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QGC
QCLNG Upstream Project Technical Specification - Pressure Vessels
QCLNG Document Number: QCLNG-BX00-MEC-SPE-300002
17 Sept 2014
QCLNG Phase I scope shall continue to be executed against Rev 00 of this document. For any work
undertaken in Phase I (scope sanctioned prior to January 2014) refer to Revision 00 unless otherwise
expressly requested by QGC.
Hydrocarbons Level 3, 60 Albert Street BrisbaneQLD 4000 Australia Telephone: +61 7 3239 7400 Facsimile: +61 7 3221 7791 www.worleyparsons.com ABN 61 001 279 812
© Copyright 2014 WorleyParsons
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CONTENTS
1 INTRODUCTION ................................................................................................................ 1
1.1 Scope .................................................................................................................................. 1
1.2 Definitions ........................................................................................................................... 1
1.3 Acronyms and Abbreviations .............................................................................................. 1
1.4 Referenced/Associated Documents ................................................................................... 3
1.4.1 Project Specifications ............................................................................................. 3
1.4.2 BG Standards ......................................................................................................... 3
1.5 Codes, Requirements and Standards................................................................................. 4
1.5.1 Australian Standards .............................................................................................. 4
1.5.2 Other Applicable Standards ................................................................................... 4
1.6 Order of Precedence .......................................................................................................... 6
1.7 Units .................................................................................................................................... 6
1.8 Technical Integrity ............................................................................................................... 7
1.9 HSE Requirements ............................................................................................................. 7
2 MATERIALS OF CONSTRUCTION ................................................................................... 8
2.1 General ............................................................................................................................... 8
2.2 Positive Material Identification ............................................................................................ 8
3 DESIGN .............................................................................................................................. 9
3.1 General ............................................................................................................................... 9
3.2 Design Life ........................................................................................................................ 10
3.3 Corrosion Allowance ......................................................................................................... 10
3.4 Design Loads and Requirements ..................................................................................... 10
3.4.1 Design Loads ....................................................................................................... 10
3.4.2 Design General Requirements ............................................................................. 11
3.5 Nozzles, Flanges & Manways ........................................................................................... 16
3.6 Equipment Supports & Anchor Bolts ................................................................................ 18
3.7 External & Internal Attachments and Packing .................................................................. 20
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3.8 Platforms ........................................................................................................................... 22
4 MANUFACTURE .............................................................................................................. 23
4.1 Fabrication, Welding and Heat Treatment ........................................................................ 23
5 INSPECTION & TESTING ................................................................................................ 28
5.1 Inspection and NDE .......................................................................................................... 28
5.2 Hydrostatic Testing ........................................................................................................... 30
6 PROTECTIVE COATINGS ............................................................................................... 32
7 MARKING AND NAMEPLATES ....................................................................................... 33
8 ASSURANCE OF PRODUCT QUALITY .......................................................................... 35
9 PROVISIONS FOR DISPATCH ........................................................................................ 36
10 SUPPLIER DOCUMENT REQUIREMENTS .................................................................... 38
11 REVISION HISTORY – REV 1 ......................................................................................... 39
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1 INTRODUCTION
Queensland Gas Company Limited (QGC) is developing coal seam gas (CSG) in the Surat Basin of
Southern Queensland for domestic and export markets through its Queensland Curtis LNG (QCLNG)
integrated liquefied natural gas (LNG) project. CSG will be gathered from individual well heads then
compressed in a number of remote Field Compression Stations (FCS). CSG from the various FCS’s
will then be further compressed and dehydrated at Central Processing Plants (CPP) before export via
a 42” pipeline to the LNG plant located at Curtis Island, Gladstone.
1.1 Scope
This document specifies the minimum technical requirements for the materials, design, manufacture,
welding, testing, inspection, coating, certification, quality assurance and dispatch of unfired pressure
vessels constructed in carbon or alloy (CRA) steels.
The scope of this document is applicable to the following:
• Pressure Vessels
1.2 Definitions
In this document, the following definitions apply:
Term Definition
Equipment Refers to pressure vessels and heat exchangers as appropriate
Specification This document and all referenced documents
Standard Refers to the applicable standards used as the basis for the supply
of equipment intended for use in Australia
1.3 Acronyms and Abbreviations
In this document, the following acronyms and abbreviations are used:
Term Description
AS Australian Standard
ASME American Society of Mechanical Engineers
BG BG Group
BGA BG Standard
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Term Description
BSI BSI Group (British Standards Institution)
CRA Corrosion Resistant Alloy
CPP Central Processing Plant
DEIR Department of Employment and Industrial Relations
DN Nominal diameter
DP Dye Penetrant Inspection/Examination
EN European Standards (Euro Norm)
FCS Field Compression Station
FEA Finite Element Analysis
ISO International Organisation for Standardisation
MDMT Minimum Design Metal Temperature
MP Magnetic Particle Inspection/Examination
NACE National Association of Corrosion Engineers
NDE Non Destructive Examination
NZS New Zealand Standard
PTFE Poly tetra fluoro ethylene
PWHT Post Weld Heat Treatment
QGC Queensland Gas Company – A BG Group business
QCLNG Queensland Curtis Liquefied Natural Gas
SI International System of Units
WRC Welding Research Council
VPI Vapour Phase Inhibitor
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1.4 Referenced/Associated Documents
1.4.1 Project Specifications
The following Project Specifications shall be used in conjunction with this specification, where
applicable:
QGC Document Number Title/Description
QCLNG-BX00-ENG-SPE-300000 Specification for Site Conditions and Utilities
QCLNG-BX00-MAT-SPE-300000 Protective Coatings Specification
QCLNG-BX00-MEC-SPE-300005 Design Requirements for Transportation and Lifting of
Equipment
QCLNG-BX00-PIP-SPE-300046 Positive Material Identification Specification
QCLNG-BX00-PIP-STD-300003-01 Allowable Nozzle Loadings Piping Standard Detail
QCLNG-BX00-PRC-PLN-300007 Material Preservation Plan
QCLNG-BX00-STR-SPE-300000 Structural Design Criteria
QCLNG-BX00-STR-SPE-300001 Structural Steelwork Specification
QCLNG-BX00-QCL-GDL-000002 Packing, Marking, Transport, Preservation and Warehousing
Guidelines
1.4.2 BG Standards
The following BG Standards shall be used in conjunction with this specification where applicable:
BG Document Number Title/Description
BGA-ENG-MATL-TS-0001 Material Selection & Corrosion Control
BGA-ENG-MATL-TS-0005 Protective Coatings
BGA-ENG-MATL-TS-0007 Fabrication of Structures, Equipment, Piping & Pipelines
BG-ST-ENG-MATL-008 Materials of Construction Requirements
BGA-POW-POW-TS-0004 Technical Specification for Power and Mechanical Equipment
BG-ST-ENG-MECH-003 Piping Design
BG-ENG-MECH-TS-0012 Flange Joint Management, Cleaning and Pressure Testing
BG-ST-ENG-MECH-009 Design and Selection of Lifting Equipment
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1.5 Codes, Requirements and Standards
All work performed pursuant to this Specification shall comply as a minimum with the requirements of
the relevant Statutory Authorities and the relevant sections of the latest edition of the applicable
Australian and International Codes and Standards and shall be in conformance with the current issue,
including amendments. Omission of a code or standard from this list does not relieve the supplier of
the requirements to carry out the work utilising all relevant standards.
