Standard Specification

For Pressure Vessels

0 ASA 23.09.02 AVV 24.09.02 AD 27.09.02 ISSUED AS STANDARD SPECIFICATION

Rev. Name Date Name Date Name Date Remark, kind of revision

Prepared, revised Checked Approved

Standard Specification for Document No. Sheet / of Revision

Lurgi India
Pressure Vessels LI-ODV-STD-1001 1/26 0
LI-0-FMT-0001
Issue: Rev. 00 , 25.08.2000
 Project Name Project No. Document No. Sheet / of Revision
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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 found
Issue: Rev. 00 , 25.08.2000 Sheet 2 of 122
 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
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 VENDOR’s Design Basis..................................................................................................................................24
4.6 Document submission......................................................................................................................................24
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
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
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
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
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
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
7 INSPECTION AND TESTING...........................................................................................................................100
7.1 General ..........................................................................................................................................................100
7.1.1 PURCHASER’s 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
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
8.5 Loading and Anchoring...................................................................................................................................116
8.6 Painting..........................................................................................................................................................117
8.7 Marking...........................................................................................................................................................118
9 DATA FOLDER.................................................................................................................................................121
1 SCOPE
This specification together with other listed Codes, Standards, Specifications and Mechanical Data
Sheets, 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
Standard Specification for contractor for the EPC No.
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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 PURCHASER’s 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 VENDOR’s scope unless excluded
specifically 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 vessels
are to be used must be complied with by the fabricator. It shall be vendor’s responsibility to take approval
for design, material of construction, fabrication, inspection and testing from statutory authorities including
and 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 used
as 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 Spherical
and 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-saddled
supports by L.P. Zick

2.3 Conflicts
If conflict occurs between PURCHASER supplied documents, it shall be informed to the PURCHASER and
shall 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 the
reference 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 PURCHASER’s requirements if significant
savings can be demonstrated. Such proposals will receive full consideration, provided each deviation is
fully described and the corresponding documents are provided.
The PURCHASER reserves the right to accept any alternative proposal without further consideration of the
Vendor. An alternative design
Standard shall not
Specification forbe used unless it is approved
Document in
No.writing by the PURCHASER.
Sheet / of Revision

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

4 DESIGN

4.1 General
Mechanical Data Sheet which includes material specifications, principal dimensions, general requirements
codes 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. It
will be the VENDOR’s responsibility to design all internals.
Vessel size and internal design shall permit internal access to all welds for inspection and non-destructive
examination 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 and
workmanship. Approval by PURCHASER of design calculations and detail fabrication drawing will not
anyway absolve the VENDOR from his responsibilities to supply equipment in accordance with order
specifications.
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 Where process design of the equipment is provided by the VENDOR, the performance of the equipment
shall 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 a
minimum 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 PURCHASER´s Mechanical Data Sheets
and/or drawings, the design, materials, fabrication, inspection and testing shall meet the requirements of
the 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 and
constructed according to ASME Section VIII - Div. 1.
When a pressure vessel designed according to ASME Section VIII, Div. 1 is specified to be in cyclic
service, 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 shall
be used.

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4.5 VENDOR’s Design Basis
Vessel data sheets, sketches and any standard details supplied by the PURCHASER are intended to
convey 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 sheet
shall be regarded as minimum values, after forming, including corrosion allowance. Should the VENDOR's
calculations 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 for
approval.
• Code calculations including nozzle reinforcement calculations, local stress analysis for
nozzles and vessel clips due to external loads, thermal stress analysis whenever applicable or if
specifically asked for, structural calculations for supports, internal lifting 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 vendor’s responsibility to
get approval from IBR authorities pertaining to design, material of construction, fabrication, inspection and
testing. Standard Specification for Document No. Sheet / of Revision

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

All documents referred above shall be submitted for approval to the PURCHASER on or before schedule
date.
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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 static
head 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 actually
subjected to external pressure during operation. Vacuum caused by emptying water after hydrostatic tests
or 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 design
temperature(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 of
pressure 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 of
that 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 be
considered 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
Standard twice theforspecified corrosion allowance
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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 Minimum
After-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 detailed
showing all working and references used and shall be presented in such a manner that they can be easily
checked.
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 centre
of gravity (empty and operating).
Vessels and their supports shall be designed for the most severe condition of coincident loading, as
defined 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 secondary
stresses due to differential thermal expansion shall be investigated, and the resulting combined stresses
and 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 be
minimum for mechanical design, plate thickness shall be maximum for weight calculations. Design
calculations 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, operating
contents 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 impact
loads) all combined with wind or earthquake.
Shop Test Includes test pressure, test load of vessel and attached equipment and
weight of test contents in the vessel and in such other equipment as may
be affected.
Field Test All vessels shall be checked in fully corroded conditions for a field test with
code 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 and
percentage 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 of
water 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, or
external 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, the
result 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/mm 2

