ges 00301

Petrokemya GES-003-01 Pressure Vessels

Rev. 3B

February, 1999 Page 1 of 53

Cover Page


Rev. 4

August, 1999 Page 2 of 53

CONTENTS SECTION PAGE

1. SCOPE.................................................................................................................................................................................... 4

2. REFERENCE DOCUMENT, CODES AND INDUSTRY STANDARDS ...................................................................... 4

3. GENERAL............................................................................................................................................................................... 5

4. BASIC DESIGN..................................................................................................................................................................... 6

4.1 DRAWINGS..........................................................................................................................................................................6 4.2 DESIGN BASIS.....................................................................................................................................................................9

4.2.1 Design Pressure..................................................................................................................................................... 9 4.2.2 Design Temperature ............................................................................................................................................. 9 4.2.3 Design Loading and Condition .......................................................................................................................10 4.2.4 Wind and Earthquake Loads............................................................................................................................11

4.3 ALLOWABLE STRESS......................................................................................................................................................13 4.3.1 Vessel Rigging Analysis/Lifting Requirements..............................................................................................15

4.4 ANALYSES........................................................................................................................................................................15 4.5 CORROSION ALLOWANCE .............................................................................................................................................15

5. DESIGN AND FABRICATION DETAILS......................................................................................................................17

5.1 SHELL AND HEAD SEAMS..............................................................................................................................................17 5.2 DESIGN OF WELDED JOINTS.........................................................................................................................................17 5.3 REINFORCEMENT OF OPENINGS...................................................................................................................................18 5.4 REINFORCEMENT AT SHARP CONE-TO-CYLINDER INTERSECTIONS...........................................................19 5.5 HEADS AND TRANSITION SECTIONS............................................................................................................................19 5.6 NOZZLES, MANHOLES, CONNECTIONS AND GIRTH JOINTS....................................................................................19 5.7 SUPPORTS.........................................................................................................................................................................22 5.8 ANCHOR BOLTS...............................................................................................................................................................22 5.9 INSULATION SUPPORTS.................................................................................................................................................22 5.10 ACCESS OPENING ............................................................................................................................................................22 5.11 VENT IN SKIRT ................................................................................................................................................................23 5.12 TOP DAVIT .......................................................................................................................................................................23 5.13 NON-PRESSURE PARTS....................................................................................................................................................23 5.14 GROUNDING CLIP ............................................................................................................................................................23 5.15 NAMEPLATE....................................................................................................................................................................24

6. MATERIALS........................................................................................................................................................................24

6.1 GENERAL ..........................................................................................................................................................................24 6.2 LININGS .............................................................................................................................................................................26 6.3 BOLTING...........................................................................................................................................................................26 6.4 GASKETS...........................................................................................................................................................................27


Rev. 4


6.5 SUPPLEMENTARY MATERIALS....................................................................................................................................28

7. FABRICATION...................................................................................................................................................................28

7.1 GENERAL ..........................................................................................................................................................................28 7.2 CUTTING...........................................................................................................................................................................28 7.3 REPAIR WELDING OF DEFECTS IN MATERIAL..........................................................................................................28 7.4 COLD FORMING ...............................................................................................................................................................28 7.5 PREPARATION FOR WELDING ......................................................................................................................................28 7.6 WELDING..........................................................................................................................................................................29 7.7 POST WELD HEAT TREATMENT .................................................................................................................................30

8. INSPECTION AND TEST.................................................................................................................................................32

8.1 GENERAL ..........................................................................................................................................................................32 8.2 MATERIAL INSPECTION ................................................................................................................................................32 8.3 WELDING INSPECTION...................................................................................................................................................32 8.4 DIMENSIONAL INSPECTION...........................................................................................................................................33 8.5 NON-DESTRUCTIVE EXAMINATION ............................................................................................................................34

8.5.1 Radiographic Examination ..............................................................................................................................34 8.5.2 Magnetic Particle and Liquid Penetrant Examination...............................................................................35 8.5.3 Ultrasonic Examination ....................................................................................................................................37 8.5.4 Impact Test Examination...................................................................................................................................38

8.6 PRESSURE TEST ................................................................................................................................................................38 8.7 REJECTION .......................................................................................................................................................................39 8.8 POSTWELD HEAT TREATMENT CHECK .....................................................................................................................39 8.9 SHIPPING PREPARATION CHECK .................................................................................................................................40 8.10 INSPECTION REPORT ......................................................................................................................................................40

9. SHOP PAINTING...............................................................................................................................................................40

10. PREPARATION FOR SHIPMENT..................................................................................................................................41

11. APPENDIXES ......................................................................................................................................................................43

Appendix 1 Summary of Inspection and Tests.......................................................................................................41 Appendix 2 Pressure Vessel Tolerances ...............................................................................................................42 Appendix 3 Material Sheets......................................................................................................................................46


Rev. 4


1. SCOPE This specification defines the mandatory technical requirements for the design, materials, fabrication, testing and inspection of pressure vessels.

2. REFERENCE DOCUMENT, CODES AND INDUSTRY STANDARDS The requirements contained in the latest edition of the following documents, codes and standards shall form a part of this specification, in the manner and to the extent indicated herein:

1) ASME Boiler and Pressure Vessel Code

Section I - Power Boilers Section II, A, B, C, D - Material Specifications Section V - Nondestructive Examination Section VIII - Pressure Vessels - Division 1 - Division 2 - Alternative Rules Section IX - Welding and Brazing Qualifications

2) ASME

Transactions - Volume 102, February, 1980 Publication - 71-DET-36

3) ASTM Standards

4) ASME B16.47 Large Diameter Steel Flanges

5) ANSI/AWS A2.4 Standard Weld Symbols

6) ASME

B1.1 Unified Screw Threads B16.5 Steel Pipe Flanges, Flanged Valves and Fittings B18.2.2 Square and Hex Nuts

7) Welding Research Council (WRC)


Rev. 4


Bulletin Number 107, Local Stresses in Spherical and Cylindrical Shells due to External Loadings Welding Journal Research Supplement, Stresses in Large Horizontal Cylindrical Pressure Vessels on Two Saddle Supports, L.P. Zick

8) OWNERs General Engineering Specifications

GES-001 Design Requirements GES-003-06 Design of Welding Requirements GES-003-51 Installation of Towers, Vessels and Heat Exchangers GES-004 Vessel Internals GES-012-01 Piping GES-014-01 Loads and Forces for Use in Designing Buildings,

Structures and Foundations GES-014-03 Fireproofing of Vessels and Structural Steel GES-019 Design of Painting GES-020 Hot Insulation GES-021 Cold Insulation GES-024 Threads and Bolts and Nuts GES-025-01 Inspection GES-025-02 Alloy Verification

3. GENERAL

1) All pressure vessels except those listed below shall conform to the requirements of the ASME Boiler and Pressure Vessel Code, Section VIII, Division 1, including latest addenda, (hereinafter referred to as Division 1), together with the supplemental requirements described herein. Code stamp requirements will be specified on vessel data sheets and/or mechanical drawings, however vessels shall be constructed and inspected in compliance to the requirements of Division 1 as a minimum requirement.

a) VENDORs standard air receivers and pressure vessels furnished as part of proprietary or

standardized equipment shall conform to the applicable code requirements and the VENDORs standards for the design conditions.

b) Pressure vessels when part of the ASME Code Section I, Steam Generating Equipment

shall be designed in accordance with Section I of the ASME Code and the requirements of this specification.


Rev. 4


c) Vessels designed for pressure above 207 Barg (3000 psig) or those of special (proprietary)

design or construction shall conform to applicable ASME Code requirements and to the VENDORs proprietary design and construction practice for such equipment.

2) Vessels shall also conform to the requirements of any applicable local rules. In case of a conflict

between requirements in this specification, applicable code and local rules, the most stringent requirement shall apply.

3) Any deviation from the requirements herein shall be subject to approval by OWNER. 4) Individual Specification for Pressure Vessels of Process Unit shall be applied to all pressure

vessels in process units as supplemental requirements to this specification.

4. BASIC DESIGN

4.1 Drawings

1) Language: The language of all drawings, specifications and calculations shall be in English. 2) All welding and other fabrication details shall be shown in the VENDORs drawings. All welds

shall be detailed and/or identified by the use of the Standard Welding Symbols of the American Welding Society ANSI/AWS A2.4.

3) Units and Dimensions: All units shall be modified SI units in accordance with GES-001. Vessel

diameter shall be specified in millimeters rounded up to nearest 100 mm.