1.5.1 Australian Standards
Standard Title/Description
AS/NZS 1200 Pressure Equipment
- Queensland Workplace Health and Safety Regulations
AS 1170 Structural Design Actions
AS 1210 Pressure Vessels
AS 1657 Fixed Platforms, Walkways, Stairways and Ladders – Design,
Construction and Installation
AS 2741 Shackles
AS 3920.1 Assurance of Product Quality – Pressure Equipment
Manufacture
AS 4037 Pressure Equipment - Examination and Testing
AS 4343 Pressure Equipment – Hazard Levels
AS 4458 Pressure Equipment – Manufacture
AS ISO 1000 The international system of units (SI) and its application
1.5.2 Other Applicable Standards
Standard Title/Description
API RP 582 Welding Guidelines for the Chemical, Oil and Gas Industries
API 661/ISO 13706 Air Cooled Heat Exchangers
ASME B16.47 Large Diameter Steel Flanges
ASME B16.5 Pipe Flanges and Flanged Fittings
ASME BPVC-V Non Destructive Examination
ASME BPVC-IX Welding and Brazing Qualifications
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Standard Title/Description
ASME BPVC-VIII-1 Boiler & Pressure Vessel Code – Rules for Construction of
Pressure Vessels
ASME BPVC-VIII-2 Alternative Rules for Construction of Pressure Vessels
ASME PCC-1 Guidelines for Pressure Boundary Bolted Connections
ASTM A380 Standard Practice for Cleaning, Descaling and Passivation of
Stainless Steel Parts, Equipment and Systems
ASTM A967 Standard Practice for Chemical Passivation Treatments for
Stainless Steel Parts
ASTM G48 Standard Test Methods for Pitting and Crevice Corrosion
Resistance of Stainless Steels and related Alloys by Use of
Ferric Chloride Solution
Bednar, Henry H Pressure Vessel Design Handbook 2nd
edition Van Nostrand
Reinhold Publication
BSI PD 5500 Unfired Fusion Welded Pressure Vessels
De Ghetto K. & Long W. Design Method To Check Towers For Dynamic Stability.
Hydrocarbon Processing Feb 1966.
EN 10204 Metallic products - Types of inspection documents
Freese, C.E. Vibration of Vertical Pressure Vessels. ASME Paper 58-PET-
13 July 1958
L.P. Zick method “Stresses in Large Cylindrical Pressure Vessels on Two
Saddle Supports,” L.P. Zick, Pressure Vessels and Piping:
Design and Analysis, A Decade of Progress. Vol. 2, 1972.
Mahajan, Kanti K. Tall Stack Design Simplified. Hydrocarbon Processing Sept.
1975.
Moody, Gene B. Mechanical Design To Tall Stacks. Hydrocarbon Processing
Sept 1969.
Moss, Dennis R. Pressure Vessel Design Manual 3rd
Edition
NACE RP0198 The Control of Corrosion Under Thermal Insulation and
Fireproofing
WRC Bulletin 107 Local Stresses In Spherical And Cylindrical Shells Due To
External Loadings
WRC Bulletin 297 Local Stresses In Cylindrical Shells Due To External Loadings
On Nozzles
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Standard Title/Description
WRC Bulletin 429 3D Stress Criteria Guidelines For Application
WRC Bulletin 444 Buckling Criteria for Torispherical Heads under Internal
Pressure
1.6 Order of Precedence
In the event of a conflict within the referenced documents, the Company shall be notified immediately
and a written decision shall be obtained prior to starting the related work. Any deviations or
exceptions shall be subject to mutual agreement on a case-by-case basis. In the event of a conflict
within the referenced documents, the following is the order of precedence:
1. Statutory Regulations, Design registration and RPEQ verification;
2. Purchase Order and subsequent Addendums;
3. Project Data Sheets;
4. Project Documentation, including this Specification, Project Drawings;
5. BG Standards and Guides;
6. Referenced Australian Codes and Standards;
7. Other Referenced Codes and Standards.
In cases where more than one code, regulation, specification or standard apply to the same condition,
the most stringent shall be followed.
1.7 Units
Company requirements are that metric SI units shall be used throughout. If an asset requires
Imperial units to be used for clarity, then SI units shall be stated, followed by the local requirement in
brackets. The following exceptions shall apply:
• Pressure shall be expressed as either gauge pressure in kPag or absolute pressure in kPaa,
gauge pressure being referenced to Standard Atmospheric pressure of 1.01325 bara.
• Temperature shall be expressed as degrees Celsius (°C).
• Dynamic viscosity shall be expressed as Centipoise (cP).
In addition, the following common industry units shall also be used (applying dual units where
appropriate):
• Volume gas flow in million standard cubic feet per day (MMscfd)
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The definition of Standard Conditions for pressure and temperature that shall be applied is 1
atmosphere pressure (or 1.01325 bara) and 15.5556 °C (rather than 1 atmosphere and 273.15
degrees Kelvin (0°C).).
1.8 Technical Integrity
The Supplier shall assume full responsibility for the technical integrity of the equipment, including
design, materials, manufacture, assembly, testing, performance, and specified engineering services.
All these activities are to be in accordance with the scope of supply.
Any deviation from this specification must be approved, in writing, by the Company. Such written
approval must be obtained prior to the commencement of any work which would constitute such a
deviation.
Compliance by the Supplier with this specification does not relieve the Supplier of the responsibility of
furnishing equipment and accessories of proper design, mechanically suited to meet operating
guarantees at the specified service conditions. Neither does it relieve the Supplier of the
responsibility of furnishing the correct equipment, or assembling and suitably preparing the equipment
for shipment.
1.9 HSE Requirements
Queensland statutory authority health and safety practises, acts and regulations shall apply in full.
The Supplier shall be fully responsible for ensuring the equipment, services and materials within the
supplier’s scope meet all applicable national, international statutory codes and regulations with regard
to health, safety and environmental requirements.
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2 MATERIALS OF CONSTRUCTION
2.1 General
Materials of construction shall comply with the Design Code, the Data Sheets, this Specification and
the following BG Standards:
• Material Selection and Corrosion Control (BGA-ENG-MATL-TS-0001);
• Materials of Construction Requirements (BGA-ENG-MATL-TS-0008); and,
• Specification for Plant Piping Material Requirements (QCLNG-BX00-PIP-SPE-300042).
All material shall be specified in the equipment datasheet(s) or specifications. Materials not explicitly
defined shall be as per the requirements of the referenced equipment Standard or selection based on
best practice for the specific duty. Materials of unknown specification or unidentifiable shall not be
used.
Products containing asbestos, lead or mercury are prohibited. Copper and copper alloys if in contact
with the process environment are prohibited.
Materials shall be supplied to a recognised national or international material specification in
accordance with the requirements of the selected design code and this specification. Mixing of
materials from different national or international material specifications is not permitted unless
acceptable to the design code or as approved by the Company.
Non-ferrous and non-metallic materials shall be non-sparking, anti-static, non-combustible or fire
resistant, non-irritating to skin, corrosion resistant and UV stabilized.
2.2 Positive Material Identification
For duplex and austenitic stainless steels selected to resist corrosion, positive material identification
shall be carried out in accordance with the requirements of Project Specification QCLNG-BX00-PIP-
SPE-300046 “Positive Material Identification”.
PMI activities1 shall be performed at the source of supply prior to shipment. Only quantitative analysis
using either portable X-ray fluorescence or arc-emission analysers are permitted.
PMI results shall be recorded and included in the final handover documentation.
1 It is to be noted that PMI is not to be considered as a substitute for material traceability using MTRs but, an additional check prior to final acceptance of the product / component. Any materials where traceability cannot be confirmed shall not be used.
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3 DESIGN
3.1 General
Pressure equipment shall be designed in accordance with the data sheet, this Specification, as well
as Australian Standards or compliant international standards endorsed by the Australian Standards;
and as per BG Standard requirements. Pressure equipment shall be designed and manufactured in
accordance with AS/NZS 1200, its referenced standards, the project specifications and this
Specification. In general pressure vessel equipment shall be built to AS 1210, or compliant standards
ASME BPVC-VIII-1 or BSI PD 5500.
Equipment shall be designed for maximum shop assembly of all component parts including platforms
and other attachments. Only bolted connections shall be used for field assembly.
Equipment will be located in an outdoor environment and shall be designed for the conditions as
specified in the Requisition and the Specification for Site Conditions and Utilities (QCLNG-BX00-
ENG-SPE-300000).
AS/NZS 1200 identifies the requirements and applicable Standards/Codes acceptable for use in
Australia.
All pressure equipment shall comply with the requirements of the Queensland Workplace Health &
Safety Regulations.