4.7.7 Loading
The following load conditions
Standard and combinations
Specification for 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 internal
pressure.

4.7.7.2 Dynamic Loads

The design for wind and seismic shall be performed for the geographical area of the installation site and
shall 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 design
practice.
Seismic Considerations: for vessels Seismic coefficient method and for column response spectrum
method 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 5000m
consecutive platform
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 surface
area 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 of
the 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 so
on, 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 the
sum 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 (at
room temperature) or 2/3Specification
Standard of the yieldfor
strength (at design temperature)
Document No.or that producing
Sheet / aofcreep rate of 1
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 % in 10 000 hours, except that the following non-pressure parts shall be designed using the stress for
pressure 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 their
supports.
When creep becomes a design consideration, VENDOR shall submit detailed design to PURCHASER for
review.
The calculated stresses for the design conditions shall be limited to the following:
Erection basic allowable stress at ambient temperature and uncorroded thickness
Operation/empty basic allowable stress at design temperature and corroded thickness
Test 90 percent of the minimum specified yield stress at test temperature and corroded
thickness for pressure parts & 1/3 of the basic allowable stress at test temperature and
corroded thickness for non-pressure parts
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 For all design conditions the maximum allowable longitudinal compressive stress for shells including skirt
to 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 including
impact 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 shall
be seamless .
Forged nozzle necks are preferred in lieu of pipe necks and shall be used when shell thickness is 40 mm
or over.
All plates and forgings with a shell or flange thickness of 40 mm or greater (except ASME B 16.5 standard
flanges) 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. sour
gas, 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, authentic
material 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 the
mill. 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 the
fabrication 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 to
pressure 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 or
manufacturing 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 1
square foot in each 10 square feet or fraction thereof, shall be ultrasonic examined for lack of bond after
forming. The cladding shall
Standard be 100% for
Specification ultrasonically examined in areasNo.
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Sheet / of be welded

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 directly to the cladding. Unbonded areas that cannot be encompassed by a 3 inch diameter circle shall be
repaired by weld deposit overlay in accordance with the specification “Welding of Pressure Vessels“. When
repairs in excess of 5% of the total examined area are required, the vessel shall be 100% ultrasonic
examined. Repaired areas and weld deposit overlay at weld seams shall be 100% liquid dye penetrant
examined in accordance with ASTM E165. Ultrasonic examination shall be in accordance with ASTM A578
S6 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 be
made with weld deposit which is at least as thick as the lining when properly machined and of the same
alloy as the lining. When nozzles are lined with ferritic type 405 or 410S stainless steel linings, the facing
weld deposit shall be made with type 309 welding electrode. The facing weld deposit for austenitic
stainless steel linings shall be made with type 309 welding electrode for the first pass, and the welding
electrode 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 weld
deposit 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 PURCHASER’s Design
Standards.
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 When a difference in thickness exists between shell plates or plates and heads, the inside diameter shall
be maintained, unless specified otherwise.
Tell-tale holes are required in all places where a lap or void occurs. This hole shall be deburred before
assembling the joint.
Individual shell courses shall have their longitudinal seams welded separately before assembly with other
shell 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 shrinkage
shall be carefully estimated and allowed for the welding of circumferential seams, fittings, 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 are
applicable to stainless steel.

6.2.2 Materials Segregation

In storage areas, stainless steel and high alloy materials shall be stored together and physically separated
from carbon steel materials. There shall be no contact between stainless steel and high alloy material to
carbon 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 steel
working. 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 for
stainless 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 to
the PURCHASER for review.