4) Data and Specifications: The OWNER will furnish the VENDOR with drawings or data sheets specifying the design conditions and showing the shape, dimensions, and material specifications for all primary parts, and certain construction details. In addition, the OWNER will supply such engineering data as required by the VENDOR to mechanically design and construct the vessel.

5) When OWNER requests the VENDOR to furnish a vessel conforming to the VENDORs

proprietary design, the materials of construction and other construction details shall be selected by the VENDOR based on the design conditions specified by OWNER.

6) VENDORs drawings shall include:


Rev. 4


a) OWNER item number, P.O. Number, and M.R. number b) Local rules (if applicable) c) References to Specifications and Codes: Also to include all OWNER specifications and

standards as applicable and VENDORs own standards. Copies of such standards shall be included with the submitted working drawings.

d) Material specifications e) Maximum allowable working pressure f) Maximum operating pressure (if specified) g) Maximum operating temperature (if specified) h) Minimum operating temperature (if specified) i) Design pressure j) Design temperature k) Minimum design temperature l) Postweld heat treatment (required or not) m) Radiography (full, spot or not required) and/or other inspection and testing requirements

and NDE requirements n) Shell joint efficiencies o) Head joint efficiencies p) Corrosion allowance


Rev. 4


q) Hydrostatic test pressure (both at shop and in field) with minimum permissible test temperature and quality of water.

r) Pneumatic test pressure (if required) s) Erection weight t) Operating weight u) Full water weight v) List of reference drawings w) Nozzle schedule and flange rating/design basis x) Vessel volume y) Insulation thickness z) Thickness of all components aa) Surface preparation and painting or other protective coating specifications. bb) Under Special Notes: VENDORs drawings shall also include the following notes as

applicable:

For Stainless Steel (S.S.) Vessels, galvanized parts or zinc coating shall not be used to avoid zinc dripping on S.S. during fire condition.

Hastelloy B., Monel or nickel and nickel alloy vessel shall be kept clean and away from

substances containing sulphur (e.g. lubricants). Lubricants containing sulphur shall not be applied to any alloy parts of the vessel.

Substances containing chlorine or which will decompose to hydrogen chloride shall not

be applied to any part of a vessel regardless of the material of construction of the vessel.


Rev. 4


4.2 Design Basis

4.2.1 Design Pressure

1) The design pressure specified in the design specification summary sheet shall be defined as the pressure at the highest point of a vessel in its operating position, and in its corroded condition when corrosion allowance is required by code or this specification. Alloy cladding thickness shall not be included in the calculated wall thickness required for design conditions. Additional pressure due to any static head of the liquid shall be considered in the design of the vessel.

2) Vessels shall be designed to withstand the specified Design Pressure at both the maximum and

minimum design temperature, including any additional loadings as specified under 4.2.2., the ASME Code and GES-014-01.

3) Vessels protected by safety valves shall be designed for a minimum internal pressure of 3.5 barg

or the maximum specified operating pressure plus 10% [1.75 bar (25 psi) minimum] when conventional or balanced (bellows) type safety relief valves are used, and operating pressure plus 5% [1.75 bar (25 psi) minimum] when spring pilot operated safety valves are used.

4) Vessels without pressure relieving devices shall be provided with an outlet which cannot be

completely blocked off. The minimum outlet opening shall be sized so that the maximum pressure which can be developed in the vessel is not greater than the design pressure.

5) Only those vessels actually subjected to external pressure in operation shall be designed for

external pressure. Vessels shall not be designed and protection shall not be furnished for vacuum caused by emptying water after hydrostatic tests. Vessel shall be designed for steaming out condition per GES-001.

6) Vessels subjected to partial operating vacuum shall be designed in accordance with UG 28(f)

for external pressure design and the design external pressure shall be given on the vessel name plate. Code stamping shall be provided only if specified on the vessel data sheet.

4.2.2 Design Temperature

1) Vessels shall have both a maximum and minimum temperature rating stamped on the vessel nameplate. The design metal temperature for vessels except for conditions as described under a and b listed below shall be at least equal to the maximum operating temperature of the fluid in the vessel after considering over pressure, unsafe and shutdown condition plus quenching or


Rev. 4


flashing, if such occurs, plus 14C (+25F), but in no case less that 150C (300F) unless a lower temperature is shown on the Design Specification Sheet as approved by OWNER.

a) When exposed to fluids before quenching or flashing occurs, the design metal temperature

for vessel parts such as inlets and the adjacent area shall be the temperature of the fluid before quenching or flashing occurs or the design metal temperature of the vessel, in zone, whichever is higher.

b) The design metal temperature for internally insulated vessels shall be based on the

temperature calculated using maximum operating fluid temperature, no wind, and 38C (100F) ambient temperature plus a minimum of 28C (50F) above the calculated metal temperature.

2) The minimum design temperature rating shall be the highest of the minimum temperature

permitted for any component. For vessels whose metal temperature in normal service is dependent on ambient temperature, the minimum design temperature shall be taken as the lowest one day mean temperature based for the local Al-Jubail Al-Sinaiyah weather statistics record temperature.

3) Vessels shall have a minimum design temperature equal to or lower than the anticipated

temperature (considering start-up, normal operating, upset and shutdown condition), but in no case higher than 3C (37F).

4.2.3 Design Loading and Condition

Vessels and their supports, including anchor bolts, shall be designed for the following combinations of loading and condition, shown in Table 1.

TABLE 1

COMBINATIONS OF LOADING AND CONDITION

Condition Loading

Normal Operation

(2)

Testing and Flushing (2) (3)

As Erected

(2) (14)

During Erection

(13) (14) Dead Load

(4)

(4)

(5)

(5) (12)

Internal and External Pressure

(6)

(7)

--

--


Rev. 4


Condition Loading

Normal Operation

(2)

Testing and Flushing (2) (3)

As Erected

(2) (14)

During Erection

(13) (14) Weight of Contents

(8)

(9)

--

--

Wind Load or Earthquake Load

(10)

(11)

(10)

--

Metal Temperature

D.T.

A.T.

A.T.

A.T.

New or Corroded

Corroded

New

New

New

Additional Loads and Forces

(15)

(15)

(15)

(15)

NOTES: 1) Abbreviations:

D.T = Design Temperature A.T. = Ambient Temperature

2) In operating position 3) Only when field testing or flushing is specified by OWNER. 4) All internals, insulation, fire proofing, piping and platforms attached to the vessels to be included. 5) All loose internals, insulation, fire proofing, piping and platforms attached to the vessels to be excluded. 6) In accordance with Subsection 4.2.1 design conditions specified. 7) Pressure including liquid head. 8) Weight of operating liquid to the maximum specified operating liquid level and of operating liquid on the trays and in the

packing to be considered. 9) Weight of water for testing or flushing. 10) Design wind load or earthquake load, whichever is greater (in accordance with Subsection 4.2.4) 11) One third of design wind load or one half of design earthquake load, whichever is greater. 12) Actual weight multiplied by a dynamic load factor of 1.2. 13) In accordance with OWNERs instruction. 14) Calculations may be omitted for smaller vessels when approved by OWNER. 15) Required only if specified by OWNER.

4.2.4 Wind and Earthquake Loads

1) Wind Loads

Wind pressure will be specified in GES-014-01. The shape factor 0.6 shall be used for cylindrical vessels.


Rev. 4


2) Earthquake Loads

Earthquake loads shall be based on the static seismic coefficient as specified in GES-014-01. 3) Tall vessels L/D > 15 shall be investigated for dynamic behavior (vibration) due to wind

excitation in accordance with ASME Paper No. 58-PET-13, 71-PET-36 or approved alternate.

Alternate: 5.45 x 10-6 D5 E < 1

L3 x W 15 D: Nominal/Average Diameter (mm) E: Modulus of Elasticity of Column material at design temperature (Mpa) L: Vessel height (mm) W: Weight of vessel and internals (kg)

4) The effective diameter to be used for vertical vessel wind design shall be:

De = 1.1 Di + 915 + 2(ts + ti) + Pf

Where: (De) is effective wind diameter (mm) (Di) is vessel inside diameter (mm) (ts) is vessel shell thickness (mm) (ti) is vessel insulation thickness (mm) (Pf) is insulated overhead line outside diameter (mm) [OD of top head nozzle plus

2 ti]. 915 accounts for ladders and platforms

NOTE: Do not use less than 150 for 2 (ti + ts) This effective diameter includes wind loads on platforms, ladders and piping. The 915 factor in the above equation may be deleted for small vessels that do not have platforms or ladders. In addition to the above effective vessel diameter, the top head platform contribution to the total wind load shall be: Fp = W Qf Where: Fp is the force on the top head platform (kilograms-force) W is the larger of 1.4 or the vessel outside diameter (meters) Qf is the wind pressure at the top head platform level (kgf/m2).