Applications for plant (pressure equipment) design registration must be submitted by an applicant in
Queensland. In satisfying the above, each item of pressure equipment will usually require
independent third party design verification as defined in Table 2.1 of AS 3920.1, according to
equipment Hazard Level (as defined in AS 4343). An RPEQ engineer shall review the 3rd
party
verification and design calculations for each pressure vessel. The RPEQ engineer is also then
required to fill in the registration documents for the vessel(s) and submit to Workplace Health and
Safety Queensland.
International or interstate organisations can provide the relevant documentation to an agent in
Queensland who can submit the application for plant design registration on their behalf. The applicant
must complete the approved DEIR form 14.
Queensland will accept design registration or reference numbers issued by another Australian State
(under a corresponding law).
Further information can be obtained from the Queensland Government DEIR website
www.deir.qld.gov.au or the Division of Workplace Health and Safety Tel: +61 7-3872 0586.
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Equipment incorporating formed heads shall employ 2:1 Semi-Ellipsoidal type, or as permitted in
Section 3.4.2 of this Specification, unless specifically approved otherwise by Company.
3.2 Design Life
The selection of materials and corrosion mitigation measures shall ensure that the facilities are
suitable for a minimum design life of 20 years unless otherwise specified.
Where applicable design life includes fatigue design in which case the equipment shall be designed
for a fatigue life of at least 20 years unless otherwise specified.
3.3 Corrosion Allowance
The following corrosion allowances shall be used, unless specified otherwise in the equipment
datasheet:
• Carbon steel (general): 3.0 mm (each surface exposed to process
fluid)
• Stainless or Duplex Steel: Nil
This allowance to be used as a general guideline. Actual corrosion allowance will be decided based
on 20 years life, process fluid conditions etc.
Corrosion allowances shall be applied to the required throat thickness of fillet and seal welds on
internal attachments.
3.4 Design Loads and Requirements
3.4.1 Design Loads
Equipment and their supports shall be designed to meet the most severe of all the possible load
combinations of live, dead loads and occasional loads, including thermal effects and piping loads,
anticipated during the normal life of the equipment, exclusive of any corrosion/erosion allowance. The
controlling load combination shall be indicated in the design calculations, in addition to any other
combinations required by the Standard.
The loadings and conditions to be considered in the design and support of the equipment shall
include the following, as appropriate:
• Design pressures and static head
• Weight of plant and contents under operating, upset and test conditions, including hydrotest (shop
& in-situ)
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• Impact loads due to changes in fluid flow, surge, slugs or fluid density
• Forces due to temperature gradient and differential expansion and friction
• Wind loads and earthquake loads (not acting concurrently)
• Maximum and minimum temperatures, and Minimum Design Metal Temperature (MDMT) shall be
defined on the vessel General Arrangement Drawing
• Dynamic wind loads
• Superimposed loads from the weight of other equipment / piping being supported, as well as
insulation and lining
• Cyclic loads due to pressure and or temperature fluctuations
• Vibration/pulsation loads
• Loads due to handling, erection and transportation conditions. Additional design factors for road,
rail and sea transport handling shall be accounted for as defined in QCLNG-BX00-MEC-SPE-
300005: Design Requirements for Transportation and Lifting of Equipment
Wind and earthquake load basis shall be in accordance with the Specification for Site Conditions and
Utilities (QCLNG-BX00-ENG-SPE-300000).
3.4.2 Design General Requirements
For all vessels up to 1500 mm shell diameter, minimum supplied shell thickness including corrosion
allowance shall not be less than 6 mm for formability and transportability reasons. For larger diameter
vessels, minimum supplied thickness shall be 8 mm up to 2200 mm diameter, and 9 mm up to 3600
mm diameter.
The vessel Maximum Allowable Working Pressure (MAWP) shall be determined, and is to be
stamped on the nameplate. This shall be the calculated maximum allowable working pressure at the
top of the vessel in the corroded condition. The supplier shall base their calculations for the entire
vessel on the MAWP. The vessel MAWP shall not be limited by flanges or nozzles.
In addition to the design loads referenced above, any tall vertical and slender equipment with
H/D( overall height / OD of upper third of shell) ratio exceeding 10 shall require consideration for
potential vibration due to wind induced vortices. The deflection at the top of slender vertical vessels
shall be limited to 1/200 of the overall height.
All nozzles with connected piping as well as support attachments (lugs, clips, trunnions) shall be
considered for effects of localised stresses. Local stress analysis of nozzle to equipment junctions, as
well as where clips and other attachments including temporary transport supports apply, shall be
carried out per the applicable “manual procedure” given in WRC Bulletin 107, WRC 297 or Annex G
of BSI PD 5500 as detailed below (note the restrictions on use of WRC 107) using Nozzle Pro
software. Nozzle necks shall also be checked for stresses due to external loads. Nozzles and
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attachments which fall outside the geometry limits of WRC 107, WRC 297 or BSI PD 5500, shall be
analysed using FEA.
All FEA calculations shall be in accordance with this Specification and WRC Bulletin 429.
In accordance with AS 1210, WRC 107 may not be used for any vessel nozzles that penetrate the
cylindrical shell, but may be used for nozzles in heads. For nozzles that penetrate the shell, required
analysis using “manual procedures” shall either be using PD 5500 Annex G, or by using WRC 297,
but in the latter case with the effects of stress-intensified pressure loading being added algebraically
to the sum of stresses due to mechanical loadings alone. Evaluation of pressure stress-intensification
can be made using PD 5500 or as otherwise agreed with Company.
Process nozzles in heads, as well as attachments which don’t penetrate the shell (lugs, clips,
trunnions) may be evaluated using WRC 107, WRC 297 or PD 5500 as appropriate.
Process nozzles with attached piping shall be designed with externally applied loads as defined in the
Allowable Nozzle Loadings Piping Standard Detail (QCLNG-BX00-PIP-STD-300003-01).
For ASME BPVC VIII-1 and AS 1210 vessels with large openings exceeding DN 500, or with d/D
(nozzle diameter/shell diameter) exceeding 0.5 on shells not exceeding 1500 mm ID, or for d/D ≥ 0.33
on larger shells, additional pressure reinforcement compliance shall be included in calculations.
These shall comply with ASME VIII-1 Appendix 1 Section 1-7 or Section 1-10 for ASME or AS 1210
designs, or PD 5500 when appropriate.
The likelihood of fatigue occurring shall be evaluated as a result of:
• Low cycle fatigue due to pressure and/or temperature cycling.
• High cycle fatigue due to pressure and/or temperature cycling.
• Mechanical/flow/acoustic induced vibration or pulsation.
Where the possibility of fatigue is considered appreciable, integral nozzles are required (not preferred
with reference to Section 3.5), and measures to reduce peak stresses at nozzle or support weld
attachments shall be required. Measures can include dressing welds to increase intersection radii. If
fatigue is considered likely, the requirements of either ASME Section VIII Division 2, PD 5500 Annex
C or AS 1210 Appendix M shall apply.
Flange ratings listed on the equipment datasheets and drawings are based on design
pressure/temperature conditions only and do not take account of external loads from piping reactions.
The design of flange joints shall take into account external loads from piping reactions and differential
thermal expansion for dissimilar materials.
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Process nozzle flanges for DN 300 and larger flanges, or for all size flanges where nozzle design
loads higher than in QCLNG-BX00-PIP-STD-300003-01 are considered, shall be checked to
withstand both pressure and external loads using equivalent pressure formulas, as follows:
Pe = 16 M / π G3 + 4 F / πG2 + P≤ 1.0 Pf (if M ≤ F*G) or
Pe = 16 M / π G3 + 4 F / πG2 + P ≤ 1.2 Pf (if M > F*G)
Where, P = Design Pressure (MPa)
Pe = Effective Pressure (MPa)
Pf = Flange nominal pressure rating (e.g. ASME B16.5)
F = Radial load (N)
M = Resultant bending moment (N-mm)
G = Gasket reaction diameter (mm)
Where Pf (above) is infringed, a full flange stress analysis using either ASME VIII-1 or ASME VIII-2
can be performed using Pe above as design pressure, before resorting to increasing flange pressure
rating.
