qclng-bx00-mec-spe-300002_01

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

QCLNG UPSTREAM PROJECT

TECHNICAL SPECIFICATION - PRESSURE VESSELS

g:\401001\00771 prjt - cproj bg standards challenge\10.0 engineering\3 me & pi - mechpiping\vp002 spec incorporating client comments\for issue\qclng-bx00-mec-spe-300002.doc

QCLNG-BX00-MEC-SPE-300002 Rev 01 : 17 Sept 2014 Page iii

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




QCLNG-BX00-MEC-SPE-300002 Rev 01 : 17 Sept 2014 Page iv

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




QCLNG-BX00-MEC-SPE-300002 Rev 01 : 17 Sept 2014

Page 1

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





Page 3

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





Page 4

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


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





Page 5


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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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.





Page 10

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)





Page 11

• 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





Page 12

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.





Page 14

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





Page 17

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.





Page 18

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





Page 19

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:





Page 20

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





Page 21

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.





Page 22

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.





Page 23

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





Page 24

• 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:





Page 25

• 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.





Page 26

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.





Page 27

Pickling and passivation of stainless steels shall be performed using nitric acid in accordance with

ASTM A380/ASTM A967.





Page 28

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%





Page 29

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





Page 30

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.





Page 31

Minimum hydrotest duration shall be 1 hour at required test pressure excepting where the design

code specifies longer.





Page 32

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.





Page 33

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.





Page 34

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.





Page 35

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.





Page 36

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.





Page 37

Tolerances on dimensions for use in the dimensional checking of the equipment prior to delivery shall

be in accordance with AS 4458 Appendix F.





Page 38

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)





Page 39

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.





Page 40

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.

qclng-bx00-mec-spe-300002_01

Documents

qclng phase

australian standards

applicable standards

technical integrity

project specifications

hse requirements

albert street brisbaneqld

client commentsfor