessible after assembly, such as mating surfaces of lap-joint stub ends, flanges and nozzle necks, flange bolt holes, welded joints, shall be painted before assembly and pressure testing.

2.

Welded joints that are inaccessible after assembly, such as joints covered by lap-type flanges, shall be examined by PT or MT and repaired before painting, assembly and pressure testing. See 12.1f for specific examination requirements.

d.

The test pressure shall be measured at the high point of the vessel in the test position.

e.

Welds shall be cleaned and free of scale or paint before pressure testing to permit examination for defects.

f.

Reinforcing pad attachment welds and accessible surfaces of inside nozzle to vessel wall welds shall be tested for leaks with a gauge pressure of 100 kPa (15 psig) dry air or nitrogen and bubble forming solution. Test shall be performed before the final hydrostatic or pneumatic test.

g.

All facilities and materials, including blinds, bolting, and gaskets, required for testing shall be provided.

h.

The service bolts shall be used for the pressure test.

i.

The temperature of the pressure-retaining components during the pressure test, regardless of test media, shall be: Page 52 of 96



j.

15.2

1.

At least 15ºC (60°F), but not higher than 50ºC (120ºF) and

2.

At least 17ºC (30ºF) higher than the vessel minimum design metal temperature.

Gaskets shall be used for test purposes in conformance to the following: 1.

The specified service gasket shall be used. If a flanged joint is not being disassembled after testing, service gaskets used for testing shall be left installed for shipment for all blind flanged connections.

2.

Flanged joint assemblies fitted with service gaskets, such as main body flange joints, manways, blind flange nozzles, and disassembled following tests shall be reassembled using new service gaskets. If the joints are shipped unassembled, new service gaskets for field installation shall be packaged, marked, and shipped with the vessel. See 17.1c.

3.

Joints being disassembled after testing, employing nonstandard flanges and service gasket is not specified, the test gasket description shall be submitted to Company for agreement.

k.

Joint sealing compound or gasket lubricant shall not be used.

l.

Bolting and washers used for testing shall be lubricated for assembly before the initial hydrostatic test.

m.

Leakage shall not be permitted at the time of the required inspection except for leakage that can occur at temporary closures for openings intended for welded connections.

n.

Leakage from temporary seals shall be directed away from vessel to avoid masking leaks from other joints.

o.

Sensitive leak tests, if specified, shall be performed before hydrostatic testing.

p.

Welding, burning, or grinding, including cosmetic grinding of pressure retaining welds, shall not be performed on vessels that have been pressure tested unless agreed by Company. This includes but shall not be limited to welds for shipping attachments, refractory or insulation clips, stiffeners, spiders, or grinding for surface preparation.

q.

If field assembly and erection is specified in the Purchase Order documents, the final pressure test shall be performed at the installation site. A detailed test procedure shall be provided to Company for review before testing.

r.

If hydrostatic testing at the installation site is specified in the Purchase Order documents, Company shall furnish a fill line and a drain line for the test water at a location adjacent to the test site.

s.

A detailed test procedure shall be submitted to Company for review and agreement.

Hydrostatic test a.

Liquids other than water may be used for hydrostatic testing in conformance to the design code, if specified on the data sheets.

b.

Horizontal vessels designed to support a full weight load of water shall be tested resting on its support saddles, without additional supports or cribbing.

c.

Vertical vessels being tested in the erected position, whether shop or field, shall have design consideration given to the additional pressure and weight from the fluid head.

d.

Vessels shall be supported during the pressure test to prevent damage.

e.

Testing of vessels shall be performed with test water that is clean and free of debris.

f.

Water shall not contain more than 10 ppm suspended solids.

g.

Brackish or untreated water shall not be used. Page 53 of 96



15.3

h.

Except as permitted in 15.2i, testing of vessels or components made of austenitic stainless steel materials shall be performed with water containing a maximum of 30 ppm chloride.

i.

If the duration of the test procedure is 72 hours or less and the procedure includes rinsing with water containing less than 30 ppm chloride, testing of vessels or components made of austenitic stainless steel materials may be performed with water containing greater than 30 ppm chloride but less than 250 ppm chloride.

j.

Test water shall not be in contact with austenitic stainless steel for greater than 72 hours unless treated with a biocide.

k.

Before application of the test pressure, the test water and the vessel material shall be permitted to equalise to approximately the same temperature.

l.

The test pressure shall be held for a minimum of one hour, or as specified on data sheets.

m.

After completion of the hydrostatic test:

16.1

The vessel shall be immediately drained.

2.

Standing water (including on internals) shall be wiped dry and shall not be allowed to evaporate to dryness.

3.

Vessel shall be closed as quickly as practicable.

Pneumatic test a.

Detailed, written procedures for pneumatic testing shall be submitted for review and agreement by Company.

b.

If acoustic emission monitoring of the pneumatic test is specified on the data sheets, procedures for the monitoring shall be submitted to Company for review and agreement.

c.

The pneumatic test medium shall be one of the following:

d.

16

1.

1.

Inert gas.

2.

Clean, dry, oil-free air in conformance to ISO 8573-1 Class 1, 2, or 3 air, with a dew point ranging from -20°C to -70°C (+4°F to -94°F).

Pneumatic testing shall not be permitted unless: 1.

Hydrostatic testing is not practical as determined by Company.

2.

Butt-welds have received full volumetric examination.

3.

Attachment welds, including weld attaching non-pressure parts to pressure parts have received full surface examination.

4.

Non-essential personnel have evacuated the testing area for a safe distance specified in ASME PCC-2 Article 5.1.

5.

Supplier demonstrates that all materials used ensure fracture toughness during the test at the test temperature.

Cleaning, surface preparation, painting, and marking Cleaning a.

The vessel shall be thoroughly cleaned inside and outside.

b.

Grit, scale, oil, grease, weld rod stub ends, sand, water, free moisture, and all other foreign material shall be removed from the vessel.

c.

High alloy vessels shall be blown dry with ambient temperature air, only after all standing water has been removed. Page 54 of 96



d.

16.2

The following vessel cleaning procedure shall be performed before shipping, if specified on the data sheets: 1.

Perform solvent or detergent wash.

2.

Rinse.

3.

Perform wet-dry test in conformance to ASTM A380.

4.

If rust stains appear in wet-dry test, acid clean with passivation solution.

5.

Repeat wet-dry test.

6.

If rusting reappears, consider pickling solution.

7.

Rinse.

8.

Dry.

Surface preparation painting and non-metallic lining a.

Surface preparation, external painting and non-metallic internal lining shall conform to GIS 06-602.

b.

Internal and external surface preparation, priming, painting and lining shall only proceed after completion of pressure tests.

c.

Austenitic alloy steel and nickel-iron-chromium alloy material parts with design metal temperatures above 400°C (750°F) shall not be painted.

d.

External coating and internal lining shall be as specified on the data sheets.

e.

Removable lifting flanges, removable tailing lugs shall be painted yellow.

f.

Lifting devices that are intended to be cut off after erection shall receive full surface preparation, priming, and painting as the component it is attached to, except the final colour shall be yellow for the areas that are to be cut off.

g.

The Company inspector shall have absolute and immediate authority to reject any stage of surface preparation, priming, painting or lining.

h.

Rejected surface preparation, priming, painting or lining shall be remediated as instructed by the Company inspector to include possibly re-surface preparation on the entire vessel.

i.

Vessels coated with non-metallic linings shall conform to the following additional requirements: 1.

All butt and fillet welds shall be ground smooth.

2.

Grinding shall be kept to a minimum to achieve a minimum radius of 6 mm (1/4 in) for a smooth surface for the lining.

3.

Nozzles and manways shall be flush on the lining side with all corners rounded to a radius of 6 mm (1/4 in).

4.

All outside corners and edges shall be ground to a minimum radius of 6 mm (1/4 in). See Figure 13 for typical details. Fillet welds that are to be ground shall be oversized, so that the grinding the radius does not reduce the fillet weld throat dimension below the minimum Code thickness.

Page 55 of 96



Figure 13 - Surface Contours

5.

Partitions, braces, supports or other attachments on the lined side of the vessel shall be fitted flat against the vessel surface and continuously welded around the entire perimeter. See Figure 14 for typical details. Figure 14 - Internal attachments

16.3

6.

Pockets or crevices that cannot drain or be abrasive-blast cleaned shall not be permitted.

7.

Lined bolt holes shall be drilled oversized for the lining. All edges shall be rounded to a radius of 6 mm (1/4 in) by grinding.

Marking a.

Markings shall be in the English language.

b.

Markings shall also be in an additional language if specified on the data sheets or Purchaser Order documents.

c.

Markings shall be at least 150 mm (6 in) high letters in contrasting paint.

d.

PWHT vessels shall have the following notice painted on two sides of the shell and insulation covering, if present, in three-inch high letters visible in the shipping position from grade (See 11.1d): POSTWELD HEAT TREATED - DO NOT BURN OR WELD

e.

Vessels with non-metallic linings shall have the following notice painted on two sides of the shell and insulation covering, if present, in three-inch high letters visible in the Page 56 of 96



shipping position from grade (See 11.1d): LINED VESSEL - DO NOT BURN OR WELD f.

The marking on vertical vessels shall be located on two opposite sides near the bottom tangent line and repeated at approximately each 3 m (10 ft) of height, but rotated π/2 radians (90 degrees).

g.

The markings on horizontal vessels shall be located on both sides near the horizontal centreline.

h.

The North and East orientations shall be centre-punched on the outside of each vertical vessel approximately 150 mm (6 in) above the bottom tangent line and 150 mm (6 in) below the top tangent line. The punch marks shall be circled with white paint.

i.

The Purchase Order number and the vessel identification number shall also be painted with contrasting paint on non-pressure attachments such as saddles, skirt, or support brackets.

j.

Temporary support components required for maintaining vessel roundness or shipping shall be painted yellow and marked: SHIPPING/FABRICATION DEVICE. REMOVE BEFORE UNIT STARTUP.

k.

17 17.1

The centre of gravity of the vessel shall be marked in contrasting paint.

Preparation for shipment General a.

Each vessel and vessel internals shall be packaged, supported and protected from damage or loss during handling and shipment.

b.

Certified weight shall be obtained for the vessel prior to shipment preparations if specified on the data sheets.

c.

A packing list shall be included in each shipment.

d.

Spares shall be packaged, marked, and shipped with the vessel.

e.

Bolting and other loose parts shall be packaged and identified with the Purchase Order number and vessel tag number.

f.

Uncoated bolts and nuts shall be coated with a thread lubricant to prevent corrosion during transportation and storage. The lubricant shall be easily removable with mineral spirits or a solvent.

g.

Internals which cannot be safely shipped in place shall be identified, tagged, and shipped separately.

h.

