D
OMIT 13mm (1/2 in) OF WELD TO PROVIDE DRAIN
2 PLACES A RADIUS ALL CORNERS G A J R1.5mm (1/16 in) TANGENT LINE WELD SEAM A H
K LUG REMOVAL LINES
E
F
E/2
C
B
Table 6 - Dimensions of heavy lifting lugs
9.11.7.2 Tailing lugs
a. A typical design of tailing lug is shown in Figure 7 with dimensions in Table 7. b. Calculations for the design of tailing lugs, including quantities shall be submitted for
review and agreement. Requirements specified in 9.11.7.1c.1 and 9.11.7.1c.2 shall be incorporated. Max vessel erect wt. kg (lbs) Thickness
of plate Width Length
Dia. of holes Width of notch Notch height and side weld Weld leg size Brace to top of lug T.L to bottom of lug Bottom of brace to T.L. mm (in) mm
(in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
A B C D E F G H J K 22 750 (50 000) 25 (1) 225 (9) 460+K (18+K) S e e 9 .1 1 .7 .1 .c .1 75 (3) 125 (5) 16 (5/8) 225 (9) 225 (9) By Supplier 45 000 (100 000) 40 (1 1/2) 300 (12) 585+K (23+K) 100 (4) 125 (5) 22 (7/8) 300 (12) 275 (11) 90 000 (200 000) 50 (2) 400 (16) 760+K (30+K) 150 (6) 200 (8) 32 (1 1/4) 400 (16) 350 (14) 136 000 (300 000) 65 (2 1/2) 500 (20) 915+K (36+K) 175 (7) 250 (10) 38 (1 1/2) 500 (20) 400 (16) 181 500 (400 000) 75 (3) 600 (24) 1095+K (43+K) 200 (8) 300 (12) 44 (1 3/4) 600 (24) 475 (19)
c. Tailing lug load shall be determined assuming vessel is lifted from horizontal unless otherwise agreed.
d. Tailing lug material shall be the same as the vessel skirt e. A skirt stiffening spider shall be provided as required.
Figure 7 - Design of tailing lug
B/2 C SECTION A-A TOP PLATE G B D BASE PLATE SKIRT A L PLAN BUTT WELD A A 10mm (3/8 in) 25mm (1 in) PLATE x Ø305mm (12 in) BOTH SIDES BEARING PLATE C/L VESSEL
Table 7 - Tailing lug dimensions
9.11.7.3 Horizontal vessels
a. Horizontal vessels shall be provided with lifting lugs welded to the shell if specified on the data sheets.
b. Calculations for the design of lifting lugs shall be submitted for review and agreement. Requirements specified in 9.11.7.1c.1 and 9.11.7.1c.2 shall be incorporated.
Max. load per lug kg (lbs) Thickness of plate mm (in) Width mm (in) Length mm (in) Dia. of holes mm (in) Weld leg size mm (in) Lug spacing mm (in) A B C D G L 22 750 (50 000) 30 (1 1/8) 150 (6) 300 (12) See 9.11.7.1.c.1 10 (3/8) By Supplier see 9.11.7.2.b 45 000 (100 000) 50 (1 7/8) 200 (8) 400 (16) 16 (5/8) 67 750 (150 000) 60 (2 3/8) 230 (9) 430 (17) 16 (5/8) 90 000 (200 000) 65 (2 1/2) 300 (12) 500 (20) 16 (5/8) 117 000 (260 000) 70 (2 3/4) 340 (13 1/2) 550 (21 1/2) 16 (5/8) 135 000 (300 000) 75 (3) 355 (14) 560 (22) 16 (5/8)
9.11.8 Earthing (grounding) bosses
a. Vessel shall be supplied with two 40 mm (1 1/2 in) diameter x 50 mm (2 in) minimum length earthing (grounding) bosses each complete with M12 x 30 mm (1/2 in x 1 1/8 in) brass bolt, flat washer, and phosphor bronze lock washer. Length of earthing (grounding) bosses may be increased to enable them to protrude fireproofing on supports.
b. Earthing (grounding) boss material shall be of same quality of supports and attached to the supports with 6 mm (1/4 in) continuous fillet weld.