Rev. 4


The top head platform force is to be applied at 0.46 meters above the top head.

4.3 Allowable Stress

1) The allowable stress values for vessels shall be established by Table 2. For all design conditions: The maximum allowable longitudinal stress for support skirts shall be determined in accordance with ASME Section VIII, Division 1, Paragraph UG-23.

2) The basic allowable stresses for detail stress analyses shall be the maximum allowable stresses S

above, in lieu of stress intensity Sm of the ASME Code, Section VIII, Division 2; stresses shall be categorized and limited in accordance with the ASME Code, Section VIII, Division 2, Appendix 4.

3) The allowable bending stress of the base plate shall be 1600 kgf/cm2, for a combination of wind or

earthquake loads. 4) The allowable bearing stress for the concrete foundation shall be 60 kgf/cm2. 5) The allowable stresses for non-pressure parts shall be in accordance with ASME B31.3, except as

modified below:

a) Welds attaching non-pressure parts to the pressure shell and supports for important internal equipment such as cyclones or grids shall be designed to the allowable stress for pressure parts.

b) The allowable stress for anchor bolts shall be 1400 kgf/cm2, for a combination of wind or

earthquake loads. 6) Any unusual piping thrust loads and eccentric platform loads along with the earthquake loads and

wind loads shall be considered in design of vessel shell and skirt.


Rev. 4


TABLE 2

ALLOWABLE STRESS VALUES

Stress Condition

Loading

Category (Membrane

Stress)

Normal

Operation

Testing & Flushing

As Erected

During

Erection Internal Pressure

Tensile Stress

S

0.9.Y.S.

--

--

External Pressure

Buckling

Division 1, Paragraph UG-

28

--

--

--

C.L

A ________

B

Tensile or Com- pressive Stress

1.2S

S

0.9.Y.S.

1.2 S

S

1.2 S S

A ________

B

Compres- sive

Stress for Buckling

Division 1, Paragraph UG-23 (b)

A Shear 0.25 Y.S. x 1.5 0.25 Y.S. B Stress 0.25 x Y.S. -- x 1.5

Note: 1) Abbreviations

S = maximum allowable strength in tension Y.S.= minimum yield strength given by the ASME Code, Section II Part D. C.L.= combination loadings

2) Combination loading means

A: including wind or earthquake loadings B: excluding wind or earthquake loadings


Rev. 4


4.3.1 Vessel Rigging Analysis/Lifting Requirements

1) Impact Factor

Unless otherwise specified by the user, a minimum impact factor of 2.0 be applied to the lift weight for designing the lift devices. The basis for the lift weight must be established during the design phase of the vessel so that the design of lifting devices includes all components to be included in the lift. (e.g., trays, ladder/platforms, insulation, piping, etc.)

2) Vertical Vessels

Vertical vessel having height to diameter ratio greater than 8 and weight more than 11,500 kgs. shall be checked for the bending stress in the vessel shell/skirt. Calculated tensile stress shall not exceed 80% of the materials specified minimum yield strength at 38C of and calculated.

3) Welds

Shear stress for fillet welds on the lifting attachments to the vessel shell/head shall not exceed 0.55 times the code allowable stress at 38o C for the selected material.

4.4 Analyses

1) The deflection of vessels at the design wind load under normal operating conditions shall not exceed H/100, where H is the total height in mm. Earthquake loads need not be considered in connection with this deflection limitation.

2) Stresses in the vessel shell due to support lug or leg attachments shall be analyzed using the WRC-107.

3) Horizontal vessels on saddle supports shall be checked for buckling, local circumferential

bending and shear stress. The vessel shall be analyzed using Stresses in Large Horizontal Cylindrical Pressure Vessels on Two Saddle Supports by L. P. Zick for both, operating and hydro test, conditions.

4) The hydrostatic test pressure at the top of a vessel shall be in accordance with Division 1,

Paragraph UG-99 (c).

4.5 Corrosion Allowance

A corrosion allowance, as specified on individual data sheets and mechanical drawings, shall be added to the thickness calculated for the loadings and conditions in accordance with Table 1 as follows:


Rev. 4


1) In alloy, alloy lined, or clad vessels or sections of clad vessels or sections of vessels, all surfaces

of pressure parts, and nonpressure parts which are nonremovable and exposed to the contained media, shall either be fabricated of or protected by the alloy or alloy lining material specified for the vessel.

2) In unlined vessels or sections of vessels, all surfaces of pressure parts and nonpressure parts

welded directly to the pressure shell or those which are otherwise nonremovable and are exposed to the contained media, shall have the specified vessel corrosion allowance added to each surface.

3) On each surface of removable internal parts exposed to the vessel contents -- one fourth the

specified corrosion allowance shall be applied. However, corrosion allowance in GES-004 shall be applied for process units.

4) Unless otherwise specified on vessel drawings/data sheets, when the service conditions are such

that it is not practical to provide corrosion allowance by added base metal, the following shall be accomplished:

a) With prior written approval of OWNER, a corrosion resistant lining within 2 mm (5/64 in.)

minimum thickness shall be attached to the pressure parts; or b) Integrally cladding thickness or weld overlay or solid alloy material shall be used.

5) No unfired pressure vessel shall be of a plate thickness less than that indicated below

Min Thickness Excluding Corrosion

Allowance mm

Diameter Range (mm) Min. Thickness (include Corrosion Allowance, mm)

Carbon Steel or Low Alloy Steel

High Alloy Steel

914 mm dia. and under 6 5 3 2134 dia. and under, up to 914 mm dia.

9 5 3

3658 dia. and under, up to 2134 mm

12 5 3

Over 3658 mm dia. 14 5 3


Rev. 4


5. DESIGN AND FABRICATION DETAILS

5.1 Shell and Head Seams

1) All vessel seams shall be located to clear important internals. 2) Longitudinal seams in cylindrical and conical shells and all seams in spherical shells and built-up

heads shall be located to clear openings. 3) Where possible, circumferential seams in cylindrical and conical shells shall be located to clear

openings and reinforcing pads. When reinforcing pads are required and they cover seams, the seam welds that are to be covered by the pads shall be ground flush and 100% radiographically examined before attachment of the reinforcing pad. The alignment of the butted plates shall allow a proper fit-up of the reinforcing pad to the vessel shell.

4) Joints in horizontal vessels shall not be located coincident with or across saddle supports.

5.2 Design of Welded Joints

1) Pressure retaining shell, head, and transition section seams, nozzle and manway attachments to a shell, head, or transition section, and similar joints shall be full penetration double-welded joints except as noted in Paragraph 5.2.2 (Nozzles shall be inserted through the wall of the vessel; nozzles abutting the vessel wall shall not be used.) This requirements is not intended to prohibit reinforcing pad attachment details similar to ASME Section VIII, Division 1, Figure UW 16.1 (h), provided the requirements of UG-41 are met. Other joints are subject to approval by OWNER.

2) When sound back-welding is not feasible, single-welded joints utilizing a root pass of GTAW or

GMAW are required. 3) Temporary backing strips may be utilized if, after removal, the joint is examined visually for

contour and undercutting and for cracks by the magnetic particle or the liquid penetrant method of examination. These examinations shall be performed after any postweld heat treatment.

4) All nozzles shall be installed with full penetration and fusion welds.


Rev. 4


5.3 Reinforcement of Openings

1) Nozzle reinforcement shall be designed for the maximum allowable working pressure (MAWP) for which the vessel can be rated. The MAWP shall be determined by calculation; it shall not be assumed to the vessels design pressure. Nozzle reinforcement shall not limit the vessels MAWP.

2) The following reinforcing requirements shall apply to all vessels. These requirements do not

apply to openings that are not required to have reinforcement by ASME Section VIII, Division 1, Paragraph UG-36 (c) (3).

a) The total cross-sectional area of reinforcement required, A, shall not be less than :

A = d x t (square millimeters), where: d = the diameter of the finished opening in its corroded condition (mm), and t = the required thickness of the shell less corrosion allowance (mm), at the nozzle location.