A minimum of one of each type of internals which have specified clearances or tolerances, such as tray type or distributor type, shall be trial assembled into the vessel to ensure fit-up before shipment.

i.

Design and construction details for shipping saddles shall be submitted to Company for review and agreement.

j.

Austenitic stainless steel vessels shall be protected from exposure to salt water, salt spray, and chlorides during ocean or over the road shipment.

k.

Vessels that undergo ocean shipment shall have a preparation and shipping plan submitted for agreement. 1.

Vessels shall not be transported to the jobsite as above-deck cargo without prior written agreement of Company. Page 57 of 96



2.

l. 17.2

Packaging and protection shall be designed for outdoor storage for a minimum period of 6 months, unless otherwise specified in Purchaser Order.

Preparations for the vessel a.

17.3

Vessels containing nitrogen shall be clearly marked identifying that nitrogen is present. The method and location of such marking shall be agreed upon between Supplier and Company.

Flanged openings shall be protected with one of the following: 1.

Plastic flange protectors.

2.

Metal flange protectors with rubber gaskets.

b.

Covers for flanged opening shall be secured with at least 25% complement of total flange bolting (minimum of 4 bolts).

c.

Welding stub ends shall be protected with plastic caps.

d.

Threaded couplings shall be protected with bull plugs and sealed with joint compound.

e.

Socket weld fittings shall be protected with plastic caps.

f.

Weld bevels shall be closed with plastic caps.

g.

Nozzles, including attached piping, within or passing through vessel support skirts shall be supported for shipping and handling.

h.

Machined surfaces (except weld bevels), flange faces, threaded surfaces, and other finished or delicate parts shall be well-greased and protected against rusting and damage during shipment.

i.

Weld bevels shall be free of dirt, oil, grease, scale, rust, and other foreign materials.

j.

Weld bevels of carbon steel and ferritic alloy steel materials shall be coated, after cleaning, on the inside and outside for a distance of approximately 75 mm (3 in) from the end of the weld bevel with a weldable rust preventive agreed by Company.

k.

Holes in reinforcing pads and saddle wear plates shall be plugged with RTV silicone sealer or rust preventative grease that shall not damage the base material.

l.

Blind flanged connections, including manways, shall have the blinds attached with a full complement of new service bolts and service gasket.

m.

Joints shall be assembled in conformance to ASME PCC-1.

n.

Saddle extensions constructed of timber or other materials shall be secured to permanent saddles of horizontal vessels if the saddles are used for support during shipment.

o.

Saddle extensions shall provide the required ground clearance for boot or nozzle projections that extend below the permanent saddle base plate.

Preparations for spares and crated parts a.

Items shipped not attached to the vessel shall be packaged and crated for secure shipment.

b.

Parts with nozzles, flanges, or connections, such as piping spools, shall be protected as listed in 17.2.

c.

Crates shall be durably marked with: 1.

The receiving address.

2.

The vessel item number.

3.

The Purchase Order number.

Page 58 of 96



17.4

17.5

d.

Markings shall be in a minimum of two locations and a minimum lettering size of 25 mm (1 in).

e.

Markings shall be in the English language.

f.

Markings shall also be in an additional language if specified on the data sheets, or Purchaser Order documents.

Securing and padding a.

Ropes, chains, and straps may be used to secure the vessel and associated equipment to the transporter deck.

b.

Padding shall be placed between cables or chains and stainless steel or high alloy equipment to prevent discoloration of the vessel shell or contamination of the metal.

c.

Nozzles and manways shall not be used as tie-down points.

d.

External attachments other than lifting lugs and tailing lugs shall not be used as tie down points unless specifically designed to.

e.

Carbon steel shipping saddles that are used for stainless steel or high alloy vessels shall be padded.

Material safety data sheets a.

18

Vessels or materials that contain or are coated with any of the following shall be prominently tagged at openings to indicate nature of contents and precautions for shipping, storage, and handling: 1.

Insulating oils.

2.

Corrosion inhibitors.

3.

Antifreeze solutions.

4.

Desiccants.

5.

Chemical substances.

6.

Hydrocarbon substances.

b.

Regulated substances shall have a MSDS.

c.

MSDS shall fully conform to regulations for MSDS preparation specified by entity that has jurisdiction and shall include a statement that the substance is considered hazardous by regulation.

d.

If any products are exempt from regulation, a statement to that effect shall be included.

e.

MSDSs shall be forwarded to the receiving facility before shipment.

f.

MSDSs shall be placed in a protective envelope(s) and shall be affixed to the outside of the shipment.

Documentation The following documentation shall be required.

18.1

Proposal documentation a.

The Supplier shall supply all specified information required for appraisal of the mechanical design by Company, which includes but is not limited to the following: 1.

Confirming conformance to code of construction and all documents within the enquiry or provide requests for clarification or deviations. Page 59 of 96



A typical quality control plan.

3.

The proposed manufacturing plan.

4.

Listing of proposed Suppliers and sub-Suppliers, including names and addresses.

5.

Definition of the welding processes and techniques to be used, including that for overlay applications.

6.

List of any requested exceptions or deviations to the Purchase Order documents including this Specification.

7.

Details of previous fabrication experience on vessels of similar size and of the same materials and construction.

b.

The base proposal for construction of vessel shall be provided in conformance to the request for proposal.

c.

An alternative design proposal may be submitted if considered less costly or an improvement in the delivery schedule. The improvements in cost and schedule shall be realised without any of the following:

d.

18.2

2.

1.

Loss of capability.

2.

Shortening the anticipated life of the vessel.

3.

Increase in the total lifecycle cost of the vessel.

Alternative design proposals shall conform to the following and: 1.

Shall be accompanied by the base proposal and be clearly identified as an alternate proposal.

2.

Shall clearly state the intended use of ASME Code Cases.

3.

Shall be fully and clearly described and substantiated by sketches or drawings.

4.

Shall include a list of specific exceptions to Company’s request for proposal, the data sheets, and the Purchase Order documents including this Specification.

During design and fabrication a.

Work shall not begin unless the plans and procedures applicable to that work have been agreed by Company.

b.

The following shall be submitted for review and agreement by Company: 1.

Quality plan.

2.

Inspection and test plan.

3.

Fabrication plan.

4.

Names and addresses of all Suppliers and sub-Suppliers.

5.

Full set of fabrication drawings.

6.

Complete calculations.

7.

WPS.

8.

PQR.

9.

Weld map.

10. Heat treatment procedures. 11. Pressure test procedure. 12. PWHT procedure.

Page 60 of 96



13. NDE procedures. 14. Drawings of trays, packing, and internals, if applicable. 15. Centre of gravity and foundation loading diagram. 16. Draft ASME forms. 17. Draft final pressure vessel record book (see 18.3b). c.

The fabrication drawings shall include, but shall not be limited to, the following: 1.

Applicable information on the pressure vessel data sheets.

2.

Dimensions of vessel components.

3.

General vessel details including nozzle details.

4.

Gasket and flange details including flange face finishes.

5.

Internal construction details including shell attachments and location.

6.

Full scale drawing of the vessel nameplate.

7.

Support and other appurtenance details including an anchor bolt template.

8.

Weld joint details in cross-section, weld map, and applicable welding procedures.

9.

Clad and weld overlay details.

10. Heat treatment requirements. 11. Weld hardness requirements. 12. Non-destructive testing requirements. 13. Identification of pressure limiting components. 14. Tolerances to which the vessel shall be built. d.

Fabrication drawings shall use the system of units specified in the Purchaser Order.

e.

Revisions of drawings, plans, procedures, and other previously submitted documents shall be submitted for further agreement by Company.

f.

No modifications shall be made to the agreed drawings, plans, procedures, and other agreed documents without the agreement of Company.

g.

Documents shall reference both the Purchase Order number and the vessel item number.

h.

As a minimum, the following documents shall be available for review during manufacture:

i. 18.3

1.

Purchase orders and specifications for plates and forgings, CMTRs, chemical analysis, and mechanical properties of pressure containing materials including weld filler materials, except weld filler materials in carbon steel vessels.

2.

Copies of actual heat treatment charts indicating complete temperature cycles, holding times, cooling and heating rates.

3.

Radiographs.

4.

WPSs, PQRs, and welder qualification records.

5.

NDE examination reports.

Calculations shall be provided for design of components that fall beyond the scope of the code and shall be submitted to Company for review and agreement.

Final documentation a.

Pressure vessel record books shall be assembled and delivered to Company on completion of construction of each vessel. Page 61 of 96



b.

The pressure vessel record book shall contain, as a minimum, the following information: 1.

Manufacturer’s Data Report (ASME forms).

2.

Photocopy or photograph (not a rubbing) of the vessel nameplate.

3.

Mechanical design calculations required to demonstrate conformance to code, or to justify and prove the integrity of the design for components and aspects that fall beyond the scope of the code.

4.

The latest revision of the data sheets marked up to reflect the as-built conditions.

5.

Quality control plan including fabrication sequence, all heat treatment requirements, forming and rolling procedure, an inspection and test plan with schedule identifying all inspection points required by Company and signed inspection reports.

6.

As-built fabrication drawings.

7.

Welding procedure specifications (WPS), procedure qualification records (PQR), weld map, and welder or welding operator qualification test results.

8.

Personnel qualification certificates for all non-destructive examinations.

9.

Reports required by the code of construction stating the results of non-destructive inspection and testing including RT, UT, MT, PT, and hardness tests.

10. Pyrometer charts or other detailed records for all heat treatment performed, such as PWHT, normalising, and heating for forming. 11. Exceptions, deviations, and non-conformance reports (including resolution) and a detailed description of any repairs including a sketch, photo, or drawing indicating the location and size of the repaired area. 12. Charts or other records of required pressure tests. 13. Certified material test reports or certificates of conformance which fully identify the specific materials they represent. 14. The PMI report for all materials subject to PMI examination. 15. A completed inspection checklist in conformance to the inspection test plan. 16. Results of all impact testing. 17. Operations and maintenance requirements procedures as applicable. c.

Three (3) copies of the pressure vessel record book shall be delivered to Company unless a different number of copies is specified in the Purchase Order documents.

d.

The pressure vessel record book shall also be provided on a CD or DVD securely attached within each furnished hardcopy of the book containing the following: 1.

A PDF version of the pressure vessel record book.

2.

The computer files of the pressure vessel calculations (i.e., COMPRESS, PVElite, Finglow, FE/Pipe, NozzlePro files).

3.

FEA model files with solution (i.e., ANSYS or Abacus files).

e.

The pressure vessel record book shall include all correspondence relating to the approval of “state special” designs as required by the applicable jurisdictions.

f.

The pressure vessel record book shall be retained by the vessel manufacturer and shall be furnished to Company upon their request for a minimum of five (5) years.