In addition for special flanges, especially integral body flanges not conforming with ASME B16.5 or
ASME B16.47 Series B, flange design shall consider bolt force for operating conditions Wm1 based
on Pe above in the case of nozzles, and shall consider bolt force for “bolt up” or gasket seating Wm2
based on Wm2 = Ab.Sb. In this case Ab = total bolt area (mm2), and Sb = 310 MPa, the assumed bolt
stress necessary to maintain a leak tight joint in service. The latter definition for Wm2 derives from
Para 3.21.6.2 in Appendix 2 of ASME BPVC-VIII-1.
Equipment shall be designed for safe transportation, lifting and installation, preserving technical
integrity and suitability for operation.
Design for applied modes of transportation and lifting shall be in accordance with recognized
international standards or guidelines. Design for road transportation as well as for marine
transportation shall employ appropriate factors for vertical and horizontal dynamic design forces.
These are defined in QCLNG-BX00-MEC-SPE-300005: Design Requirements for Transportation and
Lifting of Equipment. As a minimum the design shall consider vertical dynamic forces onto
transportation supports of 1.5g together with 1.0g horizontal dynamic forces. The reactions back onto
the shell in such cases shall be considered in the design, excepting that the horizontal component
need not be considered where a full AS 1210/Zick analysis is not required as defined below.
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Vertical equipment may be required to be erected in the fully dressed condition; the design shall take
this into account. Lifting and tailing calculations for individually transported vertical equipment shall
consider lifting the equipment from the horizontal position in increments of at least 30 degrees, up to
the required vertical (90 degrees) position. For all lifting and tailing lugs for vertical and horizontal
equipment, shackle sizing shall comply with AS 2741. A dynamic impact factor of at least 1.5 shall be
used for all lifting calculations.
Formed heads shall preferably be of ellipsoidal or hemispherical type. Where torispherical heads are
offered as an alternative the potential for hydrotest buckling or wrinkling in thin torispherical heads
shall be investigated and included in calculations when D/t > 100 (D = head/vessel OD, t = head
thickness in corroded condition). Method of analysis shall be to WRC 444, and the analysis shall be
based on the highest exposure pressure (e.g. hydrotest, which may be required in service after
equipment modifications). Pressed and spun heads shall be supplied, and crown and segment type
are not permitted for torispherical heads.
Ellipsoidal, torispherical and toriconical heads shall have straight flanges at least 38 mm long, or
longer in order to accommodate a taper as shown below. Where a different thickness head is welded
to a shell with more than 3 mm difference in thickness, the details for ASME BPVC VIII-1 and AS
1210 shall be as follows based on Figure 3.1 below derived from ASME VIII-1 Figure UW-13.1. For
PD 5500 vessels the parameter ℓ shall be increased to ℓ ≥ 4y.
Figure 3.1
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Horizontal vessels shall be supplied on two saddles with saddle reinforcing wear plates with contact
angle at least 120 degrees. Analysis of local stresses around the saddle area shall normally be
evaluated in accordance with L.P. Zick’s method, as employed in AS 1210 and PD 5500 Annex G.
Small and lightly loaded horizontal vessels may be considered for exclusion from the full analysis
when the following is satisfied:
If 0.78 (W/ (S*Tc))*(R/Tc)0.5
≤ F - then full saddle analysis not required
W = vertical load on individual saddle –including transportation factors above (N)
S = saddle chord length = Do*sin ( Ө/2) (mm)
Do = vessel OD (mm)
Ө = saddle chord angle, degrees (120º maximum shall be used or less if applicable)
R = shell mean radius (mm)
Tc = corroded shell thickness (mm)
F = design stress at temperature for shell- maximum of 140 N/mm2 to be used.
The above formula, or the full AS 1210/Zick analysis when applicable should be checked for three
cases:
• Empty with applied transportation loading factors of QCLNG-BX00 ENG-SPE-300005;
• Hydrotest at ambient temperature and;
• Operating with seismic or wind loading at design temperature.
Each pressure vessel design shall explicitly state the maximum design temperature as well as
minimum design metal temperature (MDMT).
Cylinder to cone transitions shall be made with a toriconical section with knuckle when:
• Cyclic service applies, or Cone half apex angle exceeds 30º, or
• Shell wall thickness exceeds 32 mm, or
• Vessel requires impact testing, or
• Code requires toriconical transition.
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3.5 Nozzles, Flanges & Manways
Minimum connection size for equipment shall be DN50, and manway size shall be DN600 for all 900
mm diameter (OD) and larger vessels. Where the design does not permit a DN 600 manway, and
removable internals apply, a flanged head shall be provided. For smaller diameter vessels (outside
diameter of less than 900 mm) and where no removable internals apply, a minimum of two DN100
inspection ports may be considered as an alternative.
Non preferred connection nominal sizes are DN65, DN90 or DN125.
Columns and vertical vessels to be packed with removable internals shall be provided with manways
with blind flange and a davit near the top or the location for removing internals.
At least two manways shall be provided for vessels (excluding heat exchangers) with diameter 900
mm and larger. Further additional manways shall be provided for vertical trayed vessels with one
extra for each additional ten trays
For horizontal vessels, at least one manway shall be located on the top of the shell.
Permanently installed davits shall be installed for manway blind flanges. Vertical hinges may be fitted
where davits are not practical subject to approval. Davit capacity shall be specified on the drawing
and permanently located on the davit.
Nozzle orientations and locations should be located to best facilitate piping and instrumentation,
maintenance, and plant operations. Nozzles for external-mounted level devices and level sight
gauges should be jig-set during fabrication. Flange bolt holes orientations shall straddle major
centrelines.
Nozzle construction shall be of the set-in type, and shall not pass through weld seams, excepting if
reinforced, and the weld proximity requirements of Section 4.1 are adhered to. Unreinforced nozzles
may only pass through weld seams when holes are machine cut and when the entire attachment and
affected seam area are subject to 100% volumetric and surface examination, and Section 4.1 weld
proximity requirements are adhered to.
Integrally (self) reinforced nozzle necks are preferred – and are mandatory in the following cases:
• fatigue susceptible service (especially close to reciprocating equipment);
• shell thickness 40 mm or greater:
• class 900 and higher pressure ratings;
• design temperature exceeds 230 ºC
Reinforced nozzle openings of built up (pad reinforced) construction are permissible in non-fatigue
situations and when not required above, however such designs shall consider high cycle low
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amplitude fatigue effects from variable pressure and temperature cycles, and the need for appropriate
dressing of attachment welds (i.e. pad to nozzle and pad to shell welds). For vessels with 20 year
design life specified this dressing of built up welds shall be performed.
Reinforcing pads shall be provided with a ¼” NPT tapped hole to permit an air test. Such holes shall
be sealed with heavy grease post testing.
Reinforcing pad thickness shall not exceed the thickness of equipment to which it is attached, and
shall not be thinner than 50% of the shell or head thickness. Reinforcing pads shall be close fit type
with a maximum gap of 1.5 mm from the shell or head before welding.
A pressure fluctuation of at least 5–10% of design pressure occurring more than 6 times per day over
20 years has the potential to develop small fatigue cracks due to low amplitude high cycle fatigue at
fillet type welds around nozzles, assuming the absence of cyclic mechanical or thermal loads. In such
circumstances where built up nozzles are used, the dressing of attachment fillet type welds using a
suitable method is required to limit the potential for weld toe cracking into shell and nozzle.
Acceptable methods are as per ASME Section VIII Division 2, PD 5500 Annex C Section C.4, or AS
1210 Appendix M Section M.6.8.
If cyclic fatigue service is identified on the vessel data sheet then the potential for high amplitude low
cycle fatigue must be considered as well. In this case all attachment welds, including integrally
reinforced nozzle welds and support attachment welds shall be dressed appropriately, such as by
using the approach described above.
Nozzles shall be flanged, welding neck type. Flange facings shall be raised face, serrated spiral
“smooth” finish (3.2 to 6.3 micron) in accordance with ASME B16.5 for spiral wound gasket types. In
case other types of gasket are specified the flange facing shall be appropriate for the gasket; for RTJ
type the contact surface finish shall be to 0.8-1.6 micron, and for compressed fibre gaskets shall 3.2
to 12.5 micron surface roughness.