6.3 Reference Work Line

VENDOR´s fabrication drawings for each vessel shall indicate a permanent reference work line which shall
be marked around the vessel perimeter on approximately 305 mm centres. Marks shall be both outside
and inside except clad or weld overlay vessels shall be marked on outside only. All dimensions shall be
from this line. For marking vibro-etching or low stress multi-dot stamping may be used.
The reference work line shall
Standard always be
Specification for located at a tan lineDocument
(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 clear
openings 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 PURCHASER´s written agreement shall be obtained. Any additional
NDT specified by the PURCHASER in such cases shall be performed at the VENDOR´s 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 are
not 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 shall
not 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 or
behind any obstruction that prevents inspection of these welds. Circumferential seams shall not fall on a
tray 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 diameter
and an insert plate of same thickness as end, formed to correct radius shall be butt welded. This
requirement 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 particle
inspection technique (or liquid penetrant if stainless steel) and shall show freedom from cracks and splits
after final forming.
Butt welds in heads which are fabricated from more than one plate shall be fully radiographed after all
forming and heat treatment. One chordal joint in dished ends is acceptable, the joint shall be located in the
middle 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 centre
marked (in accordance with paragraph 6.3) on head straight flange 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 integrally
welded bolting flange or welding neck flange. The joint between all necks and welding neck flanges
shall 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 VENDOR´s fabrication drawings and approved by the
PURCHASER.
− Slip-on flanges class 150 lb may be used for access and inspection openings for design temperature
up to and including 260°C and non-cyclic service. Not to be used for austenitic steel vessels and
when the service is designated to be hydrogen, hydrogen sulphide, sour water or cyclic and in
service 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 fillet
welds.
Cover plates for manholes, handholes and nozzles shall be forged of the same material and be of the
same 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 than
that 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 fully
radiographed 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 steel
flanges 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 withSpecification
Standard a jig to prevent
for 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 PURCHASER’s data sheets.

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 All connections for nozzles, manways, handholes and so forth which do not extend into the vessel for
internal connections are to be finished flush with the inside of the shell. The inner circumference of nozzle
necks 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 plates
are required for saddles.
- Self reinforced type nozzles shall be provided.
Bolt holes in external and internal flanges shall straddle the principal vessel centrelines unless otherwise
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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 3”NB 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 PURCHASER´s Mechanical Data Sheet plus limitations of this
specification.
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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 ¼“ NPT drilled and tapped tell-tale holes to permit testing attaching
welds with air and soap suds prior to final hydrostatic test. Drilled hole shall be deburred before attaching
pad to vessel.
Where fillet welds on nozzle reinforcing pads are smaller than the pad thickness the corner of the pad shall
be 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 and
3” 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 are
specified (allow one bolt diameter extra on length for bolt tensioner). Threads shall be UNC up to and
including 1“ and unified 8 UN over 1“ (ASME/ANSI B1.1, Class 2A or Class 2B). All nuts shall be heavy
series. (Three nuts required for stud bolt tensioning when a bolt tensioner shall be applied). The strength of
studs shall be based on the cross-section of the smallest diameter. Studs shall extend 10 mm beyond each
nut. Hard steel washers 6 mm thick shall be furnished under studs 1 ½ 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 gasket
seating, 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 material
grade) 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 lines
coincide, 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 the
vessel.
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 minimum
distance of 4 times the anchor bolt diameter between the outer flange diameter of the outcoming bottom
head 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 thickness
not 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. An
alloy ring of same quality as the head material shall be provided on the head for attachment to the carbon
steel 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 (-) 50°
C 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. Notification
shall be given to PURCHASER at least 5 working days before shipment so that PURCHASER's authorised
representative can perform a dimensional check.
The gauge plate shall remain in the manufacturers workshop and shall be attached to the vessel skirt base
ring 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 the
vessel circumference and shall have sufficient thickness or stiffeners to be suitable for design and
hydrotest conditions. Material in the vessel support reinforcing pad shall be the same as in the vessel. A ¼”
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 NPT vent hole shall be provided in each backing plate. Reinforcing pads shall be continuously welded to
the vessel shell.
For vessels built of solid alloy steels, with shell thickness less than 10 mm and supported on legs or
saddles, the carbon steel supports shall not be welded directly to the vessel shell. Alloy backing plates
shall be used between the shell and the carbon steel support. Backing plate shall be made of the same
material as the shell, except that for all grades of austenitic stainless steel shells, the backing plate may be
of 304 stainless steel.
Where horizontal vessels are installed on concrete foundations, a sliding plate shall be furnished under the
sliding support for shell expansion.
Long holes in sliding supports shall provide sufficient space for shell expansion.