Page 62 of 96



19

Quality management The quality management system shall conform to ISO 9001, API Specification Q1, or other agreed internationally recognised standard to ensure that the products and services provided conform to the requirements for supplier quality identified in the Purchase Order.

20 20.1

20.2

20.3

Inspection, test and certification Inspection and test plan a.

Prior to the start of manufacture, an ITP shall be submitted for approval by Company responsible engineer.

b.

The ITP shall include inspection and testing activities to be performed, including those at sub-suppliers’ works and shall make reference to all testing procedures, control documents, and resulting records and reports.

c.

The ITP shall be approved by Company prior to start of manufacture.

Inspection access a.

Company and the Company appointed representative shall at all times have access to the workshops and testing facilities, including workshops of sub-suppliers engaged in supplying material or in fabricating the equipment for the purpose of inspecting the purchased equipment.

b.

Company and the Company appointed representative shall be granted permission to photograph the equipment in the scope of the Purchase Order during manufacturing, assembly and test.

Quality assurance a.

A quality control system shall be operated to ensure technical requirements of the specified pressure vessel code are achieved.

b.

A fabrication plan, an inspection and test plan, and a quality plan shall be submitted for agreement by Company prior to the start of fabrication.

c.

The inspection and test plan shall contain the following elements as a minimum:

d.

1.

Activities and associated control procedure and specification reference governing the activity.

2.

Acceptance criteria.

3.

Responsible party for activity execution.

4.

Objective evidence of activity execution or verifying document.

5.

Quality documents including inspection and test records to be compiled into the pressure vessel record book.

6.

Supplier participation at the inspection and test stages.

7.

Company participation at the inspection and test stages.

8.

Regulatory agency or third party authorised inspector participation at the inspection and test stages.

Quality plan shall state all quality related activities, reference standards, acceptance criteria, and names of the responsible persons in the Supplier’s organization. Spaces for signatures and dates for each inspection activity shall be provided.

Page 63 of 96



e.

21

Technical and quality assurance requirements specified in the purchase order shall apply to all materials, equipment and services provided by sub-Supplier.

Packing, preservation, marking and shipping Preparation of equipment for transportation shall conform to the packing, marking, and shipping instructions or other documents identified in the Purchase Order.

22

Supplier deliverables Technical data, registers, documents, and drawings that together define the scope of the Purchase Order shall conform to the requirements for supplier information identified in the Purchase Order.

Page 64 of 96



Annex A (Normative)

Supplementary requirements for special services A.1

General If data sheets indicate any of the following special services are present, the requirements contained within that clause below shall apply.

A.2

A.3

A.4

A.5

A.6

Anhydrous ammonia service a.

Longitudinal and circumferential butt welds shall receive full volumetric NDE, after any PWHT.

b.

All welds, including external and internal non-pressure containing welds, shall be subject to 100% surface inspection by MT or PT after any PWHT.

c.

Carbon steel vessels shall receive PWHT.

Butane storage a.

The specified minimum tensile strength of C-Mn steels shall not exceed 550 MPa (80 ksi).

b.

Weldment hardness shall not exceed Hv10 248 (Brinell 237 HBW).

Amine service a.

Carbon steel vessels shall receive PWHT.

b.


c.


d.

In amine service, welds and HAZ shall be blasted and examined by WFMT. This examination shall be performed after any PWHT.

e.

Full penetration welds shall be provided on pressure boundary parts to internal attachments such as downcomer bolting bars and segments, bed support beam seats, or any load-carrying attachments that have the long axis parallel to the longitudinal axis of the vessel. This requirement for full penetration welds does not extend to tray support rings, or other circumferentially oriented attachments.

Caustic service a.

Longitudinal and circumferential butt welds shall receive full volumetric NDE after any PWHT.

b.


Cyanides service a.

Longitudinal and circumferential butt welds shall receive full volumetric NDE after any PWHT. Page 65 of 96



b.

A.7

A.8

A.9


Cyclic service a.

Fillet welds shall be contoured.

b.

Fillet welds shall receive toe grinding.

c.

Butt weld joints shall receive full volumetric examination.

d.

All welds shall receive surface examination by PT or MT.

e.

For vessels with a shell thickness of 50mm or more, all nozzles shall be swept-type forgings that allow full volumetric examination.

Hydrofluoric acid a.


b.


c.

Material shall be to licensor and Company requirements, with restrictions on composition. Unless otherwise agreed, it shall be ASME SA-516/SA-516M Gr. 60 normalised with: 1.

Carbon equivalent less than or equal to 0,40%.

2.

Combination of Ni + Cu + Cr less than or equal to 0,15%.

3.

S less than 0,002%.

4.

Oxygen content less than 0,002%.

5.

P less than 0,008%.

6.

Nb (Cb) less than 0,005%.

d.

The steel shall not be calcium treated for shape control.

e.

Full penetration welds shall be provided on pressure boundary parts to internal attachments such as downcomer bolting bars and segments, bed support beam seats, or any load-carrying attachments that have the long axis parallel to the longitudinal axis of the vessel. This requirement for full penetration welds does not extend to tray support rings, or other circumferentially oriented attachments.

Hydrogen service a.


b.


c.

Materials shall be subject to UT to ASME SA-578/SA-578M, including supplementary requirements S1, S2, S3, and S4. Acceptance standard shall be Level A.

d.

Internal and external attachments welds should be full penetration welds. The enclosed space shall be vented if a full penetration weld is achievable.

e.

Longitudinal and circumferential butt welds shall receive full volumetric NDE after any PWHT. Page 66 of 96



f.

A.10

Cryogenic service a.

b.

A.11

A.12


NDE inspections shall include the following if the lowest operating temperature is below 0°C (32°F): 1.

All butt welds shall receive full volumetric NDE after any PWHT.

2.

All welds, including external and internal non-pressure retaining welds, shall receive 100% surface inspection by MT or PT after any PWHT.

All pressure containing welds shall be subject to full volumetric examination after any PWHT if the lowest operating temperature is below -20°C (-4°F).

Propane storage a.

The specified minimum tensile strength of C-Mn steels shall not exceed 550 MPa (80 ksi).

b.

Weldment hardness shall not exceed Hv10 248 (Brinell 237 HBW).

Sour water, wet H2S, or wet sour service a.

Materials shall meet the requirements of NACE MR0175/ISO 15156 parts 1 and 2 and API 5L/ISO 3183 Annex H and K.

b.


c.


d.

Materials specified shall be purchased and fabricated in order to be resistant to environmental cracking in sour service and conform to the hardness and other requirements of GIS 36-025 and ISO 15156 for upstream applications and for downstream (refinery) applications to NACE MR0103 and sour service requirements defined in GP 36-26.

e.

Material shall be in the normalised condition unless agreement is given for the steel to be supplied quenched and tempered (Q+T) or made by TMCP as specified in data sheets and the following: 1.

Normalised plate shall conform to EN 10028-3 or ASTM A516/A516M.

2.

Quenched and tempered plates shall conform to EN 10028-6.

3.

TMCP plates shall conform to EN 10028-5 or ASTM A841/A841M.

f.

The vessel shall be PWHT.

g.

Z quality and HIC plate shall be used for carbon steel. Z-quality steel plate shall be designated as one of the following:

h.

1.

EN 10028-3 Grade P275NH + EN 10164, Z35.

2.

ASME SA-516/SA-516M Grade 70 (or equivalent) + ASTM A770/A770M with S3 at 35%.

The plate shall meet EN 10028-3 or equivalent steel grades together with the following supplementary requirements.

Page 67 of 96



1.

Steels shall be made by a low sulphur and low phosphorus refining process, for example, in an electric furnace with double de-slagging or in the basic oxygen furnace. The steel shall be vacuum degassed while molten.

2.

The following limits by check analysis (product analysis) shall apply: a)

Carbon

0,200% max.

b)

Sulphur

0,008% max.

c)

Phosphorus

0,025% max.

d)

Carbon equivalent (CE) 0,430 max. The carbon equivalent value shall be calculated by the following formula:

CE  C 

Mn (Cr  Mo  V ) ( Ni  Cu )   6 5 15

i.

Plate shall be ultrasonically examined and meet EN 10160 quality classes S1/E1 or equivalent.

j.

Through-thickness tensile test 1.

Each plate shall conform to acceptance class Z35 of EN 10164 or equivalent.

2.

Company may agree to a retest after consideration of information supplied. The through-thickness test shall be made after the completion of all heat treatments.

3.

In addition to the above, the tests required by the material specification shall be carried out.

k.

Plate shall not be weld repaired without agreement and shall be subject to an agreed repair procedure before repair.

l.

The following additional requirements shall apply if data sheets specify that HIC resistant plate shall be used. 1.

Plates shall meet one of the following: a)

EN 10028-3/ASME SA-516/SA-516M (normalised).

b)

EN 10028-6 (Q+T).

c)

ASME SA-841/SA-841M (TMCP)/EN 10028-5.

2.

For low temperature applications (down to -46°C) the impact tested carbon steel plates meeting ASTM A516/A516M Grades 60, 65, 70 or EN 10028-3 grades P275 (NL2) and P355 (NL2) shall be used.

3.

Steels shall be made by a low sulphur and low phosphorus refining process, for example in an electric furnace with double de-slagging or in the basic oxygen furnace. The steel shall be vacuum degassed while molten.

4.

Plates shall be in the normalised, Q+T, or TMCP condition as specified in data sheets.

5.

The following limits by check analysis (product analysis) shall apply: a)

Carbon

0,200% max.

b)

Sulphur

0,002% max.

c)

Phosphorus

0,008% max.

d)

Oxygen

0,003% max.

Page 68 of 96



e)

Carbon equivalent (CE) 0,430 max. The carbon equivalent value shall be calculated by the following formula:

CE  C 

Mn (Cr  Mo  V ) ( Ni  Cu )   6 5 15

6.

Plate shall be ultrasonically examined and meet EN 10160 quality classes S1/E1 or equivalent.

7.

Plate shall not be weld repaired.

8.

HIC/SWC test

9.

a)

Tests shall be made in conformance to NACE TM0284, in the NACE TM0284 Test Solution A (i.e., 5 wt.% NaCl + 0,5 wt.% glacial acetic acid).

b)

One set of 3 specimens shall be tested from each thickness of plate from each heat.

c)

Following exposure, the test coupons shall be ultrasonically tested for evidence of hydrogen-induced cracking and stepwise cracking before sectioning. Additional sections for microscopic examination shall be prepared through any suspect locations, agreed by Company.

d)

The acceptance criteria shall be all of the following: 1)

Less than 5,0% CLR (crack length ratio).

2)

Less than 1,5% CTR (crack thickness ratio).

3)

Less than 0,5% CSR (crack sensitivity ratio).

