a. The manufacturer shall be responsible for suitably packaging each vessel or component and adequately supporting and securing all vessel internals to protect them from damage or loss during handling and shipment.
b. When specified on the EDS, a certified weight shall be obtained for the vessel prior to shipment preparations.
c. The manufacturer shall include a packing list in each shipment.
d. All spares shall be suitably packaged, marked, and shipped with the vessel.
e. All bolting and other loose parts shall be suitably packaged and identified with the purchase order number and vessel tag number.
f. Uncoated bolts and nuts shall be coated with a suitable thread lubricant to prevent corrosion during transportation and storage. The lubricant shall be easily removable with mineral spirits or a solvent.
g. Internals which cannot be safely shipped in place shall be identified, tagged, and shipped separately.
h. For internals which have specified clearances or tolerances, a minimum of one of each type (e.g., tray type or distributor type) shall be trial assembled into the vessel to ensure proper fit before shipment.
i. Design and construction details for shipping saddles shall be submitted to BP for review and approval.
j. Austenitic stainless steel vessels shall be protected from exposure to salt water, salt spray, and chlorides during ocean or over the road shipment.
k. Vessels that will undergo ocean shipment shall have a preparation and shipping plan submitted for approval.
1. Vessels shall not be transported to the jobsite as above-deck cargo without prior written approval of BP.
2. If nitrogen is used, the vessel shall be clearly marked identifying that nitrogen is present.
The method and location of such marking shall be agreed upon between vessel manufacturer and BP.
l. All packaging and protection shall be suitable for outdoor storage for a minimum period of 6 months.
16.2 Preparations for the vessel
a. Flanged openings shall be protected and made waterproof with one of the following:
1. Plastic flange protectors.
2. Metal flange protectors with rubber gaskets.
b. Covers for flanged opening shall be secured with at least 25% complement of total flange bolting (minimum of 4 bolts).
c. Welding stub ends shall be protected with plastic caps.
d. Threaded couplings shall be protected with bull plugs and sealed with joint compound.
e. Socket weld fittings shall be protected with plastic caps.
f. Weld bevels shall be closed with plastic caps.
g. Nozzles, including attached piping, within or passing through vessel support skirts shall be adequately supported for shipping and handling.
h. Machined surfaces (except weld bevels), flange faces, threaded surfaces, and other finished or delicate parts shall be well-greased and protected against rusting and damage during shipment.
i. Weld bevels shall be free of dirt, oil, grease, scale, rust, and other foreign materials.
j. Weld bevels of carbon steel and ferritic alloy steel materials shall be coated, after cleaning, on the inside and outside for a distance of approximately 75 mm (3 in) from the end of the weld bevel with a weldable rust preventive approved by BP.
k. Holes in reinforcing pads and saddle wear plates shall be plugged with room temperature vulcanizing (RTV) silicone sealer or rust preventative grease that is compatible with the base material.
l. Blind flanged connections, including manways, shall have the blinds attached with a full complement of new service bolts and service gasket.
m. Hardened washers shall be provided under nuts for all bolts having diameters of 32 mm (1-1/4 inches) or larger to prevent damaging the back side of the flange. The washers shall be a minimum of 6 mm (1/4 inch) thick.
n. Joints shall be assembled in accordance with ASME PCC-1.
o. If the permanent saddles of horizontal vessels are used for support during shipment, saddle extensions constructed of timber or other suitable materials shall be secured to the saddles to provide adequate ground clearance for boot or nozzle projections, if any, that extend below the permanent saddle base plate.
16.3 Preparations for spares and crated parts
a. All items shipped not attached to the main vessel shall be packaged and crated for secure shipment.
b. All parts with nozzles, flanges, or connections (such as piping spools) shall be protected as listed in Clause 16.2.
c. Crates shall be durably marked with:
1. The receiving address.
2. The vessel item number.
3. The purchase order number.
d. Markings shall be in a minimum of two (2) locations and a minimum lettering size of 25 mm (1 inch).
e. All markings shall be in the English language.
f. All markings shall also be in an additional language if so specified on the EDS.