Flanges shall be in accordance with ASME B16.5 up to DN 600 or B16.47 Series B for larger sizes.
Custom designed flanges shall be in accordance with this Specification and shall be based on ASME
VIII-1 Appendix 2 or AS 1210, but with the amendments for bolt force design described in Section 3.4.
Slip on flanges or socket weld flanges shall not be used. Cast flanges shall not be used.
Threaded and studded connections shall not be used in any service except air and water unless
otherwise specified.
Nozzles except those directly connected to internals and drain nozzles shall be mounted with a
minimum inside projection of 3 mm and have an inside corner radius of 3 mm, unless otherwise
specified.
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The first flange on the bottom branch of vertical equipment supported on a skirt shall be located
outside the skirt.
Nozzle projection shall be sufficient to permit removal of studs between flange and equipment
components, and have sufficient clearance and access to allow the use of hydraulic tensioning
equipment.
Nozzle minimum projection from the shell shall be as follows unless noted otherwise:
• Up to DN200 shall be 200 mm
• Larger than DN 200 shall be 250 mm, or 300 mm in the case of Class 600 and higher rating
Projection shall be measured from the equipment outside surface for uninsulated equipment or
insulation surface for insulated equipment to the face of nozzle flange.
In accordance with BGA-ENG-MATL-TS-0007 clause 2.5.4.5, where internal linings or coatings are
specified on parts of vessels, for DN 100 and smaller nozzles in the affected region, nozzles shall be
clad or weld overlaid.
Spiral wound gaskets shall be employed unless otherwise specified and shall have external and
internal rings. Gaskets containing asbestos shall not be used. Gaskets containing PTFE or copper/
brass shall not be used for parts of equipment in contact with process fluid.
Flange bolting shall be stud type, threaded full length to UNC series for sizes up to and including 1”,
and 8UN series for studs 1-1/8” and above. Stud lengths shall provide a minimum 6 mm protrusion
above the nut face at each end. 1-1/4” and larger bolts shall have one and a half bolt diameters
added to their length. In addition, for bolt sizes 1-1/4” and larger hardened washers shall be provided
on both ends to prevent galling of the flange surface. Hardened washers shall be supplied in
accordance with ASME PCC-1 Appendix M.
Vortex breakers shall be included on all liquid drain nozzles.
3.6 Equipment Supports & Anchor Bolts
Equipment supports shall have a minimum thickness of 6 mm.
Supports shall generally be skirts or half skirts, and shall be designed to facilitate inspection of the
equipment. Openings shall be made in the sides of skirts or stools if applicable, and if the bottoms are
not readily visible through the supporting structure.
All skirt openings shall be provided with rings or collars, sized to provide 100% reinforcement of the
opening. In addition, provision shall be made for venting of the skirt with a minimum of two 50 mm
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openings, located near the top of the skirt, but below the head insulation or fireproofing if applicable.
Skirt openings shall be covered with fine wire mesh affixed using stainless steel screws.
Skirt outside diameter shall be based on Figure 3.2 below. Design calculations for the skirt shall be
incorporated.
Provision shall be made for thermal expansion of equipment. If the product of skirt diameter (mm),
thickness (mm) and bottom vessel temperature (in ºC) exceeds 1.6 x 107, account shall be taken of
the temperature gradient and thermal stresses in the upper skirt section.
No flanged joints shall be included within the skirt boundary.
Where support pads are required they shall be provided with a ¼” NPT tapped hole at lowest point, to
permit an air test. Such holes shall be sealed with heavy grease post testing.
Horizontal equipment shall be designed with two saddle supports, one fixed and one sliding, and with
saddle reinforcement plates that subtend at least 120° of shell circumference continuously and are
attached by welding. Such saddle wear plates shall have a minimum radius of 50 mm on the corners.
Saddle supports shall not cover shell longitudinal or circumferential weld seams. Circumferential
welds shall be located at a distance of at least 2.5 x [ radius x thickness (un-corroded) ]0.5
from saddle
wear plate edge.
Saddle supports shall be joined with a continuous weld to equipment shell.
Equipment subject to vibration shall not be supported on legs. Additionally leg supports may only be
considered for small and lightly loaded vessels not greater than 1800 mm diameter, weighing no more
than 6000 kg when empty, with overall height/diameter (H/D) ratio not exceeding 5, and with design
temperature not exceeding 230 ºC. Proposals for using leg supports outside these parameters shall
require Company approval.
Unless otherwise advised, the height of a saddle shall ensure a minimum 50 mm clearance from the
underside of the base plate to lowest point on any bottom nozzle flange.
Fixed / sliding saddles shall be indicated on equipment drawings.
Minimum anchor bolt size shall be M20.
For equipment that is located on concrete foundations, base plate design shall be based on allowable
bearing stress of 16 MPa. For equipment that is located on steelwork the allowable bearing pressure
shall be in accordance with the structural steel design Standard / code.
Required skirt connection shall be as per one of the following details in Figure 3.2:
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Figure 3.2
100% UT examination where possible at welds
3.7 External & Internal Attachments and Packing
Equipment shall be fitted with two earthing lugs as close as possible to the base.
Lifting lugs and/or trunnions shall be provided to facilitate handling during transport and erection on
site. Additional transport loading factors defined in QCLNG-BX00-MEC-SPE-300005 shall be
employed in lifting device calculations.
The design of internals shall permit all reasonable internal inspection. The service life of internals,
packing and attachments shall be a minimum of 20 years, and packing sections and other internals
shall be accessible for cleaning, repair and removal through manways as required. The design of
internal fittings shall ensure that they are proof against loosening by vibration.
Materials and components for demister pads and removable internals shall be austenitic stainless
steel 316.
The absolute maximum weight of any removable internals shall be 25 kg, but items weighing more
than about 15 kg will require more than one person for handling and will need special consideration of
space constraints and require appropriate risk assessments. In case any removable part weighs
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more than 10 kg the manufacturer shall provide a lifting and handling procedure to describe how parts
are to be removed safely.
Removable internals shall have all burrs and sharp corners removed.
All removable internals and packing sections shall be designed to pass through the nearest
equipment manway, and provide 10 mm minimum annular clearance. They shall be trial fitted in the
shop to ensure accuracy and ease of assembly/disassembly in the field. The trial fitting shall be done
prior to any required post weld heat treatment (PWHT) of the equipment, then removed before PWHT.
Removable internals shall be reinstalled for shipment where possible.
All portions of the equipment including internals shall be completely self-draining.
All external and internal attachment welds shall be continuous. All fillet welds larger than 5 mm shall
be welded in multiple passes to the vessel and shall be included with any vessel PWHT. Undercut
shall not be permitted. The corrosion allowance of all internals including attachment welds shall equal
that of the pressure containment design.
Pads attached to the vessel wall shall be circular or have a corner radius of at least 5 times the pad
thickness, and shall be fitted with a ¼” NPT vent hole. Vent holes shall be sealed with heavy grease
after completion of all pressure testing and the coating application.
Trays, packing sections and internals shall be designed and fabricated so as not to severely impact
column capacity, liquid loading or pressure drop. Trays and removable supports for internals shall be
designed and fabricated by the tray manufacturer, but installed by the vessel fabricator. Welded tray
supports shall be designed and detailed by the tray manufacturer, but shall be installed by the vessel
manufacturer. All trays and removable internals shall be installed by the vessel manufacturer, after
PWHT.
All crawl spaces through a manway entrance shall have a minimum clearance of 760 mm from
attachments/obstructions.
In addition to being designed for the fluid loadings defined in the data sheet, internal parts shall be
rigid enough to support a 1.5 kN concentrated load applied at any location. Internals and supports
shall be strong enough for typical fluid dynamic loadings and the manufacturer shall demonstrate a
proven track record in similar service.