A NACE Standard Tensile Test shall be carried out to NACE TM0177 using Method A and Test Solution A if a SOHIC or SZC test is specified in addition to the HIC test. The material test samples which pass this test shall be evaluated for acceptance by one of two methods: a)

At least two metallographic sections shall be taken parallel to the sample axis. There shall be no ladder-like cracks > 0,5 mm in length in the through-thickness direction.

b)

The remaining tensile strength (after hydrogen degassing at 150°C (302°F)) shall be ≥ 80% of the original actual tensile strength of the material.

m.

Hardness of carbon steel HAZ for downstream applications, as measured in the weld procedure test, shall not exceed 248 Hv10 (Brinell 237 HBW) as given in NACE SP0472. Hardness values for other materials shall be as given in NACE MR0103. Hardness checks on the weld deposit of the completed vessel shall conform to NACE SP0472, which specifies a maximum hardness of Brinell 200 HBW in the weld metal.

n.

Hardness in the weldment on cracking resistant carbon and low alloy steels for upstream applications, measured in the weld procedure test, shall conform to ISO 15156-2, which specifies a maximum hardness of 250 Hv10 for the weld root area and a minimum temperature for PWHT of 620°C (1 150°F).

o.

After PWHT, weldments shall be subject to blasting of surface to SSPC SP 5/NACE No. 1 and tested by WFMT.

p.

Vessels clad with a corrosion resistant lining or fabricated from solid corrosion resistant alloys for Upstream environments shall conform to ISO 15156-3. The conditions of acceptability for each of the material classes given in Annex A in ISO 15156-3 shall be met. For Downstream environments, the material requirements given in NACE MR0103 shall be met.

Page 69 of 96



q.

Full penetration welds shall be provided on pressure boundary parts to internal attachments such as downcomer bolting bars and segments, bed support beam seats, or any load-carrying attachments that have the long axis parallel to the longitudinal axis of the vessel. This requirement for full penetration welds does not extend to tray support rings or other circumferentially oriented attachments.

Page 70 of 96



Annex B (Normative)

Supplementary requirements for chrome-moly vessels B.1

General a.

The plate edge preparation for welding shall be by flame cutting and grinding or by machining. Nozzle openings shall be made by machining.

b.

Material for starting and run-off plates for longitudinal automatic welding shall be of the same chemical composition as the base material.

c.

The hardness of weld crown and root surfaces, and HAZs shall not exceed: 1.

Cr-Mo steels

225 HBW (HRB 97,6)

2.

Cr-Mo-V steels (Vanadium modified)

235 HBW (HRB 99)

d.

A fabrication sequence with IPWHT, DHT, and final PWHT, including temperature and holding times shall be submitted with the proposal.

e.

NDE inspections shall be referenced on the fabrication sequence.

f.

Procedure qualification tests shall be made on plates or forgings of the same material specification, grade, class, and thickness as the vessel using filler metal, flux, and (or) inert gases of the same type, brand, nominal chemistry, and size to be used on the actual work.

g.

Two production test specimens shall be produced to test the weld metal and HAZs. One test specimen shall simulate the weldment between two shell courses, and one test specimen shall simulate the weldment between nozzle forging and shell.

h.

The qualification test coupons shall be in the same heat treated condition as the base material prior to welding. Test coupons shall undergo the heat treatments (IWHT or PWHT) anticipated for the completed vessel before testing. The 0,2 per cent proof strength shall be determined.

i.

The temperature and maximum amount of PWHT time is applicable to base material and welding procedure qualification testing.

j.

1.

The maximum amount of time available for IWHT and PWHT shall be established.

2.

Probable times for IWHT and final PWHT to fabricate the vessel shall be reported.

3.

These times shall be subject to agreement prior to the start of work.

Temporary shop attachments such as aids for handling and fitting shall be as follows: 1.

Attachments shall be preheated (as specified for the material) with the base metal local to the attachment.

2.

If temporary attachments are of a material different from the base metal, welds shall be alloyed to match the base metal, not the attachment. After welding, the material shall be allowed to air cool to ambient temperature.

3.

Attachment welds shall be cut above the weld during removal of the attachment.

4.

The remaining stub shall be ground flush with the base material surface.

5.

The surface shall be MT inspected to confirm that it is free from defects.

k.

Material for starting and run-off plates for longitudinal automatic welding shall be of the same chemical composition as the base material.

l.

One subsize production weld for chemistry and mechanical properties verification shall be made for each heat of electrode and flux combination. Page 71 of 96



B.2

B.3

B.4

B.5

Fabrication a.

A local DHT shall be performed for all butt-welds and corner joint welds (i.e., ASME weld category A, B, and C) that are 50 mm (2 in) and greater in thickness (See Annex E).

b.

An IPWHT shall be performed for all nozzle attachment welds (i.e., ASME weld category D) that are 50 mm (2 in) and greater in thickness (See Annex E).

Examination requirements a.

UT checks for laminations shall be made on all plate.

b.

Forgings shall be subject to a 100% UT scan.

c.

Plate edges after bevelling, but prior to welding root passes in shell, heads, and nozzles, weld build-ups on shell and heads, background surfaces, skirt to head or shell attachment welds, fillet welds, attachment welds and temporary welds after removal of attachments, shall be subject to MT.

d.

Welds, including external and internal non-pressure containing welds, shall be subject to 100% surface inspection (by MT or PT) after hydrotesting.

e.

Pressure containing welds and skirt attachment or support welds shall be subject to RT or UT after hydrotesting. Radiographs shall be taken within 48 hours after weld completion.

f.

Full penetration welds shall be subject to MT on the back-chipped surface and on finished weld surfaces prior to overlay.

1,25Cr-0,5Mo vessels (including Vanadium enhanced) a.

The measured tensile strength, as recorded on the material test certificate or report, shall be limited to 585 MPa (84,8 ksi) for plate and 655 MPa (95 ksi) for forgings.

b.

The requirements included and guidance given in API RP 934-C and API RP 934-E shall apply.

c.

Head or shell plate welds shall not be subjected to an austenitising heat treatment without specific agreement.

d.

Minimum preheat temperature throughout thickness shall be 150°C (300°F). The actual interpass temperature for WPS qualification tests shall be determined and defined on PQR documents. Welding preheats shall be maintained until IPWHT has been performed.

e.

Minimum PWHT temperatures shall be based on API RP 934-C or API RP 934-E as applicable. API RP 934-E applies for vessels with operating temperatures above 440°C (825°F).

2.25Cr-1Mo vessels (including Vanadium enhanced) a.

Vessel shall be made by the electric furnace or basic oxygen process.

b.

Guidance and requirements included in API RP 934-A shall apply.

c.

A minimum and maximum PWHT shall be established. Two sets of weld procedure specimens shall be heat treated, one for each time. The strength of the vessel shall be such that at least two PWHT cycles remain available for Company in service, except that if the closing seam of the vessel requires an additional PWHT, only at least one remaining PWHT cycle shall be available for Company.

d.

Materials for reactor vessels shall be vacuum degassed.

Page 72 of 96



e.

For plate and forgings: 1.

The measured tensile strength for conventional shall not exceed 690 MPa (100 ksi).

2.

Hot tensile tests at design temperature per API RP 934-A Paragraph 5.5.2.2 shall be required.

3.

Test specimens shall be taken from the transverse ¼ t locations.

f.

Plates shall be fine grain with a grain size of five (5) or higher in conformance to ASTM E112.

g.

Step cooling tests of all materials, plates, forgings, and weld metals, shall be performed in conformance to paragraph 6.2.3 of API RP 934-A. Acceptance criteria shall conform to API RP 934-A paragraph 6.2.3.3.

h.

Welding wire heats and electrode and flux lots shall be selected and tested to confirm that tensile, impact, and step cooling requirements specified in B.6.3 are met in both the PWHTmin and PWHTmax conditions.

i.

Preheat temperatures for welding, manual weld overlay and thermal cutting operations shall conform to API RP 934-A. The following minimum preheat temperatures shall be maintained during machining and welding. 1.

200°C (392°F) for all welding.

2.

120°C (250°F) for machining.

3.

150°C (300°F) for manual weld overlay.

4.

150°C (300°F) for thermal cutting operations.

j.

The actual maximum interpass temperature for WPS qualification tests shall be determined and defined on PQR documents, but shall not exceed 300°C (570°F).

k.

During fabrication, IPWHT shall be at temperatures lower than the final PWHT temperature. The latter shall not exceed the tempering temperature performed at the mill for any of the materials used.

Page 73 of 96



Annex C (Normative) Supplementary requirements for stainless steel vessels C.1

C.2

C.3

Fabrication a.

Forming rolls used to form any austenitic stainless or nonferrous materials shall covered to prevent carbon pickup or contamination of the formed material.

b.

Formed heads shall be solution annealed after forming.

c.

An allowance shall be made for the removal of not less than 3 mm (1/8 in) of metal by machining or grinding to the finished dimension for stainless steels cut by any thermal process, such as plasma arc or air arc.

d.

Grinding and cleaning of stainless steels shall be done with tools that do not leave detrimental deposits.

e.

Only stainless steel brushes and clean, iron-free sand, ceramic, or stainless steel grit shall be used for cleaning stainless steel and non-ferrous surfaces.

f.

Cleaning tools or materials shall not have been previously used on carbon steel.

Welding a.

The ferrite content of ASS weld metal, with the exception of type 904L (which is fully austenitic), shall be in the range 3% to 10% in the as-welded and post-weld heated condition.

b.

Ferrite checks shall be made on at least 5% of the welds, unless a higher percentage is specified on the data sheets.

c.

Comparable low carbon austenitic filler materials shall be used if welding low carbon grade austenitic base materials.

d.

Additional requirements for type 904L and 6Mo are as follows: 1.

The high nickel alloy welding consumables of Ni-Cr-Mo (alloy 624 or ERNiCrMo-3) filler metals shall be used for welding of 904L and 6Mo steels.

2.

Autogenous welding techniques shall not be used.

3.

Shielding gas shall conform to ASME B31.3 paragraph 328.3.4.

Examination requirements a.

Welds shall be free from cracks and fissures. The extent of PT on welds shall be as specified on the data sheets.

b.

The pressure test fluid for ASS vessels shall not contain more than 30 ppm chlorides. See clause 15.2h

c.

ASS vessels shall be dried within 48 hours of draining, using swabs or a flow of air at ambient temperature. Heat shall not be applied.

d.

Unless directed otherwise, ASS vessels that operate in the range of 50°C to 150°C (120°F to 300°F) shall be painted externally to the specification listed on the data sheets.

e.

Insulated ASS vessels operating below 50°C (120°F) shall be painted externally to the specification listed on the data sheets.

Page 74 of 96



C.4

f.

Equipment shall be protected such that chloride contamination cannot occur during shipment.

g.

For vessel constructed to BSI PD 5500: 1.