All metal area within the limits of reinforcement may be considered as having reinforcing value as permitted by the code, unless otherwise specified on the drawings.

b) The strength of attachment welds joining the vessel wall and the reinforcement or any two

parts of the attached reinforcement shall be at least equal to the smaller of:

The strength in tension of the cross section of the area of reinforcement. The strength in tension of area A as defined in Paragraph a above.

3) Each reinforcing pad, or segment if more than one piece is used, shall be provided with one 1/4

inch NPT threaded hole. Welds in segmented two-piece reinforcing pads on cylinders and cones shall be in the vessels circumferential direction. The outside edge of reinforcing pads shall be ground or otherwise made reasonably smooth before welding to the vessel.

4) For vertical vessels that have a ratio of height (length between tangents) to inside diameter

(smallest diameter when vessel have more than one dia.) greater than 12, the reinforcement of openings in shell courses shall be calculated using the nominal thickness of the shell course under consideration minus corrosion allowance instead of the thickness required by Paragraph UG-37 of ASME Section VIII Division I.


Rev. 4


5.4 REINFORCEMENT AT SHARP CONE-TO-CYLINDER INTERSECTIONS

The reinforcement at junctions of conical reducers with heads, cylinders, or other conical reducers shall be designed for the MAWP for which the vessel can be rated. The MAWP shall be determined by calculation (see Paragraph 5.3). Cone-to-cylinder reinforcement shall not limit the vessels MAWP.

5.5 Heads and Transition Sections

1) The inside of radius of knuckles for conical transition sections, where knuckles are required, shall be as follows:

Cone to cylinder junction at large end.... 0.06 (Di + 2t) or 3t, whichever is larger

Where:

Di = the inside diameter of the adjoining cylindrical section t = nominal thickness

Alternate:

For knuckle thickness up to 19mm, 0.06 (Di + 2t)

For knuckle thickness above 19mm, 0.10 (Di + 2t)

2) An intermediate head attached to the shell shall conform to Division 1, Figure UW-13.1 (f) and

shall be provided with a vent hole, if specified on the specification sheet.

5.6 Nozzles, Manholes, Connections and Girth Joints

1) Flanges for external nozzles NPS 24 and smaller shall be in accordance with ASME B16.5 for the rating and type of facing specified. Flanges for external nozzles NPS 26 through NPS 60 shall be in accordance with ASME B16.47 Series B. For sizes over NPS 60, flange dimensions will be shown on vessel drawings or data sheets. With prior approval of OWNER, special flanges may be designed in accordance with ASME Section VIII, Division 1, Appendix 2.

2) Threaded or socket-weld couplings shall not be used, unless specified on the specifications

sheets.


Rev. 4


3) Manholes shall have a minimum nominal diameter of 24 inch with not less than 575 mm I.D. minimum unless specifically approved by OWNER per GES-001. All manhole covers and blind flanges weighing over 34 kg (75 lbs) shall be furnished with davit or hinge as specified on the drawings. Manhole opening in vertical plane shall be furnished with handgrips inside the vessel.

For small diameter vessels (


Rev. 4


9) Flanges shall be spot or full backfaced, as required by ASME B16.5. 10) All inside edges of nozzles and connections, whether flush or extended, shall be rounded off to a

minimum radius of 3 mm. 11) Vent holes shall be provided in any enclosed space of the slip-on flanges when vessels are

subject to postweld heat treatment. 12) Confined gasketed joint design shall be applied for nominal diameter larger than 610 mm and

having any of the following:

Pressure 21 kg/cmg or higher, temperature above 250 C or below minus 29 C, cyclic service or flat metal gasket.

13) Flanged connection shall NOT be provided inside the skirt volume, all nozzles shall be piped

without any flanged connection to the outside of the skirt. 14) If the Process dictated to have flanged connection inside the skirt volume, skirt vent shall be

provided, reference is made to Section 5.11. 15) When tongue and groove facing is used, the groove shall be in the nozzle flange, except when

the nozzle is located in the bottom head of a vessel, the groove shall be in the piping flange or blind cover.

16) The inside diameter of nozzles shall not be less than the inside diameter of the corresponding

size of double extra strong pipe for NPS 1 to NPS 3 nozzles inclusive, Schedule 160 pipe for NPS 4 to NPS 12 nozzles inclusive, and nominal diameter minus 2 inches for nozzles over NPS 12. Nozzles shall generally be flanged and preferable minimum size shall be NPS 2 inches. Use of nozzles 1 1/2 inch and below shall be approved by OWNER and where used shall be suitably attached and adequately reinforced. (For manway refer to Paragraph three of this section.)

17) Internal flanges for nonpressure connections may be of plate construction with machined flat

faces. 18) Flanged nozzles NPS 2 and smaller shall be long welding neck construction.


Rev. 4


5.7 Supports

1) Where vessels are supported on concrete saddles, corrosion plates shall be provided between the saddle and vessel. These plates shall be a minimum 6 mm thick, shall extend 50 mm beyond the periphery of the bearing area of the concrete saddle and shall be continuously welded to the vessel. A 6 mm vent hole shall be provided in each plate. These holes shall be filled with a heavy grease after the vessel has been pressure tested.

2) Where vessels are supported on steel saddles, the saddle pads shall be continuously welded to

the vessel. The saddle pad shall be vented with a 6 mm hole. 3) Bearing plates, 6 mm minimum thickness and smooth finished, shall be furnished by the

VENDOR for installation under supports where there are slotted holes for anchor bolts to provide for shell expansion. For heavy equipment, special material and other considerations are required to reduce the friction.

4) The center line of the skirt and the corroded shell plate (bottom course) shall be approximately

coincident except for conical skirts attached to the shells of vertical vessels. All support skirts shall have approximately the same mean diameter as the bottom head and shall be attached with a smooth flat-face weld.

5.8 Anchor Bolts

Anchor bolts holes shall straddle a position 0o - 1800 of the centerline.

5.9 Insulation Supports

Support rings shall be provided for the vessels to be insulated. Vessels with stiffening rings or shell flanges may substitute these for the insulation supports, if practical. Insulation and insulation supports shall be in accordance with GES-020 or GES-021, as applicable.

5.10 Access Opening

Skirt supports shall be provided with two round access openings spaced 180 degrees apart and reinforced with sleeves. The openings shall not be smaller than the following: Vessel OD, mm (inches) Opening Diameter, mm (inches) > 610 (24) = 762 (30) 203 ( 8) >762 (30) = 914 (36) 254 (10) >914 (36) = 1219 (48) 406 (16) >1219 (48) = 1524 (60) 456 (18) >1524 (60) 610 (24)


Rev. 4


5.11 Vent in Skirt

In service of the hydrocarbons or other combustible liquids or gases the skirts shall be provided with minimum vent holes as high as possible 180 degrees apart. the vent holes shall clear head insulation. (Refer to Table 3 for quantity). Coupling or pipe may be used for the sleeve.

TABLE 3

SKIRT VENTS

SKIRT DIAMETER AT BASE

NO.

REQ.D

PIPE SIZE

PIPE

SCHEDULE UNDER 3-0 2 3 40 3-0 TO 6-0 4 3 40 61 TO 10-0 4 4 40 10-1 TO 14-0 6 4 40 14-1 TO 18-0 8 4 40 OVER 18-0 4 SIZE ON

APPROX. 7-0 SPACES

40

5.12 Top Davit

Vessels equipped with trays, large internal pipes, packing material and safety valves, shall be furnished with a top davit. The davit shall be designed to carry a load of 1/2 ton, to enable use of a winch basket during maintenance periods. Lifting hook of davit shall vertically clear all vessel attachments and working platforms by 1 meter. Vessel design shall consider the additional moment due to operation of the davit.

5.13 Non-pressure Parts

Where possible all internal and external structural attachments shall clear pressure seam welds by at least one plate thickness. If unavoidable, these attachments may be cut at the seam weld portion to avoid any weld intersection. If continuous overlap is unavoidable, the portion of the pressure seam weld to be covered shall be ground flush and 100% radiographically examined before attachment is welded on.

5.14 Grounding Clip

Vessels are to be provided with a grounding clip.


Rev. 4


5.15 Nameplate

1) Along with the ASME minimum requirement per UG-119, additional information shall be required as follows:

a) Maximum allowable working pressure b) Maximum operating pressure (if specified) c) Maximum operating temperature (if specified) d) Minimum operating temperature (if specified) e) Design pressure f) Design temperature, maximum and minimum g) Hydrostatic test pressure (both at shop and in field) with minimum permissible test

temperature and quality of water h) Weight of unit empty and weight of removable item(s) i) OWNER equipment item number j) Internal volume of vessel.