Lifting lugs and trunnions shall be designed for the loadings defined and shall incorporate a minimum
impact factor of 1.5. All such attachments shall require a full analysis of local stresses in the shell
during the lifting condition as described in Section 3.4.2 of this Specification.
All welds of structural section and rectangular attachments such as support clips and trunnions shall
be checked for bending as well as shear loads to assure satisfactory weld stresses, taking account of
the minimum impact factor of 1.5.
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3.8 Platforms
Where applicable, equipment platforms, walkways, stairways and ladders shall be in accordance with
AS 1657 or an approved equivalent. Structural design loads for attached platforms and ladders
should comply with Structural Design Criteria QCLNG-BX00-STR-SPE-300000, but as a minimum
shall comply with AS 1657.
The requirement for access platforms at access nozzles (e.g. manways) or instruments shall be as
dictated by the data sheet, or as required by Section 3.5 of this Specification.
Platforms and associated components shall be attached to the pressure vessel using support clips
designed for the purpose. All such clip attachments shall comply with Sections 3.1 and 3.7 of this
Specification; and calculations which consider local attachment stresses shall be prepared for all clips
per Section 3.4.2.
Structural steelwork design for access ways, ladders and walkways shall comply with AS 1657 and
QCLNG-BX00-STR-SPE-300001: Structural Steelwork Specification.
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4 MANUFACTURE
4.1 Fabrication, Welding and Heat Treatment
Fabrication, welding, pre-heating and Post Weld Heat Treatment (PWHT) of equipment shall meet the
requirements of the design code, this Specification as well as those defined in BG Standard:
Fabrication of Equipment & Piping (BGA-ENG-MATL-TS-0007).
All welding, including minor repairs and temporary welding shall be carried out in accordance with
qualified welding procedures approved by Company. Major repairs shall not be carried out without
prior Company approval. Major repairs are any which exceed Code allowable defects. No fabrication
shall commence until the Suppliers quality plan, fabrication and weld procedures, heat treatment
procedures and fabrication drawings have been approved by both Company (or their nominated
engineer/consultant), and the appointed third party verification authority.
All welding consumables used in production welds shall be supplied with certificates conforming to BS
EN 10204 Type 3.1. The specified minimum yield strength of each consumable shall meet the
specified minimum yield strength of the base metal parts to be joined.
Main seam welds and nozzle welds shall be full penetration, double sided butt type. Where the design
requires the use of single-welded butt joints, the weld detail employed shall be such as to ensure a
full penetration joint and the first pass shall be GTAW.
All internal welds shall be continuous and double sided. The minimum leg length for internal fillet
welds in the fully corroded condition shall be the larger of 5 mm, or the calculated value for the
applied loads.
Equipment longitudinal seams shall be orientated such that they are above the horizontal centreline.
No welding is permitted on pressure parts after PWHT.
Fabrication, welding and post weld heat treatment (PWHT) for AS 1210 vessels shall comply with AS
4458 as well as API RP 582. Vessels designed to ASME BPVC VIII-1 or PD 5500 shall also comply
with API RP 582 for welding and heat treatment, and shall also comply with AS 4458 Appendices C
and F for mechanical data report and fabrication tolerances respectively. In all cases the
supplementary requirements defined in this Specification apply too.
For the purposes of clarification the following vessel thickness and material requirements shall
determine the construction Class to be applied in AS 1210 vessel manufacture, where Class 1
typically requires 100% radiography and Class 2 typically requires spot radiography:
• Carbon and carbon manganese steels thicker than 32 mm (non-impact tested) – Class 1
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• Austenitic and duplex CRA steels thicker than 25 mm – Class 1
• All impact tested vessels – Class 1
• Carbon and carbon manganese steels thicker than 5 mm but not thicker than 32 mm (not
impact tested)– Class 2
• Austenitic and duplex steels thicker than 5 mm – Class 2
For ASME BPVC VIII-1 the above Class 1 and Class 2 classifications shall be applied in determining
NDE and testing requirements as defined later in Section 5.1 of this Specification.
For PD 5500 vessels the Construction Categories 1 and 2 of that code shall be deemed equivalent to
the Class 1 and 2 respectively as defined above.
Minimum NDE requirements are defined in more detail in Section 5.1.
Minimum pre-heat temperatures shall meet the higher of the design code or the values tabled against
wall thickness from Section 3.5 of BGA-ENG-MATL-TS-0007 as shown below.
Carbon steel cold formed heads (ends) shall be normalized after forming in any of the following
cases:
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• Fibre strain exceeds 5%; or
• Thickness of part exceeds 13 mm before forming regardless of fibre strain induced, or.
• Temperature during forming is in range 120 – 480 °C (per 6.3.1 of AS 4458)
Austenitic and duplex steel cold spun heads shall be heat treated when fiber strain induced exceeds
15%.
Other formed heads for other metallurgies shall be heat treated as applicable after forming per BGA-
ENG-MATL-TS-0007 Section 2.4 depending on fibre strain induced during forming, with heat
treatment method suitable for equipment metallurgy. Proposed heat treatment shall be submitted to
Company for approval.
The determination of percentage (%) fibre strain induced for dished and toriconical ends shall be
made using either of the formulae in AS 4458 Section 6.3, or the formula in ASME VIII-1 Para UCS-
79 (d)(5). For ends incorporating a defined knuckle (torispherical and toriconical) the calculation of %
fibre strain shall be separately evaluated with regard to heat treatment.
Hot forming of CRAs is not permitted unless the combination of material, thickness and configuration
precludes the use of cold forming. In such case a procedure for hot forming shall be agreed with
Company.
All carbon and low alloy steel plates that have been hot formed shall be normalized, and hot forming
temperatures of components shall comply with Table 6.1 of AS 4458. Normalizing temperatures and
times for carbon steels shall meet the requirements of Table 6.2 of AS 4458. Quenching
temperatures required for austenitic and duplex steel parts shall comply with Table 6.3 of AS 4458.
Fabrication tolerances shall comply with the nominated design code as well as AS 4458 Appendix F.
In addition the maximum allowable gap between reinforcing pads and surface of shells or heads
before welding shall be 1.5 mm.
Location of weld joints shall not be closer together than the greater of 6 times material thickness or 75
mm, as defined in AS 4458. Additionally BGA-ENG-MATL-TS-0007 specifies that attachment welds
and weld toes closer than 2(R*t)0.5
apart shall require heat treatment and/or stress analysis together
with additional NDE. In such cases 100% UT or 100% RT shall be performed for the affected welds
in addition to the stress analysis requirements already required to satisfy this Specification in Section
3.4.2. When it is unavoidable for a nozzle or attachment weld to encroach upon a main shell weld the
nozzle/attachment weld shall extend beyond the seam weld by at least 50 mm. Before the
attachment weld is made, 100% volumetric examination shall be performed on the adjacent pressure
weld in the area where the attachment will cross.
If a nozzle or reinforcement pad should penetrate or cover a weld seam, the weld seam shall be
ground flush and radiographically and ultrasonically examined for a distance of 150 mm beyond the
nozzle or pad diameter location.
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Shielded metal arc welding (SMAW), gas tungsten arc welding (GTAW) and gas metal arc welding
(GMAW) are the welding processes preferred for pressure vessel manufacture. Only low hydrogen
electrodes (e.g. E7018) shall be used for SMAW on all thicknesses. Weld processes not permitted for
pressure envelope construction are FCAW-Self shielded and EGW.
All Category A and B joints shall be double butt welded, or an acceptable full penetration alternative
agreed with Company.
An acceptable equivalent for Category A or B welds in nozzles, elbows and single sided closure
seams, is a single welded butt joint with a GTAW root bead.
Category C and D joints shall be double welded with full penetration, unless agreed otherwise with
Company.
As defined in Section 3.5 nozzles DN 100 and smaller in regions where internal lining or coating is
specified, these nozzles shall be either clad or weld overlaid.
Except where code requirements are more stringent, as a minimum for all ASME and PD 5500 alloy
steel and impact tested carbon steel vessels, welded production test plates representative of the
completed vessels shall be prepared and tested to check quality of welds. One test plate is required
for each vessel and each welding procedure for Category A and B type joints. For AS 1210 vessels
production test plates shall be required for all longitudinal and circumferential welds in Classes 1 and
2A vessels.