16.4 Securing and padding
a. Ropes, chains, and straps may be used to secure the vessel and associated equipment to the transporter deck.
b. Padding shall be placed between cables or chains and stainless steel or high alloy equipment to prevent discoloration of the vessel shell and/or contamination of the metal.
c. Nozzles and manways shall not be used as tie-down points.
d. External attachments other than lifting lugs and tailing lugs shall not be used as tie down points unless the external attachment has specifically been designed as such.
e. If carbon steel shipping saddles are used for stainless steel or high alloy vessels, the saddles shall be padded.
16.5 Material safety data sheets
a. Vessels or materials that contain or are coated with any of the following shall be prominently tagged at openings to indicate nature of contents and precautions for shipping, storage, and handling:
1. Insulating oils.
2. Corrosion inhibitors.
3. Antifreeze solutions.
4. Desiccants.
5. Chemical substances.
6. Hydrocarbon substances.
b. Regulated substances shall have a material safety data sheet (MSDS).
c. MSDS shall fully conform to regulations for MSDS preparation specified by entity that has jurisdiction and shall include a statement that the substance is considered hazardous by regulation.
d. If any products are exempt from regulation, a statement to that effect shall be included.
e. All MSDSs shall be forwarded to the receiving facility before shipment.
f. All MSDSs shall be placed in a protective envelope(s) and shall be affixed to the outside of the shipment.
17 Documentation
The following documentation shall be required.
17.1 Proposal documentation
a. The manufacturer shall supply all relevant information necessary for appraisal of the mechanical design by BP, which includes but is not limited to the following:
1. Confirmation of compliance with the code of construction and all documents that are part of the enquiry or provide requests for clarification or deviations.
2. A typical quality control plan.
3. The proposed manufacturing plan.
4. A listing of any proposed suppliers and sub-contractors, including names and addresses.
5. A definition of the welding processes and techniques to be used, including that for overlay applications.
6. A list of any requested exceptions or deviations to the contract documents including this GIS.
7. Details of previous fabrication experience on vessels of similar size and of the same materials and construction.
b. The base proposal for the construction of the vessel shall be provided in full compliance with BP’s request for quotation.
c. An alternative design proposal may be submitted if considered less costly and/or an improvement in the delivery schedule.
1. The improvements in cost and schedule shall be realized without any of the following:
a) Loss of capability.
b) Shortening the anticipated life of the vessel.
c) Increase in the total lifecycle cost of the vessel.
d. Alternative design proposals shall be in accordance with the following:
1. Shall be accompanied by the base proposal and be clearly identified as an alternate proposal.
2. Shall clearly state the intended use of ASME Code Cases.
3. Shall be fully and clearly described and substantiated by sketches or drawings.
4. Shall include a list of specific exceptions to BP’s request for quotation, the EDS, and the contract documents including this GIS.
17.2 During design and fabrication
a. Work shall not begin unless the plans and procedures applicable to that work have been approved by BP.
b. The following shall be submitted for review and approval by BP:
1. Quality plan.
2. Inspection and test plan.
3. Fabrication plan.
4. Names and addresses of all suppliers and sub-contractors.
5. Full set of fabrication drawings.
6. Complete calculations.
7. Welding procedure specifications (WPS).
8. Procedure qualification record (PQR).
9. Weld map.
10. Heat treatment procedures.
11. Pressure test procedure.
12. PWHT procedure.
13. NDE procedures.
14. Drawings of trays, packing, and internals, if applicable.
15. Centre of gravity and foundation loading diagram.
16. Draft ASME forms.
17. Draft final pressure vessel record book (see Clause 17.3b).
c. The fabrication drawings shall include, but shall not be limited to, the following:
1. Applicable information on the pressure vessel data sheet.
2. Dimensions of vessel components.
3. General vessel details including nozzle details.
4. Gasket and flange details including flange face finishes.
5. Internal construction details including shell attachments and location.
6. Full scale drawing of the vessel nameplate.
7. Support and other appurtenance details including an anchor bolt template.
8. Weld joint details in cross-section, weld map, and applicable welding procedures.
9. Clad and weld overlay details.
10. Heat treatment requirements.
11. Weld hardness requirements.
12. Non-destructive testing requirements.
13. Identification of pressure limiting components.
14. Tolerances to which the vessel will be built.
d. Fabrication drawings shall use the system of units specified by BP.