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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 not
weighing more than 50 kg.
Internal non-pressure removable connections shall have machine-faced plate flanges not less than 10 mm
corroded thickness. Screwed connections are not acceptable.
All internal bolting shall be fitted with lock nuts, pins or other locking device to prevent loosening by
vibration.
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 the
following 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 minimum
nominal 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 not
separately 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 which
are 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 attaching
trays, baffles, pans, support clips and rings to the vessel interior, shall be in accordance with the tray
support 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 PURCHASER’s authorised representative has completed
all 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 corrosion
resistant 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 edges
shall be rounded to a minimum radius of 3 mm and all weld spatter removed prior to blasting. Internal
pipes 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 when
required. Shell and/or head to which such support clips are attached shall be checked for local stresses
induced by external loads to be provided by PURCHASER.
Large carbon steel attachments such as jacket closures, platforms and piping support clips, shall not be
directly welded to vessels built of solid alloy steels, but shall be welded to an alloy pad of the same
material 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 pad
closely follows the contour of the shell or head. Large size pads may require additional attachment welds
within 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 every
800 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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 Standard Specification for Document No. Sheet / of Revision

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6.13.1 Name Plate
Completed vessels shall have a nameplate in accordance with Standard Drawing. Nameplates shall be of
SS material installed on a nameplate bracket. The location of the name plate shall be as per Mechanical
Data Sheet.

6.13.2 Lifting Lugs

All vertical shop fabricated vessels with an empty weight of over 100 kg shall be provided with lifting
devices. Lifting lugs attached to the top of the vessel on the shell side or lifting trunnions attached to the
shell above the vessel gravity centre shall be used depending on the vessel size and field erection
capabilities. The construction shall be as specified on the vessel drawing/data sheet.
No lifting devices shall be provided on horizontal vessels, unless noted otherwise.
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 Lifting lugs and tailing lugs not shown on PURCHASER´s drawings shall be designed and supplied by the
VENDOR. Calculations shall be submitted to the PURCHASER for approval. For all lugs designed by the
VENDOR, including a check of the shell of local loads. Lugs shall be suitable for transportation and
erection of the vessel to its operating position. A shock factor of “two“ shall be included in lifting lug
calculations.

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 conductor
shall 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 the
applicable specification if specified.
Acceptance of welder/operator qualifications by the PURCHASER’s representative shall be obtained
before 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 steel
as 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 alloy
steel 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 thickness
shall 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“ when
hot 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 PURCHASER´s approval.

6.15.3 Treatment before and after PWHT

Flange faces and other machined surfaces shall be suitably protected against oxidation during heat
treatment 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 be
permitted. If it is not possible to heat treat the complete vessel together with all welded attachments, this
shall 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 outside
surface 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 straight
line 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 or
minus ½ % 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 the
area 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 PURCHASER’s Inspection

Inspection by the PURCHASER’s representative shall be in accordance with the VENDOR’s
Quality/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 for
inspection.

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 PURCHASER's authorised representative shall have the right to inspect all work in progress, both in the
shop or in the field, to insure that proper workmanship, orientation, welding, testing, painting, etc. are being
performed.
PURCHASER reserves the right to make preliminary intermediate and final inspection of both shop and
field 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 by
the VENDOR. The VENDOR shall prepare a dimensional record indicating the actual dimensions for each
pressure vessel (including out of roundness; offset in welded joints, deviations from true alignment) and
submit it to PURCHASER’s 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. The
hinge bolts shall fit so they can be turned freely by hand. Covers shall be swung open to ensure that no
binding occurs.

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 All loose components included in the scope of supply of the pressure vessels shall be kept ready for the
inspection.
Welds attaching welding pins or studs shall be tested by tapping with a light hammer.
Equipment or parts thereof and materials indicating irremediable or injurious defect, improper fabrication,
excessive repairs and those that require more than two PWHT, or that they are not in accordance with the
requirements of this specification shall be subject to rejection. They shall be subject to rejection at any time
or place by the PURCHASER’s authorised representative if such conditions are discovered after
acceptance of the items at the VENDOR’s plant.
Acceptance of shop tests shall not constitute a waiver of requirements to meet field tests under specified
operating condition, nor shall shop inspection by PURCHASER relieve the Vendor of responsibility in case
of later discovery of defective material or workmanship.
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7.1.2 Test Records
The records listed below shall be available for examination by PURCHASER’s authorised representative at
the time of inspection.
− Mill test reports for pressure parts. The test reports shall state the specification to which the material
complies, the heat, lot or melt number, the heat treatment (if any) given to the material, and the
results of chemical analysis and mechanical tests. Certificates are acceptable for heat treatment
information missing on mill test reports.
− Certificates for bolting material
− Welding procedure specifications, procedure qualification records and welder qualification tests

