122938019 Specification Pressure Vessel

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0 ASA 23.09.02 AVV 24.09.02 AD 27.09.02 ISSUED AS STANDARD SPECIFICATIONRev. Name Date Name Date Name Date Remark, kind of revision

Prepared, revised Checked Approved

Lurgi India

Standard Specification for

Pressure Vessels

Document No.

LI-ODV-STD-1001

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1/26

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LI-0-FMT-0001

Issue: Rev. 00 , 25.08.2000

Standard Specification

For Pressure Vessels


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Project Name Project No. Document No. Sheet / of

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EDP Ident.No. /var/www/apps/conversion/tmp/scratch_5/126763210.doc Error: Reference source not found Error:

Reference source not foundIssue: Rev. 00 , 25.08.2000 Sheet 2 of 122


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Table of Contents

Section

1 SCOPE................................................................................................................................................................14

1.1 Definitions........................................................................................................................................................14

1.2 Scope of Supply...............................................................................................................................................15

2 STANDARDS AND CODES................................................................................................................................16

2.1 Local Regulations.............................................................................................................................................16

2.2 Standards.........................................................................................................................................................16


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2.3 Conflicts...........................................................................................................................................................18

3 PROPOSAL INSTRUCTIONS............................................................................................................................19

4 DESIGN..............................................................................................................................................................20

4.1 General.............................................................................................................................................................20

4.2 Process Design................................................................................................................................................20

4.3 Guarantees.......................................................................................................................................................21

4.4 Code Requirements.........................................................................................................................................22

4.5 VENDORs Design Basis..................................................................................................................................24

4.6 Document submission......................................................................................................................................24


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4.7 Mechanical Design...........................................................................................................................................29

4.7.1 Design Pressure............................................................................................................................................29

4.7.2 Design Temperature......................................................................................................................................30

4.7.3 Corrosion Allowance......................................................................................................................................30

4.7.4 Minimum Thickness......................................................................................................................................31

4.7.5 Heads, Transitions and Discontinuities.........................................................................................................34

4.7.6 Calculation....................................................................................................................................................35

4.7.7 Loading..........................................................................................................................................................40

4.7.8 Internal Loads................................................................................................................................................50


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5 MATERIALS........................................................................................................................................................54

5.1 Material Selection.............................................................................................................................................54

5.2 Material Substitution.........................................................................................................................................56

5.3 Material Identification.......................................................................................................................................56

5.4 Alloy Lining.......................................................................................................................................................58

6 MANUFACTURE.................................................................................................................................................60

6.1 General.............................................................................................................................................................60

6.2 Additional Requirements for Fabrication of Stainless Steel.............................................................................62

6.2.1 General..........................................................................................................................................................63


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6.2.2 Materials Segregation...................................................................................................................................63

6.2.3 Fabrication Conditions...................................................................................................................................64

6.2.4 Heat Treatment.............................................................................................................................................65

6.3 Reference Work Line.......................................................................................................................................65

6.4 Location of Weld Seams..................................................................................................................................66

6.5 Heads...............................................................................................................................................................68

6.6 Nozzles.............................................................................................................................................................69

6.6.1 General..........................................................................................................................................................69

6.6.2 Nozzle Attachment........................................................................................................................................74


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6.7 Reinforcement of Openings.............................................................................................................................74

6.7.1 Nozzle Size...................................................................................................................................................75

6.7.2 Davits............................................................................................................................................................76

6.7.3 Flange Faces.................................................................................................................................................76

6.8 Gaskets............................................................................................................................................................77

6.9 Bolting..............................................................................................................................................................77

6.10 Supports.........................................................................................................................................................79

6.10.1 Skirts...........................................................................................................................................................79

6.10.2 Templates....................................................................................................................................................81


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6.10.3 Leg Supports...............................................................................................................................................83

6.10.4 Horizontal Vessels.......................................................................................................................................83

6.11 Internals..........................................................................................................................................................84

6.11.1 General........................................................................................................................................................85

6.11.2 Internal Piping.............................................................................................................................................86

6.11.3 VENDOR Scope.........................................................................................................................................87

6.11.4 Provisions for Internal Lining.......................................................................................................................89

6.12 External Attachments.....................................................................................................................................90

6.13 Vessel Accessories.........................................................................................................................................91


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6.13.1 Name Plate.................................................................................................................................................93

6.13.2 Lifting Lugs..................................................................................................................................................93

6.13.3 Earthing ......................................................................................................................................................94

6.14 Welding..........................................................................................................................................................95

6.15 Heat Treatment..............................................................................................................................................95

6.15.1 Code Requirements.....................................................................................................................................96

6.15.2 Local Heat Treatment..................................................................................................................................98

6.15.3 Treatment before and after PWHT..............................................................................................................98

6.16 Tolerances......................................................................................................................................................99


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7 INSPECTION AND TESTING...........................................................................................................................100

7.1 General ..........................................................................................................................................................100

7.1.1 PURCHASERs Inspection..........................................................................................................................101

7.1.2 Test Records...............................................................................................................................................105

7.1.3 Additional Test and Inspections...................................................................................................................106

7.1.4 Notice of Inspection and Examination.........................................................................................................107

7.1.5 Pre-Inspection Meeting...............................................................................................................................108

7.2 Air Testing of Reinforcing Plates ...................................................................................................................108

7.3 Hydrostatic Tests............................................................................................................................................109


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7.3.1 General........................................................................................................................................................109

7.3.2 Pneumatic Test...........................................................................................................................................110

7.3.3 Bolts and Gaskets.......................................................................................................................................111

7.3.4 Testing Water Conditions............................................................................................................................112

8 PREPARATION FOR SHIPMENT....................................................................................................................113

8.1 Preservation...................................................................................................................................................113

8.2 Closures.........................................................................................................................................................114

8.3 Loose Items....................................................................................................................................................115

8.4 Match-Marking................................................................................................................................................115


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8.5 Loading and Anchoring...................................................................................................................................116

8.6 Painting..........................................................................................................................................................117

8.7 Marking...........................................................................................................................................................118

9 DATA FOLDER.................................................................................................................................................121


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1 SCOPE

This specification together with other listed Codes, Standards, Specifications and Mechanical DataSheets, defines the minimum technical requirements for the mechanical design, fabrication, inspection,

testing, transportation packing and supply of unfired pressure vessels.

1.1 Definitions

For the purposes of this specification the following definitions shall be used:

PURCHASER means the prime contractor for the EPC


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VENDOR means the person, firm or company who sells or furnishes the materials

1.2 Scope of Supply

All vessels shall be supplied complete as shown on the PURCHASERs drawings and as specified herein

including all necessary blind flanges, studs, nuts, gaskets, clips, davits and internals piping.

As a minimum all parts welded to pressure parts shall be within VENDORs scope unless excludedspecifically from the scope.


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2 STANDARDS AND CODES

2.1 Local Regulations

National Laws and regulations together with any local by-laws for the country or state wherever the vesselsare to be used must be complied with by the fabricator. It shall be vendors responsibility to take approval

for design, material of construction, fabrication, inspection and testing from statutory authorities includingand not limited to IBR, Chief controller of explosive, etc.

2.2 Standards

The latest issues of the following codes/ standards are referenced by this specification and shall be usedas minimum requirements:


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ASME Sec II Materials

ASME Sec V Non-destructive Examination

ASME Sec VIII Div. 1 Rules for Construction of Pressure Vessels

ASME Sec VIII Div. 2 Alternative Rules for Construction of Pressure Vessels

ASME Sec IX Welding and Brazing Qualification

WRCB 107 Welding Research Council Bulletin 107: Local Stresses in Sphericaland Cylindrical Shells due to External Loading

IBR Indian Boilers Regulation (where ever applicable)


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SMPV Rules The Static and Mobile Pressure Vessels Rules (where ever applicable)

BS-5500 Appendix G Stresses in large horizontal cylindrical pressure vessels on two-saddledsupports by L.P. Zick

2.3 Conflicts

If conflict occurs between PURCHASER supplied documents, it shall be informed to the PURCHASER andshall be clarified by PURCHASER.


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3 PROPOSAL INSTRUCTIONS

Each Vendor shall submit a base proposal for equipment complying strictly with this specification and thereference documents listed in Paragraph 2.2. Conflicting requirements in these documents shall be

referred to PURCHASER for resolution prior to submission of the proposals.Vendors may submit alternative proposals that deviate from PURCHASERs requirements if significantsavings can be demonstrated. Such proposals will receive full consideration, provided each deviation isfully described and the corresponding documents are provided.

The PURCHASER reserves the right to accept any alternative proposal without further consideration of theVendor. An alternative design shall not be used unless it is approved in writing by the PURCHASER.


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No subletting of any fabrication or welding will be permitted after the award of contract, unless priorapproval has been taken from PURCHASER.

4 DESIGN

4.1 General

Mechanical Data Sheet which includes material specifications, principal dimensions, general requirementscodes etc. will be furnished by PURCHASER.

4.2 Process Design


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Where process design by the VENDOR is required it shall be so indicated on the vessel data sheet.

The VENDOR shall size the vessel when so required within limitations stated on the vessel data sheet. Itwill be the VENDORs responsibility to design all internals.

Vessel size and internal design shall permit internal access to all welds for inspection and non-destructiveexamination proposed during fabrication and for in-service inspection/ maintenance.

4.3 Guarantees

The Vendor shall guarantee the equipment and their components against defect in design, materials andworkmanship. Approval by PURCHASER of design calculations and detail fabrication drawing will notanyway absolve the VENDOR from his responsibilities to supply equipment in accordance with orderspecifications.


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Where process design of the equipment is provided by the VENDOR, the performance of the equipmentshall be guaranteed to satisfy the specified process requirements.

4.4 Code Requirements

Except as otherwise shown or specified, all pressure vessels complying with this specification shall as aminimum meet the requirements of ASME Section VIII - Div. 1 or ASME Section VIII - Div. 2, where ever

applicable.

When ASME Section VIII - Div. 1 or Div.2 is specified on the PURCHASERs Mechanical Data Sheetsand/or drawings, the design, materials, fabrication, inspection and testing shall meet the requirements ofthe latest edition and addenda of the Code.


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Vessels intended for vacuum service greater than 500 Pa (50 mm water gauge), shall be designed andconstructed according to ASME Section VIII - Div. 1.

When a pressure vessel designed according to ASME Section VIII, Div. 1 is specified to be in cyclicservice, the design criteria and rules of ASME Section VIII, Div. 2 shall be used to perform an analysis,except that when establishing the need for analysis, the allowable stress limits of ASME VIII, Div.1 shallbe used.


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4.5 VENDORs Design Basis

Vessel data sheets, sketches and any standard details supplied by the PURCHASER are intended toconvey minimum design requirements and shall not be used by the VENDOR for fabrication purposes.

Thickness of components pre-dimensioned by the PURCHASER and specified in the drawing/data sheetshall be regarded as minimum values, after forming, including corrosion allowance. Should the VENDOR'scalculations result in greater thickness, the PURCHASER shall be informed without delay.

4.6 Document submission


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Vendor shall submit drawings and documents to PURCHASER as per following list but not limited to forapproval.

Code calculations including nozzle reinforcement calculations, local stress analysis fornozzles and vessel clips due to external loads, thermal stress analysis whenever applicable or ifspecifically asked for, structural calculations for supports, internal lift ing lugs etc.,

Complete shop fabrication drawings. Following details shall also be furnished as a minimum:

1. Erection, Empty, operating and hydrotest weights.

2. Heat treatment requirement.

3. Impact Test requirement on Weld and HAZ

4. Production Test Coupon Requirement


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5. Shell development drawings showing interference, if any, with nozzles and other attachments(for columns, reactors and other equipment with large number of nozzles and attachments)

6. Hydrotest pressure at shop and site.

7. Details of all internal and external attachments.

8. Painting details including surface preparation.

9. List of spares for erection and commissioning and two years of operations.

WPS, PQR, Welder qualification records

Quality assurance plan

Inspection and test plan


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Hydrotest procedure with sketch (sketch for showing supports for tall columns)

Any other test procedure if applicable (e.g. helium leak test procedure, etc.)

Painting Specification

Transportation sketch showing location of supports for transportation

Any other document called for specifically by purchaser

Drawing and document schedule

Purchase specification for bought out components including plates, forgings, pipes, flanges etc.

For equipment coming under the purview of Indian Boiler regulations, it shall be vendors responsibility toget approval from IBR authorities pertaining to design, material of construction, fabrication, inspection andtesting.


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For equipment coming under the purview of Static and Mobile Pressure Vessels rules, it shall be vendorsresponsibility to get approval from Chief Controller of Explosives pertaining to design, material ofconstruction, fabrication, inspection and testing.

All documents referred above shall be submitted for approval to the PURCHASER on or before scheduledate.


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No subsequent revision may be issued to the fabrication shop without prior review by the PURCHASER.

4.7 Mechanical Design

4.7.1 Design Pressure

The design pressure at the top of the vessel shall be as stated on the Mechanical Data Sheets. The statichead due to contents (min. S.G.=1) shall be added in all cases.

Vessels shall be designed and protected against vacuum only when the vessels are to be actuallysubjected to external pressure during operation. Vacuum caused by emptying water after hydrostatic testsor condensing steam after steaming out the vessel, should not be considered as a design condition.

Vessel shall be designed for Steam out condition if specified on Mechanical Data Sheet.


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4.7.2 Design Temperature

Design temperature shall be as specified on Mechanical Data Sheets. Two kinds of design temperature,one for the maximum design temperature (called as Design Temperature) and other for minimum designtemperature(called as Minimum design metal temperature = MDMT) are specified.

If several pressure-temperature combinations are specified, the most stringent shall apply.

4.7.3 Corrosion Allowance

The corrosion allowance stated on the vessel data sheet shall be added to all exposed internal surfaces ofpressure parts, non-removable internals.

Internal components welded to shell shall include corrosion allowance on all exposed sides.


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Half the minimum corrosion allowance shall be added to the exposed surfaces for removable parts.

Internal fillet welds shall be sized to include the specified corrosion allowance on the throat thickness.

4.7.4 Minimum Thickness

4.7.4.1 Shells and Heads

The thickness of shells and heads excluding allowances for forming and corrosion shall be the greater ofthat required for loadings given in 4.7.6 or the following:

5 mm for austenitic steel

5 mm for C, C.Mn and low-alloy steel vessels up to and including 1200 mm inside diameter


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7 mm for C, C.Mn and low-alloy steel vessels above 1200 mm inside diameter

10 mm plus cladding for clad vessels. (Minimum Clad thickness shall be 3mm. It shall not beconsidered while doing stress calculation)

4.7.4.2 Nozzles

The nozzle size, number of nozzles and flange rating shall be in accordance with Mechanical Data Sheet.

4.7.4.3 Skirts and Leg Supports

Skirt or leg supports shall be designed for specified loads, but shall not be less than 6 mm thick.


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4.7.4.4 Internals

Tray support rings, etc. shall be designed for specified loads but shall not be less than

6 mm thick plus twice the specified corrosion allowance for carbon steel


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6 mm thick for high alloy and stainless steel.

4.7.5 Heads, Transitions and Discontinuities

Thickness of the formed heads shall be indicated on Mechanical Data Sheet / Drawings as MinimumAfter-Forming (MAF).

Cylindrical transitions shall be toriconical sections when any of the following conditions apply:

Vessel is in cyclical service.

The section is subject to a major support reaction (for example skirt to cone attachment).

Shell thickness is over 30 mm.

The required reinforcing is not integral with the shell.


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4.7.6 Calculation

The VENDOR shall provide detailed calculations to justify the design. Calculations shall be fully detailedshowing all working and references used and shall be presented in such a manner that they can be easilychecked.

All calculations, except those for weights and Centre of Gravity, shall represent the vessel in the fully-corroded condition.

The VENDOR shall establish weights (shipping, empty, operating and test) and the locations of the centreof gravity (empty and operating).

Vessels and their supports shall be designed for the most severe condition of coincident loading, asdefined below and in paragraph 4.7.7:


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The effects of external primary mechanical loads plus design pressure and the effects of secondarystresses due to differential thermal expansion shall be investigated, and the resulting combined stressesand deflections shall be evaluated, if specifically asked in Mechanical Data Sheet.

Material tolerances shall be applied to give the most conservative design, e.g. pipe thickness shall beminimum for mechanical design, plate thickness shall be maximum for weight calculations. Designcalculations for metal clad vessels shall be based on nominal thickness of the base material.

Where the vessel is in cyclic service, fatigue shall be considered.

4.7.6.1 Definitions

Normal Operation Includes design pressure, operating vessel dead load, operatingcontents of vessel, superimposed external loads and any other


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applicable operating effects (such as unbalanced pressure,thermal induced piping or internal strain loading and impactloads) all combined with wind or earthquake.

Shop Test Includes test pressure, test load of vessel and attached equipment andweight of test contents in the vessel and in such other equipment as maybe affected.

Field Test All vessels shall be checked in fully corroded conditions for a f ield test withcode required test pressure at the top.

Shipping Weight Completed equipment together with all fittings, covers, bolts,nuts and any removable/fixed internals, if installed.


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Empty Weight As shipping plus any internals / packings installed by others,

insulation, fire-proofing, platforms, ladders, instruments andpercentage of attached pipe work.

Operating Weight As empty plus operating liquid and/or packings.


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Shop Test Weight As fabricated weight plus weight of water to fill.

Field Test Weight As empty less insulation and internals/packing plus weight ofwater to fill.

Operating dead load The weight of the empty vessel, plus internal and external

attachments, insulation, operating fluid and content weights.Test dead load The weight of the empty vessel without internal or external attachments

plus weight of water. Water volume shall equal the volume of the vessel.

Erection dead load The weight of the empty vessel without insulation, removable internals, orexternal attachments.


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4.7.6.2 Units

Calculations may be made in the units of choice. When calculations are made in units other than SI, theresult of all principal steps and the final results shall additionally be expressed in SI units:

Calculations shall use metric units as follows:

Dimensions mm

Pressure bar g

Stress Kg/mm2

4.7.7 Loading

The following load conditions and combinations shall be considered:


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4.7.7.1 Load Conditions

Operation Design pressure

Hydrostatic pressure of liquid head

Operating dead load

External attached equipment

insulation and fire proofing

Live loads

Any other operating effects such as unbalanced pressure, thermal, etc.


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Test (In the installed Test pressure

Position & corroded Hydrostatic pressure of liquid head

Condition) Test dead load

Equipment and external attachment test loads


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Erection 1 (Lifting) Erection dead load

If required, including weight of

Internals

Insulation

Equipment and external attachments (platforms, ladders,piping, etc.)

(A shock factor depending on the method of rigging - but

minimum two (2.0) shall be used.)


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Erection 2 Erection dead load (if specified including internals, ladders,

(Standing on foundation) platforms, piping and insulation, etc)

Wind or Seismic Load (also for external mounted equipment

and attachments

Empty Empty dead load

External attached equipment

Insulation and fire proofing

Live loads


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It should be noted that critical load conditions may also occur when the vessel is not subject to internalpressure.

4.7.7.2 Dynamic Loads

The design for wind and seismic shall be performed for the geographical area of the installation site andshall be in accordance with applicable regulations. Dynamic loads shall be as prescribed in these

regulations but must always take into account process induced loads.

Wind Considerations : Dynamic analysis shall also be carried out as per applicable standard designpractice.

Seismic Considerations: for vessels Seismic coefficient method and for column response spectrummethod shall be used.


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Load combinations

Analysis shall be carried out for following conditions:

Load case Wind load Earthquake Load

Operation 100% 100%

Pressure test 30% NIL

Erection 1 70% NIL

Empty 100% 100%

Seismic and Wind loads shall be considered not acting concurrently


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Following guidelines shall be used while determining weight of trays, platform, ladders, etc.


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Weight of Trays with Liquid 120Kg/m2

Weight of Caged Ladder 37 Kg/m

Weight of plain Ladder 15Kg/m

Maximum distance between two

consecutive platform

5000m

Platform Projection Min 900mm for Column diameter upto 1000mm

Min 1200mm for Column diameter above 1000mm

Height of Platform for wind loads 0.5m


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Weight of Platform 170Kg/m2

Platform shall be considered all round

To account for surface area of piping, platforms and other attachments fixed to the equipment the surfacearea of equipment exposed to wind shall be increased by 20%.

For columns, the static deflection at the top due to the wind load on the column shall be limited to 1/200 ofthe total height from the base plate.


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4.7.7.3 Nozzle Loads

Local loads in shell and dished end around attachments such as nozzles, vessel support and lifting lug soon, shall be calculated.

The following generally accepted calculation procedure may be applied:

Bulletin of Welding research council No. 107 or 297

BS 5500 Appendix G

4.7.8 Internal Loads

Packing and bed support plates and their support rings and beams shall be designed for a load equal to thesum of:


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Dry packing/bed weight

Equivalent in water weight of 35 % of the packing free volume

Pressure drop across the packing bed (if downward gas flow)

The design shall provide not less than 65 % support plate free area.

Deflection of internal support beams or other loaded members shall not exceed 1/1000 of span.

4.7.8.1 Basic Allowable Stresses

Basic allowable stresses for pressure parts shall be established by ASME Section II Part D.

Basic allowable stresses for non-pressure parts shall be the lower of 1/3 of the ultimate tensile strength (atroom temperature) or 2/3 of the yield strength (at design temperature) or that producing a creep rate of 1


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% in 10 000 hours, except that the following non-pressure parts shall be designed using the stress forpressure parts:

Welds attaching non-pressure parts to pressure parts.

Internals, whose failure would have serious consequences such as catalyst support grids.


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Internals, whose performance would be affected by deformation, such as liquid distributors and theirsupports.

When creep becomes a design consideration, VENDOR shall submit detailed design to PURCHASER forreview.

The calculated stresses for the design conditions shall be limited to the following:

Erection basic allowable stress at ambient temperature and uncorroded thicknessOperation/empty basic allowable stress at design temperature and corroded thickness

Test 90 percent of the minimum specif ied yield stress at test temperature and corrodedthickness for pressure parts & 1/3 of the basic allowable stress at test temperature andcorroded thickness for non-pressure parts


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For all design conditions the maximum allowable longitudinal compressive stress for shells including skirtto be in accordance with the applicable ASME Code.

5 MATERIALS

5.1 Material Selection

All material used in the vessels shall be of the type and grade specified on the Mechanical Data Sheet.

All material welded directly to pressure retaining parts shall be of the same material specification includingimpact requirements as the pressure retaining part.


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All pipe material for pressure retaining parts with 12 inch NPS for CS and 8 NPS for SS and below shallbe seamless .

Forged nozzle necks are preferred in lieu of pipe necks and shall be used when shell thickness is 40 mmor over.

All plates and forgings with a shell or flange thickness of 40 mm or greater (except ASME B 16.5 standardflanges) shall be ultrasonically examined in accordance with ASTM A435 and ASTM A388 (acceptance to

ASME VIII, Div 2, paragraph AM-203.2).

Rimmed, semi-killed or structural quality steels shall not be used for pressure retaining parts.

Low hardness bolting shall be used for pressure bearing connections being in contact with the process fluid( such as bolting for floating head covers) when this fluid may cause stress corrosion cracking (e.g. sourgas, caustic).


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Gaskets shall be of asbestos free material suitable for the process and service conditions.

All materials shall be new and unused.

5.2 Material Substitution

Substitution of material may be made only upon written approval of the PURCHASER and provided there

is no increase in cost. Approval must be given prior to commencement of work.

5.3 Material Identification

All materials shall be identifiable by means of certified legible markings relating to available, authenticmaterial certificates during all stages of manufacture.


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When metal stamping is done it shall preferably be on the long edge of each component as it leaves themill. Plate rolling direction shall be indicated by suitable marking.

Stockist certification will not be accepted.

The VENDOR shall maintain a system of material identification such that all materials used in thefabrication of pressure parts may be traced to the appropriate certification.


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Where the material identification mark is unavoidably removed, transfer of the identification mark topressure retaining parts shall be witnessed and documented by the third party inspector.

Unidentified material shall be rejected.

5.4 Alloy Lining

In this specification the term Alloy lining is a general term that does not imply a specific fabrication ormanufacturing process.

Alloy lining for shells and heads shall be integrally bonded cladding or weld deposit overlay.

When integrally clad vessels are used, a minimum of 10% of the clad surface , including no less than 1square foot in each 10 square feet or fraction thereof, shall be ultrasonic examined for lack of bond afterforming. The cladding shall be 100% ultrasonically examined in areas where attachments are to be welded


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directly to the cladding. Unbonded areas that cannot be encompassed by a 3 inch diameter circle shall berepaired by weld deposit overlay in accordance with the specification Welding of Pressure Vessels. Whenrepairs in excess of 5% of the total examined area are required, the vessel shall be 100% ultrasonicexamined. Repaired areas and weld deposit overlay at weld seams shall be 100% liquid dye penetrantexamined in accordance with ASTM E165. Ultrasonic examination shall be in accordance with ASTM A578S6 for spot examination or S7 for 100% examination.

Nozzles and manways in alloy lined portions of vessels shall be alloy lined and faced. The facing shall bemade with weld deposit which is at least as thick as the lining when properly machined and of the samealloy as the lining. When nozzles are lined with ferritic type 405 or 410S stainless steel linings, the facingweld deposit shall be made with type 309 welding electrode. The facing weld deposit for austeniticstainless steel linings shall be made with type 309 welding electrode for the first pass, and the weldingelectrode for the second pass shall be of the same or similar analysis as the lining.


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The method of lining connections, nozzles and manways shall be by integrally bonded cladding or welddeposit overlay.

Tubular liners are not acceptable.

6 MANUFACTURE

6.1 General

All workmanship shall be in accordance with best modern shop practice.

All work shall be true to specified dimensions within tolerances specified in the PURCHASERs DesignStandards.


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When a difference in thickness exists between shell plates or plates and heads, the inside diameter shallbe maintained, unless specified otherwise.

Tell-tale holes are required in all places where a lap or void occurs. This hole shall be deburred beforeassembling the joint.

Individual shell courses shall have their longitudinal seams welded separately before assembly with othershell courses or heads and shall be re-rolled if weld seam is peaked or inset.

To assure accurate fitting elevation location, particularly for columns or other long vessels, weld shrinkageshall be carefully estimated and allowed for the welding of circumferential seams, f ittings, tray bars,insulation rings, etc.


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6.2 Additional Requirements for Fabrication of Stainless Steel


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6.2.1 General

In addition to the general requirements of this specification the following additional requirements areapplicable to stainless steel.

6.2.2 Materials Segregation

In storage areas, stainless steel and high alloy materials shall be stored together and physically separatedfrom carbon steel materials. There shall be no contact between stainless steel and high alloy material tocarbon steel.


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6.2.3 Fabrication Conditions

Fabrication of stainless steel shall be carried out in clean workshop conditions dedicated to stainless steelworking. There shall be no contamination from carbon steel.

Only stainless steel tools which have not previously been used for carbon steel work, may be used forstainless steel fabrication.

Arc air gouging is not permissible on stainless steel.

The use of carbon steel bridges for fit-ups is not permitted


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6.2.4 Heat Treatment

Stainless steel components shall not be heated without prior written agreement of the PURCHASER, i.e.preheated, hot-formed or post-welded heat treated. Procedures for such treatments shall be submitted tothe PURCHASER for review.

6.3 Reference Work Line

VENDORs fabrication drawings for each vessel shall indicate a permanent reference work line which shallbe marked around the vessel perimeter on approximately 305 mm centres. Marks shall be both outsideand inside except clad or weld overlay vessels shall be marked on outside only. All dimensions shall befrom this line. For marking vibro-etching or low stress multi-dot stamping may be used.

The reference work line shall always be located at a tan line (the lower for vertical vessels).


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6.4 Location of Weld Seams

Shells and heads shall be formed with the minimum number of welded seams.

Longitudinal and circumferential seams in shells and all seams in built-up heads shall be located to clearopenings and their reinforcement by minimum three plate thicknesses or 50 mm, whichever is greater.

Permanent attachments shall be located to clear pressure retaining seams by at least one plate thickness.

In cases where this is impractical, the PURCHASERs written agreement shall be obtained. Any additionalNDT specified by the PURCHASER in such cases shall be performed at the VENDORs cost.

Attachments shall be designed and placed so as to allow full inspection of seam welds.

Longitudinal seams in adjacent courses shall be staggered such that the distance between weld edges arenot closer than the four times plate thicknesses or 100 mm, whichever is greater.


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For horizontal vessels longitudinal seams shall be oriented above the equipment centre line. Joints shallnot be located coincident with or across saddle supports.

The layout of seams shall be such that longitudinal seams are not within the downcomer areas of trays orbehind any obstruction that prevents inspection of these welds. Circumferential seams shall not fall on atray ring or stiffener and shall be located not less than 100 mm above or below the tray ring or stiffener.


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6.5 Heads

Where heads are formed by spinning, any spinning hole shall be increased in size to 300 mm diameterand an insert plate of same thickness as end, formed to correct radius shall be butt welded. Thisrequirement is waived where a central nozzle is to be located in the end.

The knuckle region of semi-ellipsoidal and torispherical heads shall be examined by wet magnetic particleinspection technique (or liquid penetrant if stainless steel) and shall show freedom from cracks and splitsafter final forming.

Butt welds in heads which are fabricated from more than one plate shall be fully radiographed after allforming and heat treatment. One chordal joint in dished ends is acceptable, the joint shall be located in themiddle one-third of the blank.


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When fittings are to be installed in heads prior to assembly with shell, reference lines shall be centremarked (in accordance with paragraph 6.3) on head straight f lange to locate fitting projection.

6.6 Nozzles

6.6.1 General

Nozzles and manholes shall conform to one of the following unless specifically shown on the drawings:

Flanged forged steel with or without integral reinforcement (long welding necks).

Fabricated construction using seamless steel pipe, rolled plate or forged steel necks with integrallywelded bolting flange or welding neck flange. The joint between all necks and welding neck flangesshall have full penetration welds by means of double butt welds where size and accessibility


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permits or other means as shown on VENDORs fabrication drawings and approved by thePURCHASER.

Slip-on flanges class 150 lb may be used for access and inspection openings for design temperatureup to and including 260C and non-cyclic service. Not to be used for austenitic steel vessels andwhen the service is designated to be hydrogen, hydrogen sulphide, sour water or cyclic and inservice where corrosion allowance exceeds 3 mm.

Slip-on flanges shall be drilled and tapped through the hub for air and soap suds testing of attaching filletwelds.

Cover plates for manholes, handholes and nozzles shall be forged of the same material and be of thesame rating as the flange to which attached and drilled to suit.

Corrosion allowance on nozzle and manhole necks shall not be less than that of the vessel.


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The thickness of the hub of a welding neck flange where it is welded to the nozzle shall not be less thanthat of the nozzle neck.

Flanges shall have the same inside bore as the nozzle neck.

Nozzle necks rolled from plate to the same specification as the vessel shell may be used for sizes 14 NPS& larger for CS and 8 NPS & larger for SS. The weld seam shall be full penetration butt welded and fullyradiographed or U.T. inspected (see also 5.1).

Flanges in sizes NPS 24 and smaller shall conform to the requirements of ASME B 16.5. Carbon steelflanges larger than NPS 24 shall conform to ASME B 16.47.

All instrument connections shall be a minimum of 300 lb rating.

Where two or more openings are provided for installation of equipment such as gauge glass, float controls,etc. They shall be set with a jig to prevent tolerances from being additive.


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Couplings and other threaded connections other than air test holes in reinforcing pads are not allowed.

Pad-type nozzles shall not be used unless specified on PURCHASERs data sheets.


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All connections for nozzles, manways, handholes and so forth which do not extend into the vessel forinternal connections are to be finished flush with the inside of the shell. The inner circumference of nozzlenecks inside the vessel shall have 6mm minimum radius.

All access nozzles and other blanked-off nozzles shall be supplied complete with cover, bolts, washers,nuts and gaskets.

Where vessel wall thickness is 40 mm or over :

- reinforcement pads, backing plates or wrapper plates shall not be used except where wrapper platesare required for saddles.

- Self reinforced type nozzles shall be provided.

Bolt holes in external and internal flanges shall straddle the principal vessel centrelines unless otherwisestated.


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6.6.2 Nozzle Attachment

Nozzles in vessel shell or heads shall be attached by full penetration welds and set through the vessel wall.

Nozzles inserted into or through cover plates shall be full penetration or partial penetration double welded.Attachment by fillet welds only is not permitted.

Set on type connection are permitted for nozzles size less than 3NB for CS and SS. For alloy steel,

all nozzles shall be set in type.

6.7 Reinforcement of Openings

Nozzles shall be reinforced per Code and PURCHASERs Mechanical Data Sheet plus limitations of thisspecification.


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Reinforcing pad material shall be the same as the shell or the head.

Thickness of reinforcing pads shall not exceed shell or head thickness.

Nozzle reinforcing pads shall have two NPT drilled and tapped tell-tale holes to permit testing attachingwelds with air and soap suds prior to final hydrostatic test. Drilled hole shall be deburred before attachingpad to vessel.

Where fil let welds on nozzle reinforcing pads are smaller than the pad thickness the corner of the pad shallbe chamfered to provide a continuous surface with the face of the filled weld.

6.7.1 Nozzle Size

The minimum size of nozzles shall be 2 inch NPS (Nominal Pipe Size) for CS, Alloy steel, SS Vessels and3 for cladded vessels.


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6.7.2 Davits

Davits shall be provided for all manholes and for other blind flanges weighing 35 kg and over.

For vertical man-ways of Class 900 and higher and horizontal man-ways of Class 600 and higher the man-way davit is to be supplied to suit the class of flange.

Lugs for davits shall be full penetration welded.

6.7.3 Flange Faces

Flange gasket seating faces shall be finished in accordance with ASME B 16.5, unless specified otherwise.

All facings shall be adequately protected against damage during fabrication, storage and/or heat treatment.


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6.8 Gaskets

Gaskets shall be as per Mechanical Data Sheet.

6.9 Bolting


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Stud bolts shall be fully threaded and long enough to accommodate a bolt tensioner when these arespecified (allow one bolt diameter extra on length for bolt tensioner). Threads shall be UNC up to andincluding 1 and unified 8 UN over 1 (ASME/ANSI B1.1, Class 2A or Class 2B). All nuts shall be heavyseries. (Three nuts required for stud bolt tensioning when a bolt tensioner shall be applied). The strength ofstuds shall be based on the cross-section of the smallest diameter. Studs shall extend 10 mm beyond eachnut. Hard steel washers 6 mm thick shall be furnished under studs 1 inches and larger.

Provision shall be made to use bolt tensioning equipment on flanged joints for hydrogen service.

Special consideration shall be given to the prevention of over stressing the flange or bolts during gasketseating, when Class 300 and lower flanges are used with spiral wound or metal gaskets.

Bolts and nuts shall be new and shall be lubricated with molybdenum disulphide before assembly.


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VENDOR to supply 5 % spare bolts with nuts (min. 1 stud bolt with nuts per stud bolt size and per materialgrade) for each blanked off nozzle and manhole.

All internal bolting shall be SS material or better than the vessel internals.

6.10 Supports

6.10.1 Skirts

Skirts shall be in accordance with Standard Drawing Skirt and Base Details.

Skirts generally shall be attached to the underside of heads so that the skirt and shell plate centre linescoincide, after deducting corrosion allowance.


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A toriconical transition shall be used when a cone to shell transition serves as a support point for thevessel.

Skirts shall be of sufficient length to allow 500 mm between the bottom of the head and the foundation.When skirt supports for columns and vessels are supported at ground level, there should be a minimumdistance of 4 times the anchor bolt diameter between the outer flange diameter of the outcoming bottomhead nozzles and the top plate of the anchor bolt chair or the top of the compression ring respectively.

In no case shall a skirt be positioned so that a vessel girth seam is covered.

The attachment weld between skirts and heads shall be designed for a smooth profile with throat thicknessnot less than the skirt thickness.


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Carbon steel skirts of vessels built of solid alloy plate shall not be welded directly to the bottom head. Analloy ring of same quality as the head material shall be provided on the head for attachment to the carbonsteel skirt. The thickness of this ring shall be calculated for vessel design temperature.

The length of the alloy ring shall be 600 mm minimum for vessels with design temperature of minus (-) 50C or higher and 900 mm if the design temperature is lower than minus (-) 50 C.

For all grades of austenitic stainless steel heads, the alloy ring may be of 304 stainless steel.

6.10.2 Templates

Vessel manufacturer shall deliver template for each skirt supported vessel with more than 4 anchor bolts.


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One template shall be delivered in due time before casting of the vessel foundation at site. Notificationshall be given to PURCHASER at least 5 working days before shipment so that PURCHASER's authorisedrepresentative can perform a dimensional check.

The gauge plate shall remain in the manufacturers workshop and shall be attached to the vessel skirt basering for dimensional inspection by PURCHASER during final vessel inspection.


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6.10.3 Leg Supports

If shown in Mechanical Data Sheet, the Leg supports shall be provided as per Standard Drawings.

6.10.4 Horizontal Vessels

Saddle supports shall be dimensioned in accordance with Standard Drawing. Steel Saddles.

Horizontal vessels shall be supported at two positions, on saddles that cover at least 120 degrees of thevessel circumference and shall have sufficient thickness or stiffeners to be suitable for design andhydrotest conditions. Material in the vessel support reinforcing pad shall be the same as in the vessel. A


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NPT vent hole shall be provided in each backing plate. Reinforcing pads shall be continuously welded tothe vessel shell.

For vessels built of solid alloy steels, with shell thickness less than 10 mm and supported on legs orsaddles, the carbon steel supports shall not be welded directly to the vessel shell. Alloy backing platesshall be used between the shell and the carbon steel support. Backing plate shall be made of the samematerial as the shell, except that for all grades of austenitic stainless steel shells, the backing plate may beof 304 stainless steel.

Where horizontal vessels are installed on concrete foundations, a sliding plate shall be furnished under thesliding support for shell expansion.

Long holes in sliding supports shall provide sufficient space for shell expansion.

6.11 Internals


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6.11.1 General

All removable internals shall be designed to pass through the shell manhole and shall be in sections notweighing more than 50 kg.

Internal non-pressure removable connections shall have machine-faced plate flanges not less than 10 mmcorroded thickness. Screwed connections are not acceptable.

All internal bolting shall be fitted with lock nuts, pins or other locking device to prevent loosening byvibration.

Demister pads shall be supported above and below by carbon steel or alloy (as appropriate) grids.

Unless otherwise specified, stiffeners shall be welded to shell with continuous weld seams.


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6.11.2 Internal Piping

Internal pressure piping shall conform to the requirements of the service.

Internal non-pressure carbon and low alloy (5 % Cr maximum) steel pipe and fittings shall have thefollowing minimum wall thicknesses and ratings:

Pipe in sizes 12 and smaller: Standard weight

Pipe in sizes over 12 : 9 mm wall minimum.

Internal non-pressure pipe and fittings in high alloy-lined or clad vessels shall have the following minimumnominal wall thicknesses and ratings:

Pipe sizes 2 and above: Schedule 10S or fabricated of 3 mm thick sheet.


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6.11.3 VENDOR Scope

The VENDOR shall supply and install all internals as shown on the Mechanical Data Sheet, if notseparately mentioned in exclusion. Internals shall be located and designed to permit full visual and non-destructive examination of all welds on and in the pressure retaining envelope.

The VENDOR shall furnish tray support clips and rings as well as down-comer bars and other parts whichare to be welded to the inside of the vessel.


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If required by the Purchase Order he shall install trays, baffles, pans, etc. in his shop. Details for attachingtrays, baffles, pans, support clips and rings to the vessel interior, shall be in accordance with the traysupport drawings and specifications listed on the Purchase Order.

The following requirements shall apply:

PURCHASER shall be notified before tray installation is started. Trays shall not be installed until after any required postweld heat treatment is completed.

Adjustable weirs shall be installed at the weir height specified on the tray vendor's drawings.

Tray man-ways shall not be installed until after PURCHASERs authorised representative has completedall inspections. All man-ways and gaskets shall be installed and the bolting fully tightened before shipment.


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6.11.4 Provisions for Internal Lining

Where vessels are internally lined, internal features shall be designed to permit proper surface preparation,application of lining and verification of the integrity of the lining. Impingement plates, vortex breakers, etc.shall be removable if necessary to perform these operations. Such removable items should be of corrosionresistant materials, as specified on vessel data sheet and bolted on the vessel by welded lugs. Similarly,projecting nozzles forming dip pipes and stand pipes shall be internally flanged.

Careful consideration shall be given to lining requirements of internal pipes and flanges. All internal edgesshall be rounded to a minimum radius of 3 mm and all weld spatter removed prior to blasting. Internalpipes shall be of compatible material to the vessel lining/cladding.

The surface finish of the vessel shall be approved as suitable for lining by the lining supplier.


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6.12 External Attachments

Platform support clips, ladder support and guide clips and piping support clips shall be provided whenrequired. Shell and/or head to which such support clips are attached shall be checked for local stressesinduced by external loads to be provided by PURCHASER.

Large carbon steel attachments such as jacket closures, platforms and piping support clips, shall not bedirectly welded to vessels built of solid alloy steels, but shall be welded to an alloy pad of the samematerial as the shell and/or head. Such pads shall be continuously welded to the vessel.

Reinforcing pads for attachments carrying local loads shall be formed, fitted and welded so that padclosely follows the contour of the shell or head. Large size pads may require additional attachment weldswithin the area of the pad.

Unless otherwise specified, stiffeners shall be welded to shell with continuous weld seams.


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Stiffening/insulation support rings on vertical vessels shall be provided with 25 mm diameter holes every800 mm to facilitate drainage.

6.13 Vessel Accessories

Each vessel shall be provided with:

Nameplate attached to nameplate bracket per Standard Drawing Nameplate for Vessel Two lifting lugs per Standard Drawing Lifting Lugs (on vertical vessels)

Earthing lugs as per Standard Drawing Earthing Lugs

Clips as per Standard Drawing Insulation and Fireproofing Supports, wherever required

Tailing Lug if specified


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6.13.1 Name Plate

Completed vessels shall have a nameplate in accordance with Standard Drawing. Nameplates shall be ofSS material installed on a nameplate bracket. The location of the name plate shall be as per MechanicalData Sheet.

6.13.2 Lifting Lugs

All vertical shop fabricated vessels with an empty weight of over 100 kg shall be provided with liftingdevices. Lifting lugs attached to the top of the vessel on the shell side or lifting trunnions attached to theshell above the vessel gravity centre shall be used depending on the vessel size and field erectioncapabilities. The construction shall be as specified on the vessel drawing/data sheet.

No lift ing devices shall be provided on horizontal vessels, unless noted otherwise.


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Lifting lugs and tailing lugs not shown on PURCHASERs drawings shall be designed and supplied by theVENDOR. Calculations shall be submitted to the PURCHASER for approval. For all lugs designed by theVENDOR, including a check of the shell of local loads. Lugs shall be suitable for transportation anderection of the vessel to its operating position. A shock factor of two shall be included in lifting lugcalculations.

6.13.3 Earthing

Each vessel shall be provided with two earth lugs welded to supports.

On vertical vessels located 180 apart on skirt or legs.

On horizontal vessels, one on each saddle.


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Girth flanges shall provide suitable electrical bonding across the flange connection. An external conductorshall be installed additionally when there is no conductivity through bolting and gaskets.

6.14 Welding

Welding shall be conducted in accordance with the applicable regulations, standards, codes and theapplicable specification if specified.

Acceptance of welder/operator qualifications by the PURCHASERs representative shall be obtainedbefore any welding is performed on the equipment.

6.15 Heat Treatment


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6.15.1 Code Requirements

Post weld heat treatment shall be performed for carbon steel, carbon manganese steel and low alloy steelas required by

- Design code

- Specification for Welding of Pressure Vessels

- When specified on the Mechanical Data Sheet.

Post Forming heat treatment shall be performed for carbon steel, carbon manganese steel and low alloysteel as follows:

- hot formed materials if it was heated above normalising temperature it shall be normalised


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- cold formed materials upto 16mm thickness shall be stress relieved and above 16mm thicknessshall be normalised.

This heat treatment shall be performed after final operation.

Hot formed material of Austentic steel shall be solution annealed.


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Special consideration shall be given to the forming temperature to avoid possibility of hot cracking whenhot forming is proposed for austenitic materials.

All materials shall be mechanically certified in the final heat treated condition.

6.15.2 Local Heat Treatment

Local heat treatment is not permissible without PURCHASERs approval.

6.15.3 Treatment before and after PWHT

Flange faces and other machined surfaces shall be suitably protected against oxidation during heattreatment and shall be checked after heat treatment for warpage and distortion.


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Internal surfaces of CS and low alloy steel vessels shall be cleaned after post weld heat treatment.

After post weld heat treatment of vessels no welding, hammering, grinding or deformation shall bepermitted. If it is not possible to heat treat the complete vessel together with all welded attachments, thisshall be stated at the initial proposal stage.

6.16 Tolerances

Fabrication and material Tolerances shall conform to the requirements of the code.

Dimensional tolerances for all vessels shall be in accordance with Standard Drawings.

Vertical vessels shall be checked for plumbness. After the ring sections have been assembled. The outsidesurface of the cylinder shall not vary from a straight vertical line more than 6 mm in any 6000 mm, nor


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more than 19 mm in the total length. When shell thickness is 200 mm or more, the variation from a straightline shall not exceed 31 mm in the total length.

The maximum out of roundness variance of vessels with internal trays any diameter may not vary plus orminus % from the nominal diameter, with a maximum variation in diameter from nominal of 13 mm.

7 INSPECTION AND TESTING

7.1 General

All mandatory inspection requirements of applicable national, regional, local laws and regulations for thearea of installation or as furnished by the PURCHASER have to be observed.


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Acceptance criteria for weld defects shall be in accordance with the design code.

7.1.1 PURCHASERs Inspection

Inspection by the PURCHASERs representative shall be in accordance with the VENDORsQuality/Inspection Test Plan that has been reviewed by the PURCHASER.

A visual and dimensional spot check by PURCHASER's authorised representative will be carried out prior

to the hydraulic test and/or heat treatment or coating of the vessel, if any.

The VENDOR shall inform PURCHASER by fax at least 15 working days before the vessels are ready forinspection.


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PURCHASER's authorised representative shall have the right to inspect all work in progress, both in theshop or in the field, to insure that proper workmanship, orientation, welding, testing, painting, etc. are beingperformed.

PURCHASER reserves the right to make preliminary intermediate and final inspection of both shop andfield fabricated equipment.

The vessels as made available for the inspection shall be free from slag, dirt, oil, welding spatter and other

foreign matter.

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The pressure vessels presented for the inspection shall be subjected to a previous dimensional check bythe VENDOR. The VENDOR shall prepare a dimensional record indicating the actual dimensions for eachpressure vessel (including out of roundness; offset in welded joints, deviations from true alignment) andsubmit it to PURCHASERs authorised representative. Any deviations from the specified tolerances shall

be clearly marked in this record.

Manway and handhole cover hinges and hinge bolts shall be placed before the vessel is inspected. Thehinge bolts shall fit so they can be turned freely by hand. Covers shall be swung open to ensure that nobinding occurs.


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All loose components included in the scope of supply of the pressure vessels shall be kept ready for theinspection.

Welds attaching welding pins or studs shall be tested by tapping with a light hammer.

Equipment or parts thereof and materials indicating

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122938019 Specification Pressure Vessel

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