Inspection of forgings by PT shall be to EN 10228-2 and the required quality class shall be class 3 unless otherwise specified on the data sheets.

2.

Inspection of forgings by UT shall be to EN 10228-4 and the required quality class shall be class 3 unless otherwise specified on the data sheets.

Cleaning and surface preparation Water used during cleaning shall not contain more than 30 ppm chlorides.

Page 75 of 96



Annex D (Normative)

Supplementary requirements for clad plate or weld-overlay construction D.1

Design a.

Linings, made by strips fillet welded to the base material, shall not be used.

b.

Corrosion resistant alloy cladding or weld overlay shall not be considered in calculating required pressure boundary thickness.

c.

All cladding materials, other than titanium, for nozzles shall be made either by weld overlay or from roll clad plate as shown in Figure D.1.

d.

Solid alloy nozzles DN 100 (NPS 4) and less may be used instead of clad nozzles provided: 1.

The design temperature is less than 300°C (570°F).

2.

The vessel is not in any of the special services listed in Annex A of this Specification.

3.

An analysis of the thermal and mechanical stresses at the interface is performed.

e.

Raised faced clad flanges shall be fabricated as shown in Figure D.4.

f.

Ring type joint clad flanges: 1.

Shall be fabricated as shown in Figure D.5.

2.

A minimum of 3 mm (1/8 in) of cladding material shall remain under the ring groove.

3.

Flange thickness, Tf, shall conform to ASME B16.5 and ASME B16.47 and shall not be reduced. Figure D.1 - Typical clad nozzle attachment to shell

Figure D.2 - Attachment of lightly loaded attachment to a clad vessel

Page 76 of 96



Figure D.3 - Attachment of a moderately loaded attachment to a clad vessel

Figure D.4 - Method for cladding a raised face flange

Figure D.5 - Method for cladding a ring type joint flange

3 mm (1/8 in)

STANDARD RING TYPE GROOVE

Tf 3 mm (1/8 in) MINIMUM CLADDING THICKNESS

Page 77 of 96



D.2

D.3

Clad plate material a.

Clad plate shall conform to GIS 18-013.

b.

Integrally clad plate shall be ordered per ASME SA-263, SA-264, or SA-265 with Quality Level 1 with supplementary requirement S12.

c.

Integrally clad plate shall be ordered with examination in conformance to ASME SA-578/SA-578M with Acceptance Level B and supplementary requirements S1, S3, and S4.

d.

Integrally clad plate shall be ordered with shear strength tests performed in conformance to the applicable material specification.

e.

The heat treatment of integrally clad plate in conformance to ASME SA-263, ASME SA-264, and ASME SA-265 shall be performed by the plate manufacturer.

f.

Integrally clad plate, including explosion clad plate, in conformance to ASME SA-263, ASME SA-264, and ASME SA-265 shall be cold flattened, if required, after final heat treatment and descaling.

g.

Following forming and any associated heat treatment, the knuckle region of heads pressed or spun from clad plate shall be subject to UT and PT, and weld overlay seams shall be inspected by UT for lack of bond at the weld to clad interface along the entire seam length.

h.

Clad plate on PWHT vessels shall have indications that show a 50% or greater loss of back reflection marked and recorded prior to heat treatment.

i.

Subsequent to PWHT, integrally clad material shall be re-examined ultrasonically in locations of previously recorded discontinuities and other indications that resulted in 50% or greater loss of back reflection.

Cladding re-instatement a.

The typical detail applied in cladding re-instatement local to a seam is shown in Figure D.6.

b.

Chipped, gouged, or ground surface shall be cleaned of all residual alloy material.

c.

The removed of the residual alloy material shall be verified with a CuSO4 etch.

d.

Depth of base material removed during clad removal shall not exceed 0,8 mm (1/32 in).

e.

If chip back or gouge is done from inside, as shown in Figure D.6b, 5 mm (3/16 in) minimum shall be left between edge of chipped or gouged surface and cladding.

f.

Final base material weld deposit from inside shall not contact cladding and shall be ground flush before depositing alloy weld material.

g.

Weld seams that require volumetric examination shall be tested before cladding re-instatement.

h.

Each main seam of 11-13% chrome (405, 410S) clad vessels shall be spot radiographed before and after cladding re-instatement.

i.

The weld overlay requirements of Clause D.4 shall also apply to cladding re-instatement welding.

Page 78 of 96



Figure D.6 - Cladding re-instatement at a vessel seam

0.8mm MAX. (1/32 in)

12mm MIN. (1/2 in)

0.8mm MAX. (1/32 in) CHIPPED OR GOUGED SURFACE

(a) MACHINING

5mm MIN. (3/16 in) AFTER GOUGING

(b) ROOT PASS

CHIPPED OR GOUGED SURFACE

COMPLETED WELD IN BASE MATERIAL. GRIND FLUSH BEFORE DEPOSITING ALLOY

12mm MIN. (1/2 in)

(c) MAIN FILL & BACK GOUGE

D.4

2 ND PASS ELECTRODE

1 ST PASS ELECTRODE

(d) BACK FILL & CLADDING

Weld overlay a.

Weld overlay shall conform to GIS 18-013.

b.

Weld overlay shall provide a minimum, guaranteed undiluted chemistry to a depth of 3 mm (1/8 in) from the surface unless otherwise specified on the data sheets.

c.

The weld overlay shall be applied in such a manner that the weld beads run circumferentially around the vessel. 1.

The surface contour shall be relatively smooth. Adjacent weld beads shall fuse and blend to create a flat surface without any interbead grooving.

2.

Waviness is permissible but without notches and undercuts that might act as stress raisers.

3.

The beads may run longitudinally for nozzles with an inside diameter of 300 mm (12 in) and smaller and for pipe elbows if followed by blend grinding.

d.

With ASS, the chemical composition of the final surface on both weld overlay and cladding re-instatement shall conform to the corresponding AWS welding consumable classification.

e.

Welding consumables used for ASS weld overlays that are subject to PWHT shall be “L” grade, or stabilised with additions of Ti or Nb (Cb) to minimise sigma phase formation during the heat treatment.

f.

The ferrite content of ASS overlays, with the exception of type 904L (which is fully austenitic), shall be in the range 3 - 10% in the as-welded and post-weld heated condition, see data sheets. Welding consumables for 904L clad restoration shall be Ni-Cr-Mo type such as ERNiCrMo3

g.

Vessels with Alloy 400 weld overlay designated for HF acid service shall have the following: Page 79 of 96



D.5

1.

Overlay shall contain a maximum of 5% iron (Fe) in the top 1,6 mm (1/16 in) of the final deposit.

2.

Overlays, deposited by manual processes, shall have a minimum of three layers.

3.

ERNi-1 filler metal shall be used for the first pass if welding with the GTAW or GMAW process.

h.

The maximum diameter of SMAW electrodes shall be 3 mm (1/8 in).

i.

Carbon content of low-carbon (L, LC, or ELC) grades of ASS, shall not exceed 0,03 %.

j.

The columbium to carbon ratio of the deposited metal for columbium (niobium) bearing grades of ASS (e.g., 347 and 309 Cb) shall not exceed 16:1.

k.

If a single layer overlay is offered, metallurgical and analytical evidence shall be produced to demonstrate its acceptability.

l.

The welding process shall not transfer alloying elements via the flux to achieve the specified weld metal composition.

m.

Flux shall not be re-used.

n.

Each batch of welding consumables, including each batch of submerged arc or electroslag flux, for ASS overlays shall be tested in conformance to the agreed weld overlay procedure to ensure that the resultant overlay conforms to the specified microstructure and chemical analysis.

Welding procedures a.

Welding procedures shall be qualified in conformance to the design code.

b.

Qualified welding procedures for weld overlay and cladding re-instatement shall be submitted for agreement.

c.

The base material for the test pieces of the welding procedure shall be of the same material specification and grade as the vessel. 1.

The same heat treatment batch of welding wire or electrode as that to be used in production welding shall be used and the same type and brand of flux.

2.

The temperature range used on the overlay qualification test plates for PWHT shall be the same as that used in production.

3.

The PWHT time at temperature for the qualification test plates shall be greater than that used in production in order to leave at least one heat treatment available for Company.

d.

The test welds shall be subject to chemical analysis throughout its depth to confirm that the required purity of Clause D.7.3 has been achieved.

e.

The test welds shall be subject to 100% UT per Clause D.7.1

f.

The test welds shall be subject to 100% PT per Clause D.7.2.

g.

The achievement of the required weld overlay thickness shall be demonstrated.

h.

A macro section of the overlay shall be prepared and a series of Hv10 measurements shall be made across the interface at three separate locations.

i.

The measurement of ferrite content shall be by metallographic determination and an instrumental technique.

j.

The chemical analysis results shall be used to calculate the ferrite content per the Schaeffler-DeLong diagram.

Page 80 of 96



k.

D.6

The ferrite content of ASS weld metal, with the exception of type 904L (which is fully austenitic), shall be in the range 3% to 10% in the as-welded and post-weld heated condition.

Internal attachments a.

If the design temperature is greater than 300°C (570°F), full penetration welds shall be used for internal attachments.

b.

Internal attachments shall be classified as follows:

c.

1.

Lightly loaded supports: Average shear stress across the section does not exceed 25 MPa (3 625 psi).

2.

Moderately loaded supports: Average shear stress across the section lies between 25 MPa (3 625 psi) and 50 MPa (7 250 psi).

3.

Heavily loaded supports: Average shear stress across the section exceeds 50 MPa (7,25 ksi).

On vessels made from clad plate, lightly and moderately loaded supports (e.g., tray support rings) may be welded directly to the cladding without stripping back to the base material providing the following two conditions are satisfied: 1.

The weld is essentially unidirectional (such as at a tray support ring) and not multi-directional (such as at a bracket).

2.

The area is checked with UT for lack of bond prior to welding.

d.

On vessels with weld overlay, lightly loaded supports (such as tray support rings) may be welded to the overlay without stripping back to the base material.

e.

Heavily loaded supports shall be integral with the shell if thermal stress is present.

D.7

Examination of weld overlay and clad re-instatement

D.7.1

UT examination a.

b.

Weld deposited overlay shall be subject to UT in conformance to ASTM A578 primarily to establish the presence of any lack of fusion between the weld deposit and the base material. 1.

10% of the overlay deposited during each shift shall be examined.

2.

Any area of lack of fusion or other defect that cannot be contained within a 25 mm (1 in) diameter circle shall be cause for rejection and 100% of the overlay completed during the shift by the equipment or operator concerned shall be examined.

3.

Defects shall be repaired by an agreed procedure and re-examined.

After DHT or IPWHT (if performed), the stainless steel overlay shall be spot checked for bond consistency by UT on strips 75 mm (3 in) wide over the vessel length at four equally-spaced positions around the circumference. 1.