2) All vessels shall be furnished with a stainless steel nameplate. Required markings shall not be

stamped directly on the vessel. Nameplates shall be installed on the VENDORs standard nameplate holder of sufficient length to project at least 25 mm (1 inch) beyond the vessel insulation.

3) The nameplates of vertical vessels shall be located on the shell above the lowest manhole. On

horizontal vessels, they shall be located in the center of a head or above a manhole in a head. The nameplate location shall be shown on the VENDORs drawings.

6. MATERIALS

6.1 General

1) The selection of material for pressure parts shall be based on the service and design temperature and the material shall be in accordance with one of the appropriate specifications listed in Section II of the ASME Code except that for vessels subject to pressurization at metal temperature below 16oC (60oF) the material shall be selected, as a minimum requirement, in accordance with Appendix 3, Table I and II. Vessel material shall be new and as specified on the drawings.

2) Materials shall conform to ASTM material specifications and shall normally be limited to those listed in ASME Section II for pressure parts.


Rev. 4


3) Substitute material with equivalent chemical composition and mechanical properties to those listed in ASME Section II, Part D can be used with the approval of OWNER. Allowable stress in tension for the substitutes shall be established in accordance with Division 1, Appendix P. However, when using JIS material as a substitute, the allowable stress values permitted in JIS B 8243 may be used. ASME SA-36 material shall not be used for pressure parts.

4) Materials for support skirts welded directly to the vessel shall be selected as follows:

Design Temperature Skirt Material Over 343o C and below 16oC Unless noted otherwise on vendor drawings, at least 600

mm of the upper portion shall be of the same material as the vessel. The lower portion may be per ASTM A-283 Grade C, A-36 or A-285 Grade C.

From 16oC to 343oC ASTM A-283 Grade C, A-36, or A-285 Grade C.

5) The materials of the lifting lugs for vertical vessels shall be killed steel.

6) Materials subject to welding shall be of weldable quality. Carbon content of all carbon steel pressure parts shall be less than 0.3%.

7) Consumable insert material shall conform to the nominal chemical composition requirements of the base metal material standard. The use of consumable insert requires the advance written approval of OWNER.

8) The heat treatment for clad plate conforming to ASME SA-263 and SA-264 shall be done at the mill.

9) All clad plate, including explosion clad plate, conforming to ASME SA-263 and SA-264 shall be cold flattened, if required, only after final mill heat treatment and descaling.

10) Explosion clad plate not conforming to ASME SA-263 or SA-264 shall be stress relieved in accordance with the times and temperatures required by the applicable code and Paragraph 7.7 of this specification before commencing fabrication operations. Any required cold flattening shall be performed before stress relieving. The use of explosion clad material requires the advance written approval of OWNER.

11) The minimum shell or head thickness, exclusive of corrosion allowance, shall be 5 mm (3/16 inch) for carbon and low alloy steel vessels and 3 mm (1/8 inch) for high alloy steel vessels. Minimum composite thickness of clad shell or head materials shall be 10 mm (3/8 inch).


Rev. 4


12) When specified on the drawings, alloy verification shall be performed using a portable X-Ray spectrometric analyzer or other suitable equipment. This verification shall be performed during production at such points that will ensure the correct material has been used. Certified Material Test Reports shall not be an acceptable alternative to this verification. Unless otherwise specified in the Purchase Order, OWNERs inspector will perform this verification.

13) Pressure retaining material shall meet the tensile strength requirements of the applicable material specification after all the anticipated heat treatments including one extra PWHT cycle for a potential future field repair.

14) Welding electrodes and rods shall be selected in accordance with GES-003-06.

6.2 Linings

1) Vessels requiring linings shall be either weld overlaid or integrally clad. Strip-type linings shall not be used unless specified by OWNER.

2) When permitted, strip type lining shall be attached to the shell or nozzle circumferentially and

shall be designed so the width of the strips does not exceed that shown in Table 4. The welds between the strips shall be at least 6 mm (1/4 inch) and not more than 12 mm (1/2 inch) in width. Where vessel temperatures exceed 427oC (800oF), the width of strips will be given on the design drawings.

TABLE 4

STRIP WELDED LININGS

Vessel Design Temperature Width of Strips 343oC (650oF) and under 114 mm (4-1/2 in) Over 343oC (650o) to 427oC (800oF) 102 mm (4 in)

Vessels with integrally clad linings shall be made of plate clad with the required lining material at the steel mill in accordance with the applicable material specifications. Explosion clad material shall not be used without the advance written consent of OWNER. Clad plate shall be shear tested at the mill in accordance with SA-263 or SA-264 as specified on vessel drawing.

6.3 Bolting

1) Bolting material will be as listed in Table 5.

2) Unless otherwise specified, stud bolts shall be threaded full length.


Rev. 4


3) Bolt heads for type CB bolting shall be of heavy hexagonal (preferred) or regular square series.

4) Carbon steel and low alloy steel bolts on flanges shall be precoated with appropriate fluorocarbon polymer against corrosion up to applicable temperature limits.

5) Bolts up to and including 1 diameter shall comply with UNC standards, bolts 1-1/8 diameter and larger shall have an 8 UN thread, in accordance with ASME B1.1. Bolting material shall be in accordance with Table 5. Stainless steel bolting if specified for cyclic service shall be strain hardened type (e.g.: A193 B8 class2).

TABLE 5

BOLTING MATERIAL SPECIFICATIONS

OWNER Bolt ASME Specifications

Bolting Type Material Bolts Nuts B5 5Cr SA193 Gr B5 SA194 Gr 3 B6 12Cr SA193 Gr B6 SA194 Gr 6 B7 Cr-Mo SA193 Gr B7 SA194 Gr 2H B8 18Cr-8Ni

Type 304 SA193 Gr B8

Class 1 SA194 Gr 8

B8M 18Cr-10Ni-2Mo Type 316

SA193 Gr B8M Class 1

SA194 Gr 8M

B8T 18Cr-8Ni Type 321

SA193 Gr B8T Class 1

SA194 Gr 8T

B8C 18Cr-8Ni Type 347

SA193 Gr B8C Class 1

SA194 Gr 8C

B16 Cr-Mo-V SA193 Gr B16 SA194 Gr 4 CB Carbon Steel SA307 Gr B per SA307 HS Carbon Steel SA325 per SA325

LOW TEMPERATURE SERVICE B8LT 18Cr-8Ni

Type 304 SA320 Gr B8

Class 1 SA194 Gr 8

L7 Cr-Mo SA320 Gr L7 SA194 Gr 4

6.4 Gaskets

1) Gaskets will be as specified in OWNERs unified piping specification. The process of manufacture and any dimensions or tolerances not covered by the dimensional standards shall be in accordance with the VENDORs standards.

2) Pressure 21.4 Barg or higher, temperature above 250oC or below minus 29C, cyclic service or

flat metal gasket. Gasket material shall be in accordance with OWNERs unified piping specification.


Rev. 4


6.5 Supplementary Materials

1) The VENDOR shall furnish blind flanges, gaskets, and bolting for manholes, handholes, flanged vessel ends, and for all other nozzles indicated on the drawings as requiring closures.

a) All gaskets furnished shall be new and shall be installed prior to the shipment of the vessel.

Gaskets which have been used for test purposes shall be replaced as specified in Paragraph 9.6.6.

b) Two spare gaskets shall be furnished for each manhole, handhole, and flanged vessel head.

7. FABRICATION

7.1 General

The VENDOR shall carefully carry out thermal and workmanship control during welding, hot forming, heat treatment and other shop fabrication based on the VENDORs quality control system. Substances containing sulphur (e.g. machining lubricants) should not be applied to Hastelloy, monel, nickel or nickel alloy parts. Substances containing chlorine or which will decompose to hydrogen chloride (e.g. coatings to prevent adhesion of weld spatter) shall not be used on any material.

7.2 Cutting

Shear cutting is not permitted for plate materials to be used for pressure retaining parts.

7.3 Repair Welding of Defects in Material

Repair welding of defects in material shall be performed using a qualified procedure, after approval by OWNER.

7.4 Cold Forming

Cold formed shell and head plates shall be stress relieved in accordance with the requirements of Paragraph UCS-79 of Division 1.

7.5 Preparation for Welding

1) On alloy clad plates, if flame cutting is used for preparing plate edges, any flame-gouged areas at the junction of the alloy and the base metal shall be repaired by stripping the cladding back at least 10 mm (3/8 inch) from the gouged area and building up the base metal with weld deposits and then the clad surface with alloy weld metal.