e. Revisions of drawings, plans, procedures, and other previously submitted documents shall be submitted for further approval by BP.
f. No modifications shall be made to the approved drawings, plans, procedures, and other approved documents without the approval of BP.
g. Documents shall reference both the purchase order number and the vessel item number.
h. As a minimum, the following documents shall be available for review during manufacture:
1. Purchase orders and specifications for plates and forgings, CMTRs, chemical analysis, and mechanical properties of pressure containing materials including weld filler materials, except weld filler materials in carbon steel vessels.
2. Copies of actual heat treatment charts indicating complete temperature cycles, holding times, cooling and heating rates.
3. Radiographs.
4. WPSs, PQRs, and welder qualification records.
5. NDE examination reports.
i. For components and aspects of the design that fall beyond the scope of the code, adequate calculations shall be carried out by the manufacturer to justify and prove the integrity of the design and shall be submitted to BP for review and approval.
17.3 Final documentation
a. On completion of construction of each vessel, the manufacturer shall assemble and deliver the pressure vessel record books to BP.
b. The pressure vessel record book shall contain, as a minimum, the following information:
1. Manufacturer’s Data Report (ASME forms).
2. Photocopy or photograph (not a rubbing) of the vessel nameplate.
3. Mechanical design calculations required to demonstrate compliance with the code, or to justify and prove the integrity of the design for those components and aspects that fall beyond the scope of the code.
4. The latest revision of the EDS marked up to reflect the as-built conditions.
5. Quality control plan including fabrication sequence, all heat treatment requirements, forming and rolling procedure, an inspection and test plan with schedule identifying all inspection points required by the owner, and signed inspection reports.
6. As-built fabrication drawings.
7. Welding procedure specifications (WPS), procedure qualification records (PQR), weld map, and welder or welding operator qualification test results.
8. Personnel qualification certificates for all non-destructive examinations.
9. All reports required by the code of construction stating the results of non-destructive inspection and testing including radiographic examination, ultrasonic testing, magnetic particle examination, liquid dye penetrant examination, and hardness tests.
10. Pyrometer charts or other detailed records for all heat treatment performed, such as PWHT, normalizing, and heating for forming.
11. All exceptions, deviations, and non-conformance reports (including resolution) and a detailed description of any repairs including a sketch, photo, or drawing indicating the location and size of the repaired area.
12. Charts or other records of required pressure tests.
13. Certified material test reports or certificates of compliance which fully identify the specific materials they represent.
14. The PMI report for all materials subject to PMI examination.
15. A completed inspection checklist per the inspection test plan.
16. Results of all impact testing.
17. Operations and maintenance requirements/procedures as applicable.
c. Three (3) copies of the pressure vessel record book shall be delivered to BP unless a different number of copies is specified in the contract documents.
d. The pressure vessel record book shall also be provided on a CD or DVD securely attached within each furnished hardcopy of the book containing the following:
1. A PDF version of the pressure vessel record book.
2. The computer files of the pressure vessel calculations (i.e., COMPRESS, PVElite, Finglow, FE/Pipe, NozzlePro files).
3. Any FEA model files with solution (i.e., ANSYS or Abacus files).
e. Where applicable, the pressure vessel data book shall include all correspondence relating to the approval of “state special” designs as required by the applicable jurisdictions.
f. The pressure vessel record book shall be retained by the vessel manufacturer and shall be furnished to BP upon their request for a minimum of five (5) years.
Annex A
(Normative)
Supplementary requirements for special services
A.1 General
If the EDS indicates any of the following special services are present, the requirements contained within that clause below shall apply.