Any lack of fusion causing a loss of back reflection accompanied by an echo indication from the plane of the interface of the overlay and base metal and having an area greater than that of a 25 mm (1 in) diameter circle shall be repaired. This area may be of any shape.

2.

If any repair is needed, 100% of the surface shall be checked as above.

Page 81 of 96



D.7.2

D.7.3

PT examination a.

10% of the first layer of weld deposit overlay or clad re-instatement, plus as many “T” joints as can be examined, shall receive PT surface examination.

b.

If specified on the data sheets, the surface of weld overlay shall be subject to 100% PT in conformance to ASTM E165 following any PWHT, but prior to pressure testing.

Chemical analysis a.

The surface of weld overlay shall be subject to chemical analysis.

b.

A minimum of two checks shall be made in each shell course and each head with a minimum of one check for each 5 m (16 ft) length of butt-weld joint.

c.

A minimum of one check shall also be made at each nozzle attachment weld.

d.

The test locations shall be selected by Company.

e.

Secondary standard FN blocks shall be available to confirm the calibration of the instrument.

f.

The ferrite content of the final layer of 300 series austenitic stainless steel weld overlay deposits shall be between 3 to 10FN, except for the stabilised austenitic stainless steel types 321 and 347.

g.

Stabilised 300 series austenitic stainless steel types 321 and 347 shall have a ferrite content between 5 to 8FN in the final layer.

h.

The WRC-1992 constitution diagram shall be used to predict the ferrite number.

i.

Ferrite analysis shall be done with an instrument calibrated in conformance to AWS A4.2 or ISO 8249.

j.

Ferrite measurements shall be made adjacent to analytical checks on the as-deposited weld metal and these measurements repeated following any PWHT.

Page 82 of 96



Annex E (Normative)

Supplementary requirements for DHT and IPWHT E.1

E.2

Dehydrogenation heat treatment a.

Prior to commencing DHT, the weld joint shall not be allowed to cool below the minimum preheat temperature applicable to the weld joint. The minimum preheat temperature for P4 materials shall be 150°C (300°F) minimum. Preheat temperature for P5A and P5C materials shall be 200°C (392°F) minimum.

b.

Heating for DHT shall be provided using gas ring burners or by electrical heating elements. Ring burners shall be constructed to provide uniform heat distribution to the entire weld joint. The weld joint and a minimum of 25,4 mm (1 in) each side of the weld joint shall be heated to achieve an even temperature distribution through the full wall thickness of the weld joint.

c.

DHT temperature shall be checked using temperature-indicating crayons, contact thermometers, calibrated thermocouples, digital pyrometers, or laser heat measuring instrument. If accessible, temperature shall be measured at the side opposite from which the heat source is applied to ensure through wall thickness heating.

d.

The weld joint shall be heated and held at a DHT holding temperature of 350°C to 370°C (662°F to 700°F). Hold time at temperature shall not be less than 2 hours.

e.

After the hold time is completed, the weld joint shall be wrapped in dry thermal insulation blankets and allowed to slow cool to ambient temperature.

f.

Non-destructive testing PT or MT shall be performed 48 hours after the weld joint has cooled to ambient temperature.

g.

A written report shall be prepared traceable to each weld joint receiving DHT.

Intermediate post weld heat treatment a.

IPWHT shall be carried out in a furnace and immediately after the weld joint has been completely welded.

b.

Prior to carrying out IPWHT the weld joint shall not be allowed to cool below the minimum preheat temperature applicable to the weld joint.

c.

The preheat temperature for the following materials shall be: 1.

For P4 materials, 150°C (300°F) minimum.

2.

For P5A and P5C materials, 200°C (392°F) minimum.

d.

Preheat temperatures shall be maintained during handling and moving weld joint to the furnace.

e.

The furnace shall be prepared for IPWHT and heated to not less than the minimum preheat temperature specified in the weld procedure specification applicable for the weld joint.

f.

Furnace heating the weld joint above the minimum preheat temperature and the cooling the weld joint after the IPWHT cycle shall conform to the applicable ASME Boiler and Pressure Vessel Code.

g.

The weld joint shall be heated and held at a temperature indicated below. 1.

For P1 materials the ISR temperature shall be between 540°C and 593°C (1 000°F and 1 100°F).

Page 83 of 96



2.

For P5A and P5C materials the ISR temperature shall be between 650°C and 680°C (1 202°F and 1 256°F).

h.

Hold time at IPWHT temperature shall not be less than 2 hours.

i.

Cooling the weld joint from the IPWHT holding temperature shall be done in a closed furnace. Below 315°C (600°F) the weld joint shall be allowed to cool to ambient temperature inside the furnace with the furnace doors opened.

j.

IPWHT heat treatment shall be recorded and charted in a furnace heat treatment chart.

Page 84 of 96



Annex F (Normative)

Allowable piping loads on nozzles a.

This annex defines maximum permissible nozzle loads applied by piping to offshore and onshore pressure vessels which shall be designed to withstand these loads.

b.

Should there be a requirement for increased forces or moments due to field piping restrictions in one or more directions during detailed engineering, Supplier shall evaluate these loads and advise impact on design of pressure vessel.

c.

Nozzle reinforcement as determined by nozzle reinforcement calculations shall be used when evaluating stresses using values listed in Table F.3.

d.

If, following evaluation, the vessel shell or head is overstressed, Supplier shall not increase reinforcement on nozzle but shall submit the calculations for review by Company responsible engineer.

e.

The tabulated forces and moments are applicable for vessels fabricated in carbon steel, austenitic stainless steel and duplex stainless steel materials. The tabulated values shall be reduced to 70% for titanium and 50% for copper-nickel piping systems.

f.

The piping loads tabulated in Table F.3 shall apply at maximum design conditions.

g.

The following provides the basis for tabulated values in Table F.3 and calculation method for pipe sizes not listed in Table F.3: FS

Force allowable stress

MPa (psi)

MS Moment allowable stress

MPa (psi)

Am Metal area

mm2 (ft2)

Z

Section modulus

mm3 (ft3)

P

Axial force

N (lbf)

VL Longitudinal force (for shell nozzles)

N (lbf)

VC Circumferential force (for shell nozzles)

N (lbf)

FR

N (lbf)

Resultant force (for head nozzles)

MT Torsional moment

Nm (ft lbf)

ML Longitudinal moment (for shell nozzles)

Nm (ft lbf)

MC Circumferential moment (for shell nozzles)

Nm (ft lbf)

MR Resultant moment (for head nozzles)

Nm (ft lbf)

P is the nozzle centreline and VL and VC are mutually perpendicular to P. Values of FS and MS for each pipe size are given in Table F.2 below:

Page 85 of 96



Table F.1 - Pipe size forces Pipe size DN (NPS)

FS MPa (psi)

MS MPa (psi)

≤ 150 (6)

2,1 (304,6)

41,4 (6 004,6)

200 (8)

2,1 (304,6)

39,1 (5 671)

250 (10)

2,1 (304,6)

36,8 (5 337,4)

300 (12)

2,1 (304,6)

34,5 (5 003,8)

350 (14)

2,1 (304,6)

32,2 (4 670,2)

400 (16)

2,1 (304,6)

29,5 (4 278,6)

450 (18)

2,1 (304,6)

27,6 (4 003,1)

500 (20)

1,87 (271,3)

25,3 (3 669,5)

≥ 600 (24)

1,4 (203,1)

20,7 (3 002,3)

Allowable resultant force

FR = FS x Am

Allowable axial force

P = 0,5 x FR

Allowable longitudinal and circumferential force

VL or VC = 0,6124 x FR

Allowable resultant moment (SI Units)

MR = Ms x Z x 10-3

Allowable resultant moment (U.S. Customary Units)

MR = Ms x Z

Allowable torsional moment

MT = 0,7071 x MR

Allowable longitudinal and circumferential moment

ML or MC = 0,5 x MR

h.

All tabulated force and moment components may be +ve or –ve.

i.

Flange ratings are in conformance to ASME B16.5 and ASME B16.47.

j.

Allowable loads as given are valid for materials up to 200C (392F). Above 200C (392F), a de-rating factor shall be applied as shown in Table F.2: Table F.2 - De-rating factor Temperature °C (°F)

De-rating factor

200 (392)

1,00

250 (482)

0,92

300 (572)

0,83

350 (662)

0,75

400 (752)

0,67

450 (842)

0,58

500 (932)

0,50

Note: 1. Interpolation between given values shall be permitted

Page 86 of 96



Table F.3 - Allowable piping loads on nozzles Pipe size DN (NPS)

ASME Class

P (N) (lbf)

VL, VC (N) (lbf)

FR (N) (lbf)

MT (Nm) (ft lbf)

ML, MC (Nm) (ft lbf)

MR (Nm) (ft lbf)

40 (1 1/2)

150

725 (163)

885 (199)

1 450 (326)

200 (147,6)

140 (103,3)

280 (206,6)

300

970 (218,1)

1 185 (266,4)

1 935 (435,1)

245 (180,8)

170 (125,4)

345 (254,5)

600

970 (218,1)

1 185 (266,4)

1 935 (435,1)

245 (180,8)

170 (125,4)

345 (254,5)

900

970 (218,1)

1 185 (266,4)

1 935 (435,1)

245 (180,8)

170 (125,4)

345 (254,5)

1 500

1 280 (287,8)

1 565 (351,9)

2 545 (572,2)

290 (213,9)

200 (147,6)

405 (298,8)

2 500

1 280 (287,8)

1 565 (351,9)

2 545 (572,2)

290 (213,9)

200 (147,6)

405 (298,8)

150

1 000 (224,9)

1 225 (275,4)

2 000 (449,7)

350 (258,2)

250 (184,4)

495 (365,1)

300

1 000 (224,9)

1 225 (275,4)

2 000 (449,7)

350 (258,2)

250 (184,4)

495 (365,1)

600

1 485 (333,9)

1 820 (409,2)

2 975 (668,9)

470 (346,7)

335 (247,1)

665 (490,5)

900

1 485 (333,9)

1 820 (409,2)

2 975 (668,9)

470 (346,7)

335 (247,1)

665 (490,5)

1 500

1 800 (404,7)

2 205 (495,8)

3 600 (809,4)

530 (391)

375 (276,6)

750 (553,2)

2 500

1 800 (404,7)

2 205 (495,8)

3 600 (809,4)

530 (391)

375 (276,6)

750 (553,2)

150

1 510 (339,5)

1 850 (415,9)

3 020 (679)

825 (608,5)

585 (431,5)

1 170 (863)

300

1 510 (339,5)

1 850 (415,9)

3 020 (679)

825 (608,5)

585 (431,5)

1 170 (863)

600

2 045 (459,8)

2 500 (562,1)

4 085 (918,4)

1 070 (789,3)

755 (556,9)

1510 (1 113,8)