Rev. 4


2) Weld metal shall not be used to build up the edges of plates that are too short or those that contain large cavities without advance written approval of OWNER.

3) The maximum allowable gap between nozzle and manhole reinforcing pads and the curvature of

the vessel shells or heads before welding shall be 3 mm (1/8 inch). 4) The weld bevels of stub end nozzles shall be in accordance with ASME Section VIII for the

size, schedule, and style of bevel specified. 5) All weld bevels in material 38 mm (1-1/2 inch) thick and over shall be examined by the

magnetic particle or liquid penetrant method. Any laminations exceeding the limits specified in Paragraph 9.3 of ASME SA-20 shall be repaired. Application of Paragraph 9.3.5 of ASME SA-20 requires OWNERs advance written approval.

7.6 Welding

1) Welding shall be in accordance with the applicable code and GES-003-06. 2) Fabrication involving welding shall not be sublet to others without advance written approval of

OWNER. 3) Welding shall normally be carried out in a flat position. 4) For double welded butt joints, the reverse side of the root pass shall normally be prepared by

gouging or chipping, to secure sound metal at the base of the weld metal first deposited, before applying weld metal from the reverse side. These requirements are not intended to prohibit any welding process, approved by OWNER, by which proper fusion and penetration are otherwise obtained and by which the base of the weld remains free from impurities.

5) No welding is permitted on the pressure retaining parts after postweld heat treatment, except as

permitted by Division 1 and when approved by OWNER in writing. 6) Zinc-coated/galvanized or painted/components shall not be welded to stainless steel or nickel

alloy parts. 7) All weld slag shall be removed from austenitic stainless steels and nickel-iron-chromium alloy

material welds and parts by grinding or blast cleaning when the design metal temperature is above 400oC (750oF) to avoid the possibility of corrosion at elevated operating temperatures.


Rev. 4


8) Temporary attachment welds on pressure shells shall be removed. The surface under such

welds and under backing rings which have been removed shall be properly conditioned to eliminate surface stress raisers. Such surfaces shall be examined by either the magnetic particle or liquid penetrant method of examination when the surface material is carbon steel with a design metal temperature below 0oC (32oF), austenitic alloy steel with a design metal temperature above 400oC (750oF), or ferritic alloy steel. When the surface material is carbon steel with a design metal temperature of 0oC (32oF) and above, such surfaces shall be so examined only if attachment weld surfaces are required to be examined by Table 7.

9) Arc strikes on the pressure shell shall be minimized. When they occur, the surface shall be

properly conditioned to eliminate surface stress raisers. Such surfaces shall be examined by either the magnetic particle or liquid penetrant method of examination. Any defects found shall be removed and the surface repaired and re-examined.

10) Brinell Hardness of the weld metal and heat affected zone (HAZ) shall not exceed the limits set

in Table 6. TABLE 6

MATERIAL P NUMBER MAXIMUM BRINELL HARDNESS P1 Groups 1, 2, 3 200 P1 Group 4 250 P3, P4 225 P3, P4 225 P5 235 P6, P7 240 P10A, P10B 225

See weld overlay requirements in GES-003-06.

11) Weld overlay shall be applied circumferentially and it shall be relatively smooth with no notches,

flaws, or undercuts that would act as stress raisers. Small bore nozzles may be overlay welded longitudinally followed by grinding or machining to a smooth surface.

7.7 Post Weld Heat Treatment

1) When postweld heat treatment is required, the entire vessel shall be given the final postweld heat treatment in an enclosed furnace. When the entire vessel cannot be postweld heat treated in a furnace because of its size, or because it is finally fabricated in the field, the final postweld heat


Rev. 4


treatment may be performed locally outside of a furnace. The sections that are locally postweld heat-treated shall be sufficiently insulated (complete circumferential band) to ensure that the shell is not overstressed due to temperature gradients in area of local PWHT.

2) Vessels shall be heat treated in accordance with Paragraph. UCS.85 of Division 1 and the

VENDOR shall submit their specification with stress relieving drawings and procedure for OWNERs review.

3) Postweld heat treatment for welds between dissimilar metals shall conform to the requirements

of the material having the more stringent requirements and shall be verified by the Procedure Qualification Tests. The proposed postweld heat treatment for welds between ferritic and austenitic steels shall be reviewed by OWNER.

4) Local postweld heat treatment shall not be performed without advance written approval of

OWNER.

5) P-3 (C-Mo and Mn-Mo) materials shall be postweld heat treated at a temperature of 593oC (1100oF) minimum. Note 1 to Tables PW-39 of ASME Section I, UCS-56 of ASME Section VIII Division 1, and AF-402.1 of ASME Section VIII Division 2 shall not apply to P-3 (C-Mo and Mn-Mo) materials.

6) P-4 (Cr-Mo) materials shall be postweld heat treated at a temperature of 660oC ( 15oC)

minimum. P4 materials shall be ordered as normalized and tempered condition. Tempering temperature shall be 30 C higher than PWHT temperature. PWHT temp for P4 materials shall be reviewed (and lowered if necessary) in line with this requirement.

7) Plate, seamless heads, parts of built-up heads, and similar pressure retaining parts subjected to

cold or hot bending and forming shall be heat treated as follows:

a) As required by the applicable code and the applicable material specification. b) The hot forming temperature may be used as the normalizing temperature if the forming

temperature is at or above the normalizing temperature at the completion of forming. c) Where the code or specification requires normalizing, the hot-formed parts which do not

meet the requirements of Subparagraph 7.7.6.b above shall be normalized after forming. Material shall be re-tested and re-certified after normalizing.


Rev. 4


8. INSPECTION AND TEST

8.1 General

Vessels shall be subject to free access inspection by a representative of OWNER during fabrication. The inspection and test requirements covered by this specification are summarized in Appendix 1.

8.2 Material Inspection

Material shall be identified by a mill certificate and checked to ensure that there are no harmful defects.

8.3 Welding Inspection

1) The configuration and dimensions of prepared edges for welding shall be as those specified in the drawing.

2) Root fit-up and joint alignment shall be checked before welding. 3) Any back chipped surface of the root pass (for all seams) shall be visually inspected to ensure

that there are no harmful defects. 4) All weld surfaces shall be visually inspected to ensure that they are free from undercut, overlap,

irregular bead, unsuitable reinforcement, and other defects indicative of poor workmanship. 5) For single butt-welded joints, a visual inspection shall be made prior to the subsequent welding

to check for complete penetration and fusion at the root of the joint. 6) Samples of production weld overlay shall be taken to confirm chemical analysis to the required

depth. Samples shall be taken as follows to represent both manual and automatic overlay welding:

a) one sample from each automatically overlaid vessel part/section (e.g. each shell ring, head,

nozzle, cone, etc.). b) two samples from each manually overlaid vessel part/section and each manually overlaid

seam (longitudinal, girth and nozzle welds).

7) A quantitative chemical analysis shall report all elements for which specific values are given in ASME Section II, Part C.


Rev. 4


8) Acceptance criteria shall be that the deposited overlay have the chemical composition of the

applicable filler metal as specified in ASME Section II, Part C. In the case of low carbon grade stainless steels, the percent carbon shall not exceed 0.040%.

9) The production welds attaching welding pins or studs for external insulation or fireproofing

supports shall be tested by tapping lightly with a hammer. 10) Welds in any part of vessel, regardless of material or thickness, that is subjected to working by

any means, including spinning, pressing and rolling, shall be given a complete radiographic examination and either a magnetic particle or liquid penetrant examination after completion of the working and before further fabrication is performed when the ration of thickness to local radius of the worked part is greater than 5 percent.

11) Welds with defective areas shall have:

a. the defect removed b. confirmation of defect removal by magnetic particle or liquid penetrant examination c. repair welding using qualified welding procedures d. re-postweld heat treatment if originally required e. re-radiographed if originally required f. final weld surface re-examined by magnetic particle or liquid penetrant examination

8.4 Dimensional Inspection

1) Prior to the inspection under witness by OWNER, the VENDOR shall prepare the dimensional inspection data for the parts required by this specification, as well as parts particularly specified.

2) The measurement of the plate thickness shall be made as follows:

a) The thickness of the cylindrical shell shall be measured at one point per each ring. b) The thickness of the formed head shall be measured at one point for each knuckle and skirt

portion.

3) When pre-assembly is specified by OWNER, internal parts shall be checked for fit up and alignment as installed to the vessel.