Where PWHT is required per design code or the Data Sheet, it shall be carried out in a single heat
treatment furnace, and temperatures and control shall comply with the design code applied. Supplier
shall consider and state in their PWHT procedures how to avoid distortion. All gasket faces and
machined surfaces shall be protected against scaling during heat treatment, and shall be checked for
warp age/distortion as well as scaling after PWHT.
Corrosion resistant weld overlay and clad restoration shall meet design code requirements as well as
API RP 582. In addition, the minimum thickness of weld overlay shall be 3 mm and the top 1.5 mm of
weld deposit shall meet the nominal specified chemistry.
Repairs to welds shall only be permitted as defined in Section 3.13 of BGA-ENG-MATL-TS-0007.
Repairs of defective welds shall require first defect removal, then MP or DP examination to confirm
removal, followed by repair welding using approved procedures, and then re-heat treatment if
originally required.
Bolted internals shall be installed after PWHT. Where non carbon steel metallic components are
included in the pressure envelope design, a Positive Materials Identification (PMI) programme shall
be incorporated per BGA-ENG-MATL-TS-0007 Section 3.10.
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Pickling and passivation of stainless steels shall be performed using nitric acid in accordance with
ASTM A380/ASTM A967.
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5 INSPECTION & TESTING
5.1 Inspection and NDE
Inspection, NDE testing and acceptance criteria shall meet the requirements of the design code, the
Data Sheet, this Specification and as defined in BG Standards: Fabrication of Equipment & Piping
(BGA-ENG-MATL-TS-0007) and Flange Joint Management, Cleaning & Pressure Testing (BGA-ENG-
MECH-TS-0012) and as per the codes specified. All NDE shall be completed prior to pressure testing.
In the case that PWHT is required, the NDE shall be repeated again after completion of PWHT, and
prior to pressure testing.
Inspection and testing shall be per approved Inspection and Test Plan (ITP). Company may
nominate HOLD and WITNESS points.
Extent of radiography (volumetric examination) shall be per the most stringent requirements of the
design code, the Data Sheet, Section 3.9.6 of BGA-ENG-MATL-TS-0007, and the following:
It should be noted that in addition to design code requirements 100% volumetric examination is
required per BGA-ENG-MATL-TS-0007 for longitudinal and circumferential welds in specific cases.
In all cases the requirements for volumetric and surface examination shall be as the table below,
which also identifies which requirements emanate from AS 4037 and which are from Section 3.9.6 of
BGA-ENG-MATL-TS-0007:
Types of Welds Visual MP/DP Ultrasonic UT Radiography RT
Main seams
(longitudinal and
circumferential
Types A and B)
Wall T ≥ 50 mm
(3.9.6)
Carbon steel T >
32 mm (AS 4037)
Class 900 and
greater (3.9.6)
100%
100%
100%
100%
100%
100%
10%1
%1
%1
100%
100%
100%
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Types of Welds Visual MP/DP Ultrasonic UT Radiography RT
Alloy/CRA steels
T> 25 mm (3.9.6)
Impact tested
steels (3.9.6)
Cyclic service
(3.9.6)
Other (Class 2, 3)
100%
100%
100%
100%
100%2
100%
100%
10%
%1
%1
10%
-
100%
100%
100%
10%
Nozzle welds
(Type D)
Shell Thick T ≥
50 mm (3.9.6)
Shell Thick T< 50
mm
100%
100%
100%
100%
100%
10% (for DN >150
mm)
-
-
Attachment welds 100% 100% - -
Tubesheet welds 100% 100% 100% -
Note 1: The requirement is that %UT may replace the equivalent %RT examination, subject to the
restrictions defined here, excepting that for carbon/carbon manganese steels, the %UT shown where
applicable may replace the equivalent %RT, with the balance performed using RT. Where no
value % is shown, the vendor may propose to replace some or all RT with UT (based on ASME Code
Case 2235-9) subject to written approval of Supplier proposed UT procedures and confirmation of
acceptance of this approach by Company.
Note 2: MP is not permitted for CRA equipment welds
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As a minimum spot radiography is required for all Category A and B welds on the shell, heads and
nozzles of Class 2 vessels, but this shall include the examination of all intersections of longitudinal
(Category A) and circumferential (Category B) welds, and this shall ensure a minimum of 10% of
seam welds are examined. The general definition of spot radiography applied throughout shall be as
per Clause 1.4.10 in AS 4037.Forged products (e.g. nozzles) 100 mm thick or greater shall be
ultrasonically tested for flaws. Testing shall be in accordance with ASTM A388-11: Standard Practice
for Ultrasonic Testing of Steel Forgings, or BS EN 10228-4 in the case of austenitic or duplex steel
items.
All surface examination shall be performed before as well as after PWHT where applicable. MP
shall be performed using AC yoke and Wet Fluorescent method to avoid arc strikes after vessel heat
treatment.
Where temporary attachments have been removed after use, the affected areas shall be subject to
surface examination using MP or DP to confirm absence of flaws.
All weld overlay surfaces shall be examined using DP after completion of heat treatment. This
examination shall be performed after completion of machining where applicable (on nozzles or flange
faces).
5.2 Hydrostatic Testing
Hydrostatic testing of the complete equipment shall be undertaken upon satisfactory completion of all
other tests and PWHT (if any). Wherever possible, the hydrostatic test should be carried out in the
operating position. Hydrotest pressure shall comply with the design code used.
Test temperature shall be such that there is no risk of brittle fracture in ferritic materials.
After satisfactory completion of the test, the equipment shall be rechecked for possible distortion.
The welds of reinforcing plates shall be air tested using a soapy water solution, at a pressure of 50
kPag.
The hydrostatic test fluid shall generally be fresh water free of suspended solids, biologically inert and
have a neutral pH value (close to 7). The maximum chloride content shall be 100 ppm for unlined
carbon steel equipment, while for stainless steel, duplex steel and CRA overlaid/clad carbon steel
vessels a limit of 25 ppm (fluoride and chlorides) applies. A water certificate shall be provided.
Test water shall also be treated with a corrosion inhibiter, suitable for materials of construction, so as
to prevent the onset of corrosion upon completion of hydrostatic test. The Supplier shall provide the
Company with details about the proposed corrosion inhibitor for review and approval along with the
application methodology.
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Minimum hydrotest duration shall be 1 hour at required test pressure excepting where the design
code specifies longer.
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6 PROTECTIVE COATINGS
Surface protection system shall be per QCLNG-BX00-MAT-SPE-300000 Protective Coating
Specification and BG Standard: BGA-ENG-MATL-TS-0005 Protective Coatings.
Equipment requiring external coating shall have all exterior surfaces coated, including the inside of
skirts, the exterior of the bottom head for vertical equipment and the inside of flange bolt holes.
Painting shall include the nozzle flanges up to, but not including, the gasket contact face.
Internal coating / lining, and the system employed shall be as per the datasheet, and as defined in
QCLNG-BX00-MAT-SPE-300000.
Painting shall be performed after completion of all testing, including pressure testing.
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7 MARKING AND NAMEPLATES
Nameplates shall be mounted on brackets and shall stand clear of the supporting surface or
insulation. Nameplates shall be made of stainless steel minimum 3 mm thick, with the required data
engraved or stamped.
Nameplate shall show all the required information in accordance with the design standard, and
preferably include the following information:
• Order number
• Tag number
• Duty/Description
• Date of Manufacture
• Manufacturer’s name & Serial number
• Design code(s) with edition date
• Design pressure (external / internal)
• Design temperature:(MDMT and maximum design temperature)
• Construction class (AS 1210) or Extent of NDE
• Hazard level (AS 4343)
• PWHT requirements
• Hydrotest pressure, test date and inspectors identification (punched at the time of testing)
• Corrosion allowance
• Weight (empty & full)
• Volume
• Rating (for exchangers)
• Statutory design registration number
• Statutory plant registration number (number to be completed by others)
Equipment shall be clearly identified by painting or dye stencilling the equipment tag number with
lettering of minimum 200 mm high in a conspicuous location on the shell, head, or support.