9.12 Removable internals
a. All portions of the vessel, including removable internals, shall be completely self-draining. b. Removable internals shall be designed or sectioned to pass through vessel manways. c. Agitator baffles shall pass through the agitator mounting flange.
d. Weight of individual parts of components that are normally disassembled such as tray decks, downcomers, distributor piping, baffles, minor beams, etc. shall not exceed 25 kg (55 lbs) including attached vapour-liquid contacting devices.
e. Flanges for internal non-pressure piping may be slip-on or fabricated from plate to the dimensions of ASME B16.5 Class 150 unless otherwise specified on data sheets. f. Trays and other column internals shall conform to GIS 46-040.
g. All fasteners shall be positively locked by nut and full size locknut or cotter pin. All fasteners shall be threaded full length.
9.12.1 Mist eliminators
a. Mist eliminators shall be of the sandwich type consisting of entrainment mesh, retained between welded grid supports as shown in Figure 10.to Figure 12 and Table 8. Mesh, grids, bolting, detailed in Figures are in mist eliminator supplier scope but are shown for clarity.
b. The screen assembly shall be attached to the support beams at a minimum of four (4) points per panel with M12 (1/2 in) minimum diameter J-bolts with locknuts.
c. A pressure drop of 3,5 kPa (0,5 psi) shall be used for vessel support and mist eliminator grid design unless otherwise specified.
Figure 8 - Mist eliminator used for the full diameter of a vessel
DETAIL A
DETAIL C. (SEE DETAIL D
FOR END CONNECTION
TO SHELL)
Figure 9 - Mist eliminator for an enclosed internal cylinder
DETAIL C. (SEE DETAIL D FOR END CONNECTION TO SHELL)
DETAIL A OR DETAIL E
CYLINDER ENCLOSED
Figure 10 - Mist eliminator for a reduced diameter
DETAIL C. (SEE DETAIL D
FOR END CONNECTION
TO SHELL)
DETAIL F
DETAIL A
OR DETAIL E
Figure 11 - Mist eliminator attachment details GRID 19mm (3/4 in) MFG. CLEARANCE (REF) 19mm (3/4 in) 19mm (3/4 in) A T GRID MESH BLANKET
SEE DETAIL B FOR SUPPORT RING C/L Ø16mm (5/8 in) EQUALLY SPACED ON 140mm (5 1/2 in) APPROX CENTRES 1/2 in J BOLTS WITH HEX NUTS. TWO (2) REQUIRED AT EACH END OF DEMISTER SECTION C/L DETAIL B DETAIL A 19mm (3/4 in) 19mm (3/4 in) 1/2 in J BOLTS WITH
HEX NUTS. TWO (2) REQUIRED AT EACH END OF DEMISTER SECTION DETAIL C 12mm (1/2 in) 45mm (1 3/4 in) 32mm (1 1/4 in) TRIM FLANGE TOP & BOTTOM AS REQUIRED W
W
DETAIL D
C/L TWO (2) Ø14mm (9/16 in) HOLES IN CLIP AND 14mm x 19mm (9/16 in x 3/4 in)
SLOTTED HOLES IN BEAM FOR 1/2 in BOLTS. (TYP EACH END) GRID MESH BLANKET GRID C/L Ø16mm (5/8 in) EQUALLY SPACED ON 140mm (5 1/2 in) APPROX CENTRES
Figure 12 - Mist eliminator support details
DETAIL E
SECTIONAL DEMISTER.USE 25mm x 6mm (1 in x 1/4 in)
WITH TWO (2) CLIPS PER RING SECTION. CLIPS TO BE WELDED TO RING.
RING TO BE PROVIDED WITH Ø16mm (5/8)) HOLES ON
140mm (5 1/2 in) APPROX. CENTRES.