Rev. 4


4) Vessel camber shall be measured by laying the vessel in a horizontal position and using parallel strings method. Two directions, 90 degrees apart, shall be measured by turning the vessel.

5) Anchor bolt offset between the upper plate and lower plate of the base block shall be checked

to facilitate smooth erection in the field. 6) The top davit shall be preassembled to check both the location and smooth operation. 7) Vessels containing cartridge tray assemblies shall be checked with a template, to ensure smooth

insertion and withdrawal. The minimum diameter of the template shall be the specified inside diameter of the vessel minus 6 mm.

8) Unless otherwise noted on the drawings, dimensional tolerances shall conform to the

requirements of the applicable code or Appendix 2 of this specification, whichever is most stringent.

9) Dimensional inspections shall be performed after postweld heat treatment. 10) The tolerances on the specified thickness of the alloy on integrally clad plate shall be given in

Table 7.

TABLE 7

CLADDING TOLERANCES

SECTIONS TOLERANCE FOR THE CLAD THICKNESS NOMINAL THICKNESS MINIMUM THICKNESS

Flat plate as rolled, cylindrical & Under Tolerance 2% Under Tolerance 0% conical sections after rolling and

other formed sections Over Tolerance

(by Vendor) Over Tolerance

(by Vendor)

8.5 Non-Destructive Examination

8.5.1 Radiographic Examination

1) When radiography is not specified on the vessel drawing or data sheet, vessel seams shall be spot radiographed as a minimum requirement.

2) Spot radiography shall be in accordance with Division 1; any additional radiography shall be made, if necessary, so that at least one spot is examined for all seams defined as category A or


Rev. 4


B in Division 1. Spots shall be selected to examine welds representing each welding procedure specification utilized on each vessel.

3) Radiographic film shall be fine grain, high definition, high contrast film, Kodak AA or equivalent. Film density shall be within a range of 2.0 or 3.0 as determined by film density specimens or by densitometer.

4) Welds in any part subjected to severe working (ratio of thickness to local radius greater than 5%) by any means shall be given a complete radiographic and either magnetic particle or liquid penetrant examination after the completion of the severe working and before further fabrication is performed.

5) Main longitudinal, girth, and head seams of vessels built of the following materials shall be 100% radiographed:

a. carbon steel over 19 mm (3/4 inch) thick having a specified minimum ultimate tensile strength greater than 4921 kg/cm2 (70,000 psi).

b. all chromium-molybdenum steels having over % (nominal) chromium

c. austenitic steels over 19 mm (3/4 inch) thick.

8.5.2 Magnetic Particle and Liquid Penetrant Examination

1) Fillet welds on intermediate heads shall be examined by the magnetic particle or liquid penetrant method after hydrostatic testing.

2) Austenitic materials shall be inspected by the liquid penetrant method.

3) Internal and external finished weld surfaces shall be either magnetic particle or liquid penetrant examined in accordance with Table 8 using the procedures of ASME Section V, Articles 6 and 7 respectively. Evaluations of indications shall be in accordance with ASME Section VIII, Division 1, Appendices 6, 7, and 8. Examination shall be done after completing all required postweld heat treatment, except weld surfaces which will become inaccessible by reason of welded closures which themselves require postweld heat treatment shall be examined before such closures are welded. When the vessel wall thickness is greater than 51 mm (2 inches), the examination of accessible surfaces shall be done after the required pressure test is completed.

4) When liquid penetrant examination is required, it shall be performed on all accessible weld surfaces. Any surface irregularities which interfere with the examination shall be removed by grinding, machining, or wash-blending with gas tungsten arc welding (GTAW).


Rev. 4


5) All weld overlay, whether by manual or automatic procedures, shall be liquid penetrant examined in accordance to the methods described in ASTM E165. When the overlay involves two passes and the procedure uses an intermediate heat treatment with cooling to room temperature prior to applying the second layer, each layer shall be examined. Where overlay is to be machined, such as in nozzles and flange facing, machined surfaces shall be examined. If 100% of the overlay is examined prior to the final postweld heat treatment, the overlay shall be spot examined (no less than 10% of the surface) after heat treatment. Spot examination shall also be conducted after shop hydrostatic testing. Any surface irregularities which interfere with the examination shall be removed by grinding, machining, or wash-blending with gas tungsten arc welding (GTAW).

TABLE 8

EXAMINATION OF WELD SURFACES

TYPE OF REQUIRED SURFACE EXAMINATIONS

(MT OR PT) VESSEL MATERIAL Level of

Radiography (3)

Longitudinal and Girth Welds

Nozzle Welds

(1)

Attachment Welds

(2) Carbon & low alloy steels with

Not postweld heat treated

Spot Full

No No

No Yes

No No

% (max.) nominal chromium content

Postweld heat treated

Spot Full

No No

No Yes

No Yes

Low alloy steels over % nominal chromium content

Full or Spot No Yes Yes

Austenitic steels with DMT* less than or equal to 400oC (750oF) and thickness 19mm (3/4in) or less

Spot Full

No No

No Yes

No No

Austenitic steels with DMT* greater than 400oC (750oF) or thickness over 19mm (3/4 in)

Full or Spot Yes Yes Yes


Rev. 4


NOTES TO TABLE 8:

*Design Metal Temperature

1. Nozzle welds include the welds between nozzle and the reinforcing pad, vessel and the reinforcing pad, and the nozzle and vessel under the reinforcing pad. Welds under the reinforcing pad shall be examined before the pad is attached.

2. Attachment welds include structural support, external clips, tray support, and skirt and saddle attachment welds.

3. Longitudinal and girth welds.

8.5.3 Ultrasonic Examination

Ultrasonic examination shall be performed as follows:

1) Plate material greater than 51mm (2 inches) but less than 102 mm (4 inches) in thickness shall be ultrasonically examined in accordance with SA-435.

2) Plate material 102 mm (4 inches) thick and greater shall be ultrasonically examined in accordance with SA-435, supplementary requirement S1.

3) Integrally clad plate with a composite thickness greater than 38mm (1-1/2 inches) but less than 102 mm (4 inches) in thickness shall be ultrasonically examined in accordance with SA-578, supplementary requirement S6.

4) Integrally clad plate with a composite thickness of 102 mm (4 inches) and greater shall be ultrasonically examined in accordance with SA-578, supplementary requirements S1 and S6.

5) Forged products (except cylindrical shell rings) 102 mm (4 inches) thick or greater shall be ultrasonically examined in accordance with SA-388. Forged cylindrical shell rings greater than 51 mm (2 inches) thick shall be ultrasonically examined in accordance with SA-388. Thicknesses of forgings shall be as defined in ASME Section VIII, Division 2, Paragraph AM-200.2.

6) All nozzle-to-vessel welds in solid wall vessels or vessel sections (not layered construction) greater than 51 mm (2 inches) thick that are not radiographable shall be ultrasonically examined after PWHT.


Rev. 4


Defects detected during ultrasonic examination exceeding the acceptance standards of the applicable code ultrasonic examination specification may be repaired only with OWNERs advance written approval. Failure to obtain OWNERs approval prior to repair of such defects shall be cause for rejection of the material.

8.5.4 Impact Test Examination

The following carbon and low alloy steel material vessel components shall be impact tested using Charpy V-notch test specimens:

1) All plate material 76 mm (3 inches) thick and over

2) All forgings 76 mm (3 inches) thick and over

3) Welds in material 76 mm (3 inches) thick and over (production impact test plates for the weld metal and heat affected zone). The impact test temperature shall be the lower of the minimum vessel design temperature or 0oC (+32oF). Impact values shall meet the requirements of ASME Section VIII. The test specimens shall be subjected to the same heat treatment cycles (time and temperature) as the completed vessel.

8.6 Pressure Test

1) All vessels shall be hydrostatically tested in accordance with the applicable code. However, ASME Section I and Section VIII Division 1 designed, shop-fabricated vessels shall be hydrostatically tested in the VENDORs shop at 1 times the maximum allowable pressure (new and cold). The test pressure and the part limiting the test pressure shall be shown on the VENDORs drawings.

2) Testing of vessels partially or completely filled with air is not permitted unless approved by OWNER. When such testing is approved, the test pressure shall be in accordance with Division 1, Paragraph UG-100 and radiographs shall be taken of at least 20 percent of welds defined as category A in Division 1

3) Before the hydro test, all internal surfaces shall be cleaned by sweeping, vacuum cleaning, or other methods so the vessel will be free of welding slag and flux, weld rod stubs, loose scale, dirt, and debris.