Vertical equipment shall be marked on the base and first 300 mm of skirt, indicating the North, South,
East, and West axes. The co-ordinates shall be indicated with a painted line and letter for each,
according to the orientation shown on the equipment drawings. The markings shall be made on the
shell near the bottom tangent line if the equipment does not have a skirt.
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Horizontal equipment shall have one head marked North, South, East, or West as shown on the
equipment drawings.
The color of paint for marking and lettering shall conspicuously contrast with the equipment surface.
The centre of gravity shall be included on equipment general arrangement drawings and shall be
marked on all equipment by painting a continuous 75 mm wide circumferential stripe. The letters C-G
and shipping weight in tonnes shall be painted at 2 locations diametrically opposite and adjacent to
the stripe.
Slide plates shall be stamped with the equipment tag number.
Note: Name plate details are as per appropriate Australian design code may be accepted at the
discretion of project lead Mechanical Engineer.
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8 ASSURANCE OF PRODUCT QUALITY
Pressure equipment design and manufacture shall be subjected to appropriate quality assurance
conforming to AS 3920.1 and BG Standard: Fabrication of Equipment & Piping (BGA-ENG-MATL-TS-
0007).
Pressure equipment Hazard Level shall be in accordance with AS 4343 and as nominated on
datasheets. Regarding the Supplier, required quality system status, design verification involvement
as well as fabrication inspection body involvement shall be as per Table 2.1 in AS 3920.1, according
to Hazard Level based on AS 4343.
For most pressure vessels involving hydrocarbon fluids (i.e. Hazard Level B), design verification will
be required and an accredited quality system to AS/NZS ISO 9001 should also be in place. For most
hydrocarbon containing vessels (i.e. Hazard Level B), the absence of AS/NZS ISO 9002 certification
will mandate the requirement for an approved fabrication inspection body to be involved per AS
3920.1. In the case of Hazard Level A equipment a fabrication inspection body shall be mandatory
regardless of ISO accreditation.
Material certification shall be to the requirements of EN 10204, Type 3.1 or 3.2 for all pressure
retaining components and components directly welded to the pressure component, as well as for all
welding consumables. For other components, certification to EN 10204, Type 2.1, as a minimum,
shall apply.
Materials of unknown specification or that are unidentifiable shall not be used, and all materials shall
comply with Section 2 of this Specification.
All test and recording instruments used shall have current calibration certificates.
Hydro test water quality test certificates shall be provided as per Section 5.2.
No fabrication of pressure equipment shall occur until after the Inspection and Test Plan, design
drawings and design calculations have been approved in writing by Company.
To satisfy Queensland legislation the design registration described in Section 3.1 shall be supplied.
The vessel manufacturer shall be responsible for providing all associated design registration, design
verification as well as the fabrication inspection body within his scope of supply, and at his cost.
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9 PROVISIONS FOR DISPATCH
Equipment for dispatch shall be clean and thoroughly dry, and shall be prepared in accordance with
BG Standard: Fabrication of Equipment & Piping (BGA-ENG-MATL-TS-0007) and Material
Preservation Plan QCLNG-BX00-PRC-PLN-300007 (in particular Section 6.5).
All tell-tale holes shall be sealed with heavy grease following a successful pneumatic pad test and
after protective coating has been applied.
All equipment and materials shall be properly protected from damage for sea freight as appropriate.
Components or pressure systems with enclosed compartments shall be provided with an appropriate
preservation medium such as a desiccant, VPI or inert gas blanketing including the following
requirements:
• The desiccant shall be not have a deleterious effect on the component materials of construction
• Desiccant labels shall clearly state, type, quantity and expiration of desiccant.
• Desiccant expiry shall be stated on packing lists.
Machined surfaces and all threads shall be protected.
Internal and external parts and piping assembled with the equipment shall be suitably supported and
braced to prevent damage during handling and transportation.
For vertical equipment, or where the permanent saddles of horizontal equipment cannot be utilised for
shipping, separate steel shipping saddles shall be provided. These shall provide a 75 mm clearance
between any nozzle and the ground.
Horizontal equipment may use its permanent welded on saddles for transport during shipment. If a
boot or nozzle projection extends below the saddle base plates, then steel saddle extensions shall be
secured to the saddles to provide a 75 mm minimum ground clearance for the protruding part.
Temporary shipping saddles and/or saddle extensions shall be secured to the equipment such that
these items will remain attached to the equipment during lifting operations.
Slide plates shall be shipped with the equipment.
Packing and shipping of all equipment that will be imported to Australia shall comply with the
requirements of the Department of Agriculture, Fisheries and Forestry - Australian Quarantine and
Inspection Services.
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Tolerances on dimensions for use in the dimensional checking of the equipment prior to delivery shall
be in accordance with AS 4458 Appendix F.
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10 SUPPLIER DOCUMENT REQUIREMENTS
On completion of manufacture, the Supplier shall prepare and submit certified documentation in the
form of a Manufacturers Data Report (MDR).
Three copies shall be supplied and these shall meet the requirements of AS 4458 Appendix C, and
this Specification.
Minimum inclusions shall be:
1. Design calculations
2. As built drawings
3. Material traceability records (certificates) for all Supplier provided materials and weld
consumables.
4. Weld maps, weld history and repair details
5. Nameplate facsimile/rubbing
6. NDE Reports
7. Hydrotest results and test water quality certificate.
8. Tube to tube sheet leak test results (for air cooled exchangers)
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11 REVISION HISTORY – REV 1
Section Change From / Deleted To / Added
1.3 Correction Compressor Compression
1.4.2 BG Standards
correction
Fabrication of Structures,
Equipment & Piping
Fabrication of Structures,
Equipment, Piping & Pipelines
BGA-ENG-MATL-TS-0008 BG-ST-ENG-MATL-008
BGA-ENG-MECH-TS-0003 BG-ST-ENG-MECH-003
BGA-ENG-MECH-TS-0012 BG-ENG-MECH-TS-0012
BGA-ENG-MECH-TS-0009 BG-ST-ENG-MECH-009
General Requirements for
Lifting Equipment
Design and Selection of Lifting
Equipment
1.6 Addition 1. Statutory Regulations 1. Statutory Regulations,
Design registration and RPEQ
verification;
2 Materials – entire
section updated
3.1 Clause change Except for specifically exempt
types of pressure equipment,
the Workplace Health and
Safety Regulation requires all
pressure equipment to be
RPEQ certified / registered
and built to a registered
design, and a certificate
issued by Workplace Health
and Safety Queensland before
the equipment is installed or
used.
… (as defined in AS 4343). An
RPEQ engineer shall review
the 3rd
party verification and
design calculations for each
pressure vessel. The RPEQ
engineer is also then required
to fill in the registration
documents for the vessel(s)
and submit to Workplace
Health and Safety
Queensland.
3.3 Clause added This allowance to be used as
a general guideline. Actual
corrosion allowance will be
decided based on 20 years
life, process fluid condition
etc.
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3.4.2 Clause added as detailed below (note
restrictions on use of WRC
107).
as detailed below (note
restrictions on use of WRC
107) using Nozzle Pro
Software.
3.5 Clause changed Gaskets containing asbestos,
PTFE or copper/brass shall
not be used.
Gaskets containing asbestos
shall not be used. Gaskets
containing PTFE or copper/
brass shall not be used for
parts of equipment in contact
with process fluid.
3.5 Clause changed Nozzles not directly connected
to internals shall be mounted
flush with the inside surface of
the equipment wall and have
an inside corner radius of 3
mm, unless otherwise
specified.
Nozzles except those directly
connected to internals and
drain nozzles shall be
mounted with a minimum
inside projection of 3 mm and
have an inside corner radius
of 3 mm, unless otherwise
specified.
7 Clause changed with the design standard, and
at least the following
information:
with the design standard, and
preferably include the
following information:
Clause added Note: Name plate details as
per appropriate Australian
design code may be accepted
at the discretion of Project
lead Mechanical Engineer.
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