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 − Radiographic films for required radiographic tests incl. the experts assessment and certificates for
the results of any required magnetic particle, fluid penetrant, or other method of examination
− Charts or other records of required hydrostatic, pneumatic, and other tests
− Pyrometer charts or other detailed records of heat treatment (postweld, normalising, heating for
forming, etc.)
− Dimensional check record

7.1.3 Additional Test and Inspections

The material tests and inspections outlined in this specification shall be made for quality assurance and for
job records but shall not be considered to prohibit the Vendor from making additional tests or inspections to
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 establish or improve shop procedures which will result in a satisfactory vessel. Results of the additional
tests or inspections shall be for the Vendor’s internal use only.

7.1.4 Notice of Inspection and Examination

The Vendor shall furnish the necessary gauging and examination equipment and assist as required in all
inspections and measuring operations.

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7.1.5 Pre-Inspection Meeting
A pre-inspection meeting shall be held prior to the start of any fabrication work. The VENDOR shall
produce a VENDOR’s Schedule, witness and hold points, weld procedures and any other documents
concerning vessel fabrication as requested by the PURCHASER.

7.2 Air Testing of Reinforcing Plates

Standard Specification for Document No. Sheet / of Revision

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 Reinforcing plates for nozzles, saddles and other external welded attachments shall have tell tale holes
tapped ¼“ NPT to enable the entire attachment weld to be tested to 1.5 bar g minimum with dry air or light
oil (before any post weld heat treatment and before hydrostatic test) using soap suds solution to detect
leaks. After hydrostatic testing of the vessel, these holes shall be plugged with hard grease.

7.3 Hydrostatic Tests

7.3.1 General
Prior to pressure testing, equipment shall be thoroughly cleaned internally, and external surfaces shall be
free of weld spatter, scale, and other foreign material. All exterior surfaces and welds subjects to pressure
shall be clean and dry.
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 All vessels shall be hydrostatically tested in accordance with the design code prior to painting. The test
pressure shall be held for 1 hour per 25 mm wall thickness with a minimum period of 1 hour.
Vertical vessels which are to be shop hydrostatically tested in the horizontal position shall be supported
adequately to prevent local stresses from exceeding 90% the yield strength of the material.
Temporary supports or bracing during hydrostatic testing shall not be used.

7.3.2 Pneumatic Test

Where pneumatic (excluding reinforcing pad leak tests) and/or proof tests are required a procedure shall
be submitted for the PURCHASER´s review.
When a field fabricated pressure vessel is to be pneumatically tested, the vessel seams shall be subjected
to a 100 percent radiographic examination and all nozzle and attachment welds except welds attaching
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 welding pins or studs shall be subjected to either a magnetic particle or liquid penetrant examination on all
exposed surfaces before the pneumatic test is performed.

7.3.3 Bolts and Gaskets

Service bolts and gaskets shall only be used for hydrostatic testing, when tightened to a predetermined
tension using a procedure agreed with the PURCHASER.
Even for manholes, covers and heat exchangers, the pressure testing gaskets will not be replaced for
delivery to site. The new gaskets required for these connections, whenever the joints have to be opened at
site, shall be separately supplied and installed at site by others.

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7.3.4 Testing Water Conditions
Hydrotesting of carbon steel vessels shall be performed using clean potable water. Sea water shall not be
used.
Hydrotesting of stainless steel and high Nickel alloy vessels or those containing stainless steel lining or
fixed internals shall be performed using clean water containing not more than 30 ppm chlorides.
After hydrotesting and careful draining stainless steel and high nickel alloy vessels, it
has to be assured that only swabbing and cold air blowing (no hot air drying) is applied.