4) Clean fresh potable water shall be used for all tests unless otherwise specified by OWNER. Special precaution shall be taken to prevent stress corrosion cracking of stainless steel. Vessels fabricated of austenitic stainless steel must not come in contact with chlorides. Water used to test and wash these (stainless steel or stainless steel clad) vessels must have less than 25 PPM of chloride content.


Rev. 4


5) All water shall be drained after hydrostatic testing. Any standing water in austenitic stainless steel or austenitic stainless clad vessels shall be removed by blowing with air or by swabbing; heat or hot air shall not be used for drying.

6) Attached sleeve-type liners, including cover strips, and nozzle liners shall be tested at 1.75 kg/cm2 (25 psig) minimum in accordance with ASME Section V, Article T-1031 and T-1032 by introducing dry air between the lining and the base metal. The test shall be conducted before postweld heat treatment and before pressure testing of the vessel. Any liquid which may have become trapped between the lining and the base metal shall be completely removed and all test holes drilled in the alloy liner or base metal shall be sealed by welding.

7) Each nozzle reinforcing pad or each segment thereof and similar attachments shall be tested prior to the vessel pressure test at 1.05 kg/cm2 (15 psig) in accordance with ASME Section V, Article T-1031 and T-1032 with dry air. All welds inside and outside the vessel shall be inspected during the test. Test holes in pads shall be left open after the test.

8) The service bolting and ring joint gaskets to be furnished with the vessel may be used for testing. Any material damaged during the test and all types of service gaskets other than ring joints used in the test shall be replaced by the VENDOR with new material. Austenitic service bolts shall not be used in the shop test.

9) Following the application of test pressure, a visual inspection for leaks shall be performed at a pressure not less than the design pressure or two-thirds of the test pressure, whichever is greater. This pressure shall be held for one hour per 25 mm (1 inch) of maximum shell or formed head thickness, with a one hour minimum and a five hour maximum.

10) All vertical vessels and towers shall be designed for field hydro test in vertical position.

8.7 Rejection

1) Completed vessels, parts of vessels, or materials containing defects originating with the VENDORs design, materials, or workmanship; or that are not in complete compliance with the requirements of the Order will be rejected.

2) Discovery of conditions warranting rejection, after inspection and acceptance of the vessel by OWNER, does not relieve the VENDOR of his responsibility to comply with the Order.

8.8 Postweld Heat Treatment Check

The VENDOR shall check that the postweld heat treatment has been correctly performed, and that the temperature readings conform to the requirements of this specification.


Rev. 4


8.9 Shipping Preparation Check

The following items shall be checked:

1. Cleaning, draining, drying, and blanking 2. Supports for shipping. 3. Protection of all openings for flanged connections, beveled ends and all machined surfaces. 4. Markings 5. Nameplate data 6. Protection of austenitic S.S. from sea water exposure.

8.10 Inspection Report

1) Data reports for inspection items specified by this specification shall be kept for review by OWNERs inspector.

2) Inspection reports to be submitted for record shall include the following:

a) VENDORs data report b) Materials mill certificates c) Postweld heat treatment recording chart d) Non-destructive examination records e) Results of dimensional inspection f) Pressure test records g) Welding procedures and welders qualifications report h) Manufacturers Design Report (MDR) for vessels requiring Code Stamp.

9. SHOP PAINTING

1) Before shipping, all exposed surfaces of vessels and their supports, except machined surfaces, shall be painted in accordance with GES-019 (GES for painting).

2) Austenitic alloy steel and nickel-iron-chromium alloy material parts with design metal

temperatures above 400oC (750oF), except as required by GES-019, shall be kept free of paint to avoid the possibility of corrosion at elevated operating temperatures. All traces of paint which accidentally spatter on such parts shall be promptly removed.


Rev. 4


10. PREPARATION FOR SHIPMENT The preparation for shipment shall be as follows:

1) The vessel shell be drained and dried immediately after hydro test. Vessel shall be cleaned thoroughly so that it is free from any debris, dirt and foreign matter before shipment.

2) The VENDOR shall be responsible for suitably packaging each vessel or component and adequately supporting and securing all vessel internals to protect from damage or loss during handling and shipment in accordance with the Order and the following requirements:

a) Packages shall include lifting lugs or designated lifting points.

b) Each vessel, crate or container shall be clearly identified by painting or stenciling the receiving address, purchase order number, equipment item number, etc. according to OWNERs instructions.

c) Orientation shall be marked on the top, middle, and bottom portions of the shells at 0, 90, 180, and 270 respectively, with white paint. The orientation mark shall be a minimum of 300 mm long and maximum 2.5 mm wide.

d) Internals, clips, lugs, or other similar attachments which are removable and are to be assembled by others shall be marked with piece numbers for identification in assembly and match-marked.

e) Special tools shall be separately boxed, shipped and identified with the vessel on which they are to be used and the boxes marked as special tools.

3) For vessels that have been postweld heat treated or having a thermoplastic lining, the following sign shall be painted on the vessel after heat treatment:

NO WELDING PERMITTED ON THIS VESSEL

The sign shall be in letters approximately 76 mm (3 inches) high painted with white paint.

On vertical vessels, this sign shall be located on two opposite sides near the bottom tangent line and repeated at approximately each 3050 mm (10 feet) of height, but rotated 90 degrees.

On horizontal vessels, the sign shall be located on both sides near the horizontal centerline.

The above note shall be put on the VENDORs drawings.

4) Marking paint or water insoluble ink for use on austenitic and high nickel alloy steels shall contain no substance (e.g., metallic pigments, sulfur or chlorides) which would be harmful to


Rev. 4


these materials at ambient or elevated temperatures. The VENDOR shall submit analysis of marking material to OWNER. Submittal shall demonstrate (by chemical analysis and history of use) that the material meets these requirements.

5) Stamping on all austenitic steels and impact tested materials shall be with low stress steel stamps having round or U shaped cross sections or with interrupted-dot die stamps.

6) The VENDOR shall include a packing list in each shipment, listing the contents by assembly piece mark, individual piece mark, or by vessel number of each box, crate, bag, and skid. The list shall state whether the contents constitute complete or partial shipment.

7) For ocean shipment, vessels shall not be transported as above-deck cargo without prior written approval of OWNER.

8) Where clearances for shipping require alteration or cutting off of vessel nozzles, clips, lugs, or other similar attachments, the VENDOR shall submit loading diagrams showing the attachments which require reorientation or removal. No changes shall be made unless written approval has been obtained from OWNER.

9) Small parts of the vessel shall be shipped bagged, boxed, or otherwise protected from damage or loss. Spare gaskets shall be shipped separately and not bolted in place. They shall be clearly tagged as spares.

10) The VENDOR shall provide any special protection or packaging, and details of any storage, shelf life, or maintenance instructions which are not within the scope of the Order but which pertain to the VENDORs guarantee or are otherwise necessary for protection of the vessel.

11) Protection for flange faces, threaded connections, weld bevels, etc., shall be as follows:

All machined and threaded surfaces of carbon steel and ferritic alloy steel materials, except weld bevels, shall be coated with one of the following rust preventives or an equal approved by OWNER:

E.F. Houghton Co. Rust-Veto No. 342 Exxon Chemical Co. Rust Ban No. 326

Weld bevels shall be free of dirt, oil, grease, scale, rust, and other foreign materials. All 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 76 mm (3 inches) from the end of the weld bevel with one of the following weldable rust preventives or an equal approved by OWNER:

Deoxaluminite manufactured by:


Rev. 4


AACCOS 5220 N 125TH Street

Butler, WI 53007, U.S.A.

All weld bevels shall be closed with metal or plastic caps to prevent damage and entrance of foreign materials

All socket-weld ends and plain ends shall be closed with metal or plastic protectors that fit either inside or outside to prevent damage and entrance of foreign materials.

Threaded openings shall be plugged with hexagonal headed threaded plugs of the same material as the connected part and sealed with tetrafluoroethylene tape thread sealant.

For ocean shipment, flanged openings shall be protected and made waterproof with full size 3.4 mm (0.134 inch, 10 USS gauge) minimum thickness steel covers and 3 mm (1/8 inch) thick rubber gaskets between the flange face and cover. When steel flange covers are furnished , they shall be secured with appropriately sized machine bolts as follows: For flanges having 4 to 28 bolt holes, a bolt shall be place in at least every other hole, with a minimum of

ges 00301

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