ONE PIECE DEMISTER. USE FOUR (4) CLIPS ONLY WITH Ø16mm (5/8 in) HOLE IN CLIP. SEE VESSEL DRAWING
FOR THICKNESS CLIP ANGLE: 38mm x 38mm x 6mm x 38mm LONG. (1 1/2 in x 1 1/2 in x 1/4 in x 1 1/2 in LONG) Ø16mm (5/8 in) HOLES FOR 1/2 in BOLTS A 13mm
(1/2 in) SEE VESSEL DRAWING FOR THICKNESS
T
Ø16mm (5/8 in) HOLES EQUALLY SPACED ON 150mm (6 in) APPROX. CENTRES FOR 1/2 in BOLTS C/L
W W
DETAIL F
Table 8 - Mist eliminator dimensions
Demister Nominal Diameter Ring Beams A No. Required Carbon Steel Stainless Steel Flange Web Up to 450 mm (18 in) 2 0 _______ _______ _______ 451 mm to 1800 mm (>18 in to 72 in) 2 0 _______ _______ _______ 1801 mm to 3600 mm (>72 in to 144 in) 2 1 IPE 200 (WF 6 X 12) 100 mm x 6 mm (4 in x 1/4 in) 150 mm x 6 mm (6 in x 1/4 in) 3601 mm to 5400 mm (>144 in to 216 in) 3 2 IPE 200 (WF 6 X 12) 100 mm x 10 mm (4 in x 3/8 in) 150 mm x 10 mm (6 in x 3/8 in) Over 5400 mm (216 in) 3 Special Design. See Vessel Drawing
Notes:
1. T = 3 mm (I/8 in) plus twice corrosion allowance with 6 mm (1/4 in) minimum thickness. 2. W = T/2 plus corrosion allowance with 5 mm (3/16 in) minimum fillet weld.
9.13 External jackets
Design of half-pipe or pipe section jackets shall conform to one of the following: a. ASME BPVC VIII-1 Appendix EE.
c. Half-pipe and pipe section jacket attachment welds to shells and (or) heads shall be full penetration, full strength welds and 100% PT examined.
9.14 Nameplates
a. Unless otherwise specified on data sheets, nameplates shall be type 316L stainless steel with the data stamped or engraved with minimum height 4 mm (3/16 in) lettering. b. Nameplate shall show at least the following information:
1. Purchase Order number. 2. Item number.
3. Date of manufacture. 4. Order placed by. 5. Supplier name.
6. Supplier serial number. 7. Design code and its date.
8. Maximum pressure rating and at coincident temperature. 9. Minimum design temperature and coincident pressure.
10. Extent of volumetric weld NDE, inspection category or equivalent descriptor. 11. PWHT.
12. Test pressure new. 13. Test pressure corroded. 14. Total weight empty.
15. Required code or statutory markings.
16. Company equipment tag number or a Works Identification Number (of nine digits).
10
Spares
a. Spares shall be provided as specified on the data sheets. b. Minimum spares shall be provided as follows:
1. Two sets of spare service gaskets shall be furnished for vessel girth, manway, and blinded flanges.
2. An additional 10% (minimum quantity 2) for each size of bolting, and nuts shall be provided.
11
Fabrication requirements
11.1 General
a. Machining shall be performed after welding or heat treatment if such operations change machined surface characteristics or geometry such as flange face flatness.
b. Stainless steel, high nickel alloy, titanium, or zirconium surfaces shall be mechanically cleaned with stainless steel brushes, stainless steel grit, glass beads, or other high quality abrasive provided their use does not contaminate the material surfaces.
c. Welder’s and welding operator’s symbols and reference lines may be stamped on the material, in conformance to the design code, provided that a round-nose stamp is employed and the symbol is located a minimum of 25 mm (1 in) from the edge of the weld.
d. The following materials shall not be used to mark on or coat vessels: 1. Marking inks that contain halogens.
2. Lubricants. 3. Crayons. 4. Adhesives.
5. Tapes (e.g. duct tape).
6. Coatings to prevent adhesion of weld spatter. 7. Paints containing sulphur.
8. Chlorine compounds that decompose to hydrogen chloride. 9. Carbon.
10. Harmful metal or metal salts (e.g., zinc, lead, or copper).
e. All tools used for machining shall be dedicated for use on specific