900

2 855 (641,9)

3 500 (786,9)

5 710 (1 283,7)

1 380 (1 017,9)

975 (719,2)

1 955 (1 442,0)

1 500

3 705 (833)

4 535 (1 019,6)

7 405 (1 664,8)

1 645 (1 213,4)

1 160 (855,6)

2 325 (1 714,9)

2 500

3 705 (833)

4 535 (1 019,6)

7 405 (1 664,8)

1 645 (1 213,4)

1 160 (855,6)

2 325 (1 714,9)

50 (2)

80 (3)

Page 87 of 96



Pipe size DN (NPS)

ASME Class

P (N) (lbf)

VL, VC (N) (lbf)

FR (N) (lbf)

MT (Nm) (ft lbf)


MR (Nm) (ft lbf)

100 (4)

150

2 150 (483,4)

2 635 (592,4)

4 300 (966,7)

1 540 (1 135,9)

1 090 (804)

2 180 (1 608,0)

300

2 150 (483,4)

2 635 (592,4)

4 300 (966,7)

1 540 (1 135,9)

1 090 (804)

2 180 (1 608,0)

600

2 985 (671,1)

3 655 (821,7)

5 940 (1 335,4)

2 050 (1 512,1)

1 450 (1 069,5)

2 900 (2 139,0)

900

3 785 (851)

4 640 (1 043,2)

7 575 (1 703,0)

2 485 (1 832,9)

1 760 (1 298,2)

3 515 (2 592,6)

1 500

5 450 (1 225,3)

6 720 (1 510,8)

10 975 (2 467,3)

3 260 (2 404,5)

2 305 (1 700,2)

4 610 (3 400,3)

2 500

5 450 (1 225,3)

6 720 (1 510,8)

10 975 (2 467,3)

3 260 (2 404,5)

2 305 (1 700,2)

4 610 (3 400,3)

150

3 780 (849,8)

4 630 (1 040,9)

7 560 (1 699,6)

4 075 (3 005,7)

2 880 (2 124,3)

5 765 (4 252,2)

300

4 600 (1 034,2)

5 630 (1 265,7)

9 200 (2 068,3)

4 860 (3 584,6)

3 440 (2 537,3)

6 880 (5 074,5)

600

5 695 (1 280,3)

6 975 (1 568,1)

11 390 (2 560,6)

5 865 (4 325,9)

4 145 (3 057,3)

8 295 (6 118,2)

900

7 250 (1 629,9)

8 880 (1 996,4)

14 505 (3 260,9)

7 185 (5 299,5)

5 080 (3 746,9)

10 160 (7 493,8)

1 500

10 595 (2 381,9)

12 975 (2 917,0)

21 185 (4 762,7)

9 605 (7 084,4)

6 795 (5 011,9)

13 585 (10 020,0)

2 500

10 740 (2 414,5)

13 150 (2 956,3)

21 475 (4 827,8)

9 700 (7 154,5)

6 860 (5 059,8)

13 720 (10 119,5)

150

5 690 (1 279,2)

6 970 (1 567,0)

11 380 (2 558,4)

7 615 (5 616,7)

5 385 (3 971,9)

10 770 (7 943,7)

300

6 060 (1 362,4)

7 425 (1 669,3)

12 125 (2 725,9)

8 075 (5 955,9)

5 710 (4 211,6)

11 420 (8 423,1)

600

7 100 (1 596,2)

8 700 (1 955,9)

14 205 (3 193,5)

9 325 (6 877,9)

6 595 (4 864,3)

13 190 (9 728,6)

900

12 100 (2 720,3)

14 820 (3 331,7)

24 200 (5 440,5)

14 785 (10 905,1)

10 455 (7 711,4)

20 910 (15 422,7)

1 500

16 005 (3 598,1)

19 600 (4 406,3)

32 005 (7 195,1)

18 415 (13 582,4)

13 020 (9 603,2)

26 045 (19 210,1)

2 500

17 865 (4 016,3)

21 880 (4 918,9)

35 725 (8 031,4)

19 950 (14 714,6)

14 110 (10 407,2)

28 215 (20 810,6)

150 (6)

200 (8)

Page 88 of 96



Pipe size DN (NPS)

ASME Class

P (N) (lbf)

VL, VC (N) (lbf)

FR (N) (lbf)

MT (Nm) (ft lbf)


MR (Nm) (ft lbf)

250 (10)

150

8 070 (1 814,3)

9 880 ( 2 221,2)

16 135 (3 627,4)

12 755 (9 407,8)

9 020 (6 652,9)

18 040 (13 305,8)

300

10 910 (2 452,7)

13 360 (3 003,5)

21 820 (4 905,4)

16 820 (12 406,0)

11 895 (8 773,5)

23 780 (17 539,5)

600

12 840 (2 886,6)

15 730 (3 536,3)

25 680 (5 773,2)

19 460 (14 353,2)

13 760 (10 149,0)

27 520 (20 298,0)

900

17 795 (4 000,5)

21 795 (4 899,8)

35 595 (8 002,2)

25 755 (18 996,2)

18 210 (13 431,2)

36 425 (26 866,1)

1 500

22 920 (5 152,7)

28 075 (6 311,6)

45 845 (10 306,5)

31 555 (23 274,1)

22 315 (16 459,0)

44 630 (32 917,9)

2 500

27 150 (6 103,6)

33 250 (7 475,0)

54 300 (12 207,2)

35 800 (26 405,1)

25 315 (18 671,7)

50 625 (37 339,6)

150

9 880 (2 221,2)

12 100 (2 720,3)

19 755 (4 441,2)

17 520 (12 922,3)

12 390 (9 138,6)

24 780 (18 277,1)

300

10 665 (2 397,6)

13 065 (2 937,2)

21 335 (4 796,4)

18 830 (13 888,5)

13 315 (9 820,8)

26 630 (19 641,6)

600

17 665 (3 971,3)

21 635 (4 863,8)

35 330 (7 942,6)

29 840 (22 009,2)

21 100 (15 562,8)

42 200 (31 125,6)

900

25 010 (5 622,5)

30 630 (6 886,0)

50 020 (11 245,0)

40 250 (29 687,3)

28 460 (20 991,3)

56 925 (41 986,3)

1 500

32 930 (7 403,0)

40 330 (9 066,6)

65 860 (14 806,0)

50 160 (36 996,7)

35 470 (26 161,7)

70 940 (52 323,4)

2 500

37 630 (8 459,7)

46 085 (10 360,4)

75 255 (16 918,1)

55 395 (40 857,8)

39 170 (28 890,7)

78 340 (57 781,4)

150

10 875 (2 444,9)

13 320 (2 994,5)

21 795 (4 899,8)

19 870 (14 655,6)

14 050 (10 362,9)

28 100 (20 725,8)

300

12 640 (2 841,6)

15 485 (3 481,2)

25 285 (5 684,4)

22 895 (16 886,8)

16 200 (11 948,7)

32 375 (23 878,9)

600

21 150 (4 754,8)

25 905 (5 823,8)

42 300 (9 509,5)

36 635 (27 021,0)

25 905 (19 106,9)

51 810 (38 213,7)

900

30 050 (6 755,6)

36 805 (8 274,2)

60 095 (13 510,0)

49 580 (36 568,9)

35 060 (25 859,3)

70 115 (51 714,9)

1 500

41 830 (9 403,9)

51 235 (11 518,2)

83 665 (18 808,8)

64 465 (47 547,6)

45 585 (33 622,3)

91 170 (67 244,5)

2 500

61 185 (13 755,1)

74 940 (16 847,3)

122 370 (27 510,1)

83 345 (61 473,0)

58 935 (43 468,9)

117 870 (86 937,7)

300 (12)

350 (14)

Page 89 of 96



Pipe size DN (NPS)

ASME Class

P (N) (lbf)

VL, VC (N) (lbf)

FR (N) (lbf)

MT (Nm) (ft lbf)


MR (Nm) (ft lbf)

400 (16)

150

12 470 (2 803,4)

15 275 (3 434,0)

24 940 (5 606,8)

24 340 (17 952,6)

17 215 (12 697,4)

34 425 (25 391,0)

300

16 495 (3 708,3)

20 200 (4 541,2)

32 985 (7 415,4)

31 700 (23 381,1)

22 415 (16 532,7)

44 830 (33 065,4)

600

27 225 (6 120,5)

33 345 (7 496,3)

54 445 (12 239,8)

50 125 (36 970,8)

35 445 (26 143,3)

70 890 (52 286,5)

900

38 345 (8 620,4)

46 965 (10 558,3)

76 690 (17 240,7)

67 405 (49 716,1)

47 660 (35 152,7)

95 325 (70 309,1)

1 500

52 085 (11 709,3)

63 795 (14 341,8)

104 170 (23 418,5)

86 180 (63 564,0)

60 940 (44 947,7)

121 880 (89 895,3)

2 500

74 145 (16 668,6)

90 815 (20 416,2)

148 290 (33 337,1)

110 400 (81 428,0)

78 065 (57 578,6)

156 130 (115 157,2)

150

14 065 (3 162,0)

17 230 (3 873,5)

28 130 (6 324,0)

28 665 (21 142,5)

20 270 (14 950,6)

40 535 (29 897,5)

300

20 855 (4 688,5)

25 545 (5 742,8)

41 715 (9 378,0)

41 630 (30 705,2)

29 435 (21 710,5)

58 870 (43 420,9)

600

34 060 (7 657,1)

41 715 (9 378,0)

68 120 (15 314,1)

65 210 (48 097,1)

46 110 (34 009,5)

92 220 (68 018,9)

900

48 650 (10 937,1)

59 585 (13 395,4)

97 295 (21 872,9)

88 770 (65 474,3)

62 770 (46 297,4)

125 540 (92 594,8)

1 500

65 855 (14 804,9)

80 660 (18 133,2)

131 710 (29 609,8)

113 180 (83 478,4)

80 030 (59 027,9)

160 065 (118 059,5)

2 500

93 195 (20 951,2)

114 140 (25 659,9)

186 385 (41 901,3)

144 465 (106 553,4)

102 155 (75 346,7)

204 310 (150 693,4)

150

15 050 (3 383,4)

18 435 (4 144,4)

30 105 (6 768,0)

35 175 (25 944,1)

24 875 (18 347,2)

49 745 (36 690,6)

300

21 810 (4 903,2)

26 715 (6 005,9)

43 620 (9 806,3)

50 020 (36 893,4)

35 370 (26 088,0)

70 745 (52 179,6)

600

37 005 (8 319,1)

45 320 (10 188,4)

74 005 (16 637,1)

81 250 (59 927,8)

57 455 (42 377,2)

114 910 (84 754,4)

900

52 505 (11 803,7)

64 305 (14 456,5)

105 010 (23 607,4)

110 055 (81 173,5)

77 820 (57 397,9)

155 645 (114 799,4)

1 500

67 175 (15 101,7)

82 275 (18 496,3)

134 345 (30 202,2)

134 465 (99 177,7)

95 085 (70 132,1)

190 165 (140 260,4)

2 500

99 125 (22 284,3)

121 405 (27 293,1)

198 250 (44 568,6)

178 055 (131 328,4)

125 905 (92 864,0)

251 810 (185 728,0)

450 (18)

500 (20)

Page 90 of 96



Pipe size DN (NPS)

ASME Class

P (N) (lbf)

VL, VC (N) (lbf)

FR (N) (lbf)

MT (Nm) (ft lbf)


MR (Nm) (ft lbf)

550 (22)

150

15 630 (3 513,8)

19 140 (4 302,9)

31 260 (7 027,6)

41 790 (30 823,2)

29 ,550 (21 795,3)

59 105 (43 594,2)

300

22 110 (4 970,6)

27 080 (6 087,9)

44 215 (9 940,0)

58 120 (42 867,7)

41 100 (30 314,3)

82 200 (60 628,5)

600

38 865 (8 737,3)

47 600 (10 701,0)

77 730 (17 474,5)

97 650 (72 023,9)

69 ,050 (50 929,4)

138 100 (101 858,7)

900

54 795 (12 318,5)

67 110 (15 087,1)

109 585 (24 635,9)

131 ,605 (97 068,2)

93 ,060 (68 638,5)

186 120 (137 276,9)

1 500

74 895 (16 837,2)

91 840 (20 646,6)

149 970 (33 714,8)

169 ,585 (125 081,2)

119 915 (88 446,0)

239 830 (176 891,9)

2 500

107 155 (24 089,6)

131 245 (29 505,2)

214 310 (48 179,1)

218 390 (161 078,4)

154 425 (113 899,6)

308 855 (227 802,8)

150

16 670 (3 747,6)

20 420 (4 590,7)

33 340 (7 495,2)

50 955 (37 583,0)

36 030 (26 574,8)

72 065 (53 153,2)

300

22 755 (5 115,6)

27 870 (6 265,5)

45 510 (10 231,2)

68 475 (50 505,3)

48 420 (35 713,3)

96 840 (71 426,5)

600

39 400 (8 857,6)

48 255 (10 848,3)

78 800 (17 715,1)

113 445 (83 673,9)

80 220 (59 168,1)

160 440 (118 336,1)

900

57 040 (12 823,2)

69 865 (15 706,4)

114 085 (25 647,5)

156 400 (115 356,3)

110 590 (81 568,1)

221 180 (163 136,2)

1 500

76 260 (17 144,1)

92 405 (20 773,6)

152 520 (34 288,1)

197 660 (145 788,5)

139 770 (103 090,5)

279 535 (206 177,2)

2 500

108 905 (24 483,0)

133 390 (29 987,5)

217 810 (48 965,9)

254 550 (187 749,0)

179 995 (132 759,3)

359 990 (265 518,6)

150

18 091 (4 067,1)

22 158 (4 981,4)

36 183 (8 134,4)

60 101 (44 328,9)

42 498 (31 345,4)

84 996 (62 690,7)

300

25 432 (5 717,4)

31 149 (7 002,7)

50 864 (11 434,8)

83 141 (61 322,5)

58 790 (43 361,9)

117 581 (86 724,5)

600

44 227 (9 942,7)

54 169 (12 177,8)

88 454 (19 885,4)

138 603 (102 229,7)

98 808 (72 878,1)

196 016 (144 575,9)

900

62 160 (13 974,2)

76 133 (17 115,5)

124 320 (27 948,4)

186 779 (137 763,0)

132 074 (97 414,1)

264 148 (194 828,2)

1 500

95 439 (21 455,7)

116 894 (26 279,0)

190 879 (42 911,6)

263 915 (194 656,3)

186 618 (137 644,2)

373 236 (275 288,4)

2 500

143 549 (32 271,3)

175 818 (39 525,7)

287 098 (64 542,6)

347 240 (256 114,5)

245 538 (181 102,0)

491 077 (362 204,7)

600 (24)

660 (26)

Page 91 of 96



Pipe size DN (NPS)

ASME Class

P (N) (lbf)

VL, VC (N) (lbf)

FR (N) (lbf)

MT (Nm) (ft lbf)


MR (Nm) (ft lbf)

750 (30)

150

20 929 (4 705,1)

25 634 (5 762,8)

41 859 (9 410,4)

80 637 (59 475,6)

57 020 (42 056,4)

114 040 (84 112,8)

300

32 639 (7 337,6)

39 976 (8 987,1)

65 278 (14 675,2)

123 367 (90 992,1)

87 234 (64 341,4)

174 469 (128 683,5)

600

57 483 (12 922,8)

70 405 (15 827,8)

114 967 (25 845,8)

208 363 (153 682,7)

147 336 (108 670,9)

294 673 (217 342,6)

900

82 646 (18 579,7)

101 225 (22 756,4)

165 293 (37 159,6)

286 600 (211 388,2)

202 659 (149 475,6)

405 318 (298 951,2)

1 500

126 564 (28 452,9)

155 016 (34 849,2)

253 128 (56 905,8)

404 222 (298 142,8)

285 830 (210 820,2)

571 661 (421 641,1)

2 500

190 461 (42 817,6)

233 277 (52 443,1)

380 922 (85 635,1)

532 377 (392 666,4)

376 451 (277 659,7)

752 902 (555 319,4)

Page 92 of 96



Annex G (Normative)

Ladders and platforms G.1.

G.2.

G.3

General a.

This annex applies to the design of ladders and platforms supported off pressure vessels.

b.

Refer to structural steel materials, design and fabrication requirements included in Purchase Order.

Layout a.

Arrangement of ladders and platforms on vertical vessels shall be as detailed in Figure G.1 specifying elevation of service platforms relative to manways, maximum ladder run and minimum distance between platforms.

b.

The standout of circular platforms and ladders from the vessel shall be in conformance to PIP STF05535.

c.

Platform arrangements shall be amended to allow access around vertical piping passing through the platform, see PIP STF05530 pages 6 and 7, but for columns over 40 m (130 ft), platforms and ladders shall be orientated around the circumference of vessel to avoid vertical piping.

Platforms a.

The minimum recommended clearance between the face of a manway cover and equipment, such as control valves or handrails, shall be 0,9 m (3 ft). Minimum clearances between manways, valves, ladders, and handrails shall be as shown in Figure G.2 and Table G.1.

b.

Clearances for platforms at the top head of pressure vessel shall be as shown in Figure G.3.

c.

Typical details of vessel platforms are shown in PIP STE05535 and PIP STF05535.

d.

Unless otherwise specified in Purchase Order, floor gratings shall be fitted. Gratings shall be laid with grating bearing bars spanning across the long span, see PIP STF05530 and PIP STF05535 pages 5 and 6.

Page 93 of 96



Figure G.1 - Typical column platform and ladder elevations

TOP HEAD PLATFORM VENT ACCESS MAINTENANCE & BLIND ACCESS

LADDER RUN 2440mm (96 in) 9140mm (360 in) MAX. MINIMUM

ACCESS PER PURCHASERS SPECIFICATION 915mm TO 1525mm (36 in TO 60 in)

MAINTENANCE & VALVE ACCESS

C/L MAINTENANCE ACCESS

450mm TO 2060mm (18 in TO 81 in)

PLATFORM [TYPICAL] INTERMEDIATE PLATFORM TO SUIT MAXIMUM LADDER RUN

ALTERNATIVE VALVE ACCESS WITH OR WITHOUT EXTENSION STEM 305mm (12 in) MINIMUM T.L.

LEVEL GAUGE ACCESS BY LADDER OR PLATFORM

CONTROL INSTRUMENT & MAINTENANCE ACCESS

LADDER [TYPICAL]

GRADE

Page 94 of 96

DRAIN VALVE ACCESS FROM GRADE



Figure G.2 - Minimum clearances in platform design

N MI m IN) 7m M 45 8 i n (1

N MI ) m IN 7m n M 5 i 4 8 (1

DAVIT POINT

LADDER CAGE VESSEL

A

LADDER CAGE

B

DAVIT POINT

PROVIDE PARTIAL CAGE LADDER CAGE

LADDER TO PLATFORM ABOVE INTERMEDIATE LANDING SHALL BE DIMENSION 'B' WHERE 'B'= FLANGE O.D.+ 152mm (6 in) MIN.

VESSEL A IS SHOWN IN TABLE Z.1 TYPE 1 PLATFORM AT MANHOLE

61 0 ( 24 mm in MIN MI N)

LADDER CAGE

TYPE 2 INTERMEDIATE LANDING AT MANHOLE

VESSEL

WITH OR WITHOUT VALVE

N MI m IN) 7m M 4 5 8 in (1

IN M ) m IN 7m n M 45 8 i (1

LADDER CAGE

LADDER CAGE

PROVIDE PARTIAL CAGE EXTRA BARS

VESSEL TYPE 4 PLATFORM AT NOZZLE

TYPE 3 INTERMEDIATE LANDING

Table G.1 - Minimum platform clearances Column diameter

Dimension A

1,2 m (4 ft) or less 1,2 m (4 ft) - 2,4 m (8 ft) 2,4 m (8 ft) - 3,6 m (12 ft) 3,6 m (12 ft) or more

0,6 m (2 ft) 0,75 m (2 ft 6 in) 0,9 m (3 ft) 1,1 m (3 ft 6 in)

Page 95 of 96



Figure G.3 - Typical platform at the top of a vessel FLANGE OR MANWAY

DIMENSION TO PERMIT REMOVAL OF FLANGE BOLTS

PLATFORM

13mm (1/2 in) MAX. CLEARANCE FROM PLATFORM EDGE TO OD OF NOZZLE METAL OR INSULATION. AS APPLICABLE.

100mm (4 in) MINIMUM CLEARANCE FROM BOTTOM OF PLATFORM SUPPORT MEMBER TO OD OF VESSEL HEAD METAL ORINSULATION. AS APPLICABLE.

G.4.

G.5.

Ladders, ladder cages, and safety gates a.

Ladders complete with cages and safety gates, shall provide access to vessel platforms in conformance to standard drawings PIP STE05501 and PIP STF05501.

b.

Width of ladder rung, measured between stringers, will be specified by Company.

c.

Ladder rungs shall be equally spaced at a spacing to be specified by Company.

Handrailing a.

Handrailing shall conform to standard drawings PIP STF05520 and PIP STF05521

b.

Pipe handrailing shall be seal-welded to prevent internal corrosion.

c.

Coating of carbon steel handrailing shall conform to GIS 06-602.

Page 96 of 96


GIS 46-010 Specification for Pressure Vessels

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