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8 PREPARATION FOR SHIPMENT

8.1 Preservation
Vessel to be cleaned, dried and free from all foreign matter after hydrotest.
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 Drying to consist of wiping dry and cold air drying of inaccessible areas. General hot air drying is not
required and not allowed for stainless steel vessels.
All bolting shall be lubricated with molybdenum disulfide or equivalent before assembly.
All threaded connections such as test holes in reinforcing pads and slip-on flanges, etc., shall be filled with
heavy grease.

8.2 Closures
All flange connections shall be protected with metal (min. 6 mm thick) cover plates attached with a
minimum of four bolts
A rubber gasket shall be used between the flange and cover.
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 Permanent blind flanges or covers included in the VENDOR’s supply shall be bolted with service gaskets,
stud bolts and nuts.

8.3 Loose Items

Service gaskets and/or spare parts shall be boxed or crated to prevent damage during shipment. Boxes or
crates shall be marked to indicate the contents and equipment details.

8.4 Match-Marking
Should it be necessary to separate an unit into several parts of transport purposes, then all these parts
shall be carefully match-marked to prevent any assembly errors.
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8.5 Loading and Anchoring
VENDOR to include for all items necessary for safe transportation of the vessel to site including temporary
wooden transport saddles securely strapped or bolted to the vessel.
The VENDOR shall be responsible for loading and anchoring requirements to prevent any damage during
shipment. Anchoring shall be inspected by PURCHASER’s Inspector. Partially fabricated equipment shall
be braced as necessary to prevent any deformation that could affect construction in the field and open
ends shall be covered to keep out dirt or any foreign matter during shipment.
Internals installed prior to shipment when required, are to be properly secured and protected.
VENDOR shall submit a loading diagram for review and comment by the PURCHASER, Diagrams shall be
approved and cleared by the carrier to the final site.
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8.6 Painting
External surfaces shall be prepared for painting and painted strictly in accordance with the Painting
Specification.
Shop painting shall not be applied within 150 mm (6 inches) of any weld before PURCHASER’s inspection.
Field welds of partially shop fabricated vessels shall not be painted until after complete erection and
inspection.
Stainless steel equipment which does not require painting shall have the outside surface treated such that
an uniform appearance is achieved.

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 Only stainless steel brushes, clean, iron free grit or stainless grit shall be used for cleaning alloy surfaces.
All welding flux shall be completely removed.
Solvents used to clean or remove scale or oil shall be free of organic and inorganic chlorides.
De-rusting, painting as well as preservation of the pressure vessels shall be carried out after hydrostatic
testing and the inspection by PURCHASER.

8.7 Marking
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 Vertical vessels shall be marked on the base and with 300 mm high vertical stripes and letter on the skirt,
clearly indicating the north, south, east and west co-ordinates. The marking may be made on the shell near
the bottom tangent line if the vessel is supported on legs or lugs.
Horizontal vessels shall have one end marked north, south, east or west to indicate vessel orientation.
The vessel shall be marked with the item number (character height about 200 mm). Removable pressure
vessel components such as covers, hoods, bundles, floating heads, filter elements etc. shall be durably
marked with the item number.
Care shall be taken to ensure that water insoluble ink or paint is used for markings.
When austenitic steel and high nickel alloy material (inconel, hastelloy, etc.) are to be
marked with fabrication or shipping information, the marking shall be done with water insoluble ink that
does not contain sulphur, chlorides or metallic pigments.
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 Parts to be supplied loose such as spare parts shall be identified by means of a tag indicating the relevant
part number as per the workshop drawing as well as the item number.
Warnings about lifting limitations shall be suitably marked on the vessel.
Vessels which have been stress-relieved shall have a warning printed on two sides which states:
“HEAT-TREATED VESSEL - NO WELDING PERMITTED“
in letters 150 mm high minimum. Similarly warning shall be given for vessels with an applied lining
(epoxy,etc.)

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9 DATA FOLDER
Vendor shall submit the required number of copies of data folder as mentioned in purchase documents.
This must contain the following information duly certified by Inspector:
Manufacturer’s Code Certificate
As-Built drawings of Equipment and design calculations
Rubbing of Name Plates
Material analysis and test certificate
PQR and Welder qualification reports
Heat treatment cycle records chart, Hydrotest record chart, PTC reports,
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 Test results (UT, RT, DP, MP, Hardness, HIC, Charpy V Notch, etc.)
Any other documents as required in purchase order.

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