Project ExecutionTender to Design to Fabrication

Brief Overview of the Main Activities from

Tender stage to Fabrication of ASME VIII Vessel

Presented By:HS Compression & Process Pte Ltd(Member of Hiap Seng Group of Companies)

HL Tan/ SL Yap

Pressure Vessels – Section VIII Division 1Basic CoverageThis Division of Section VIII provides requirements applicable to the design, fabrication, inspection, testing, and certification of pressure vessels operating at either internal or external pressures exceeding 15 psig. Such pressure vessels may be fired or unfired. Specific requirements apply to several classes of material used in pressure vessel construction, and also to fabrication methods such as welding, forging and brazing. It contains mandatory and nonmandatory appendices detailing supplementary design criteria, nondestructive examination and inspection acceptance standards. Rules pertaining to the use of the U, UM and UV Code symbol stamps are also included.

Contents Scope & Service Restrictions; General Requirements; Requirements for Fabrication by Welding, Forging, or Brazing; Requirements Pertaining to Classes of Materials for Carbon & Low Alloy Steel;Nonferrous Materials; High Alloy Steel; Cast Iron; Clad & Lined Vessels; Cast Ductile Iron Vessels; Ferritic Steels with Tensile Properties Enhanced by Heat Treatment; Layered Construction; High Stresses at Low Temperatures.

Section VIII Division 2 Alternative RulesBasic CoverageThis Division of Section VIII provides requirements applicable to the design, fabrication, inspection, testing, and certification of pressure vessels operating at either internal or external pressures exceeding 15 psig. Such vessels may be fired or unfired. This pressure may be obtained from an external source or by the application of heat from a direct or indirect source, or any combination thereof. These rules provide an alternative to the minimum requirements for pressure vessels under Division 1 rules. In comparison the Division 1, Division 2 requirements on materials, design, and nondestructive examination are more rigorous; however, higher design stress intensity values are permitted. Division 2 rules cover only vessels to be installed in a fixed location for a specific service where operation and maintenance control is retained during the useful life of the vessel by the user who prepares or causes to be prepared the design specifications. These rules may also apply to human occupancy pressure vessels typically in the diving industry. Rules pertaining to the use of the U2 and UV Code symbol stamps are also included.

ContentsGeneral Requirements; Material Requirements; Design Requirements; Fabrication Requirements; Pressure Relief Devices; Inspection inRadiography; Testing; Marking; Stamping; Reports & Records.

ASME VIII Division 3 High Pressure VesselsBasic CoverageThis Division of Section VIII provides requirements applicable to the design, fabrication, inspection, testing, and certification of pressure vessels operating at either internal or external pressures generally above 10,000 psi. Such vessels may be fired or unfired. This pressure may be obtained from an external source, a process reaction, by the application of heat from a direct or indirect source, or any combination thereof. Division 3 rules cover vessels intended for a specific service and installed in a fixed location or relocated from work site to work site between pressurizations. The operation and maintenance control is retained during the useful life of the vessel by the user who prepares or causes to be prepared the design specifications. Division 3 does not establish maximum pressure limits for either Section VIII, Divisions 1 or 2, nor minimum pressure limits for this Division. Rules pertaining to the use of the UV3 Code symbol stamps are also included.

ContentsGeneral Requirements; Material Requirements; Design Requirements; Fabrication Requirements; Pressure Relief Devices; Examination Requirements; Testing; Marking; Stamping; Reports & Records.

Mandatory Appendix 13Vessels of Noncircular Cross Section

I Tender Stage

• Review Client Data sheet• Client Spec• ASME Codes’ Compliance• U-stamp? or• Third Party Inspection?

Example 1: Dehydration TEG Contactor

Data Sheet’ Cont’d

Data Sheet Cont’d

Data Sheel Cont’d

Need to pay attention on Notes

Flow Simulation

Example 2: Compressor Suction ScrubberRef: ASME VIII, API 618, Client spec etc

II Initial Phase- SizingProcess Calculation (Design flow, Pressure, Temp

etc),e.g. using Hysys program, to• Determine Vessel size • Finalize Vessel Main Parameters (Horizontal/

Vertical, materials, impact testing, CS/ SS/ Clad vessel?, 2:1 Ellipsoidal Head etc)

• Numbers of Nozzles/ Sizes required.• Thickness, nozzles ratings , vessel weight can

then be calculatedThen

• Vessel Cost ,delivery etc can now be determined

III Engineering Design PhaseUpon Award:• Kick-off meeting to reconfirm Client’s project specifications

requirements• Prepare GA Drawings with details on orientation/ evaluation of

nozzles, perform mechanical calculation etc based on calculated loadings and submit for approval (to Client, Third Party or AI)

• Finalize details on Vessel Internals , Client may have their ownstandard, e.g. Shell DEPs; ExxonMobil Basic Practices.. etc

• Prepare BOM, selection of applicable WPS, determine NDT / PWHT requirements

So enable:• Procurement of materials• Fabrication• Testing (Note: if it will be pneumatically tested in cold country, test

temperature has to be 17 C above min metal design temp, UG-100(b) )

Inlet Piping Connection

e.g. Ref: Shell DEP 31.22.05.11

UG-36 OpeningOpening shall preferably be circular,

elliptical or obroundExample of Compressor Obround Flange

Special Flange Calculation Sheet(Example only)

FEA Model and Element

FEA Analysis Result

Obround Flange installed on Compressor

Large Nozzle OpeningsUG-36(b)

1. For vessel 1500 mm inside diameter and less, ½ the vessel diameter, but not to exceed 500 mm

2. For vessels over 1500 mm ID, 1/3 the vessel diameter, but not to exceed 1000 mm

3. For nozzle openings exceeding these limits, supplemental rules of 1-7 shall be satisfied in addition to UG-36 through UG-43

Note: It is recommended that special considerations be given to the fabrication details used and inspection employed on large openings; reinforcement often may be advantageously obtained by use of heavier shell plate for a vessel course or inserted locally around the opening, note also to grind the welds to reduce stress concentrations.

UG-35Quick Opening

Note the Safety Feature

Innovative Design Features

Innovative Design Features

IV Fabrication PhaseUse of welded pipe as vessel body ?

Refer: UG-8

Chinese GB Material (16MnR)Is This Material Acceptable?

V Inspection

Inspector shall verify that• Design Calculations are available • Materials used comply with requirements UG-4

through UG-14 (UG-93)• WPS are acceptable (UW-28, UW-47 etc)• Heat treatment are per code requirements (UG-

85, UW-10, UW-40, UW-49 etc)• Visual /NDT and witness hydrotest as per code

(UG-84, UG-93, UG-95, UG-96, UG-97, UG-99, UG-100, UW-50, UW-51, UW-52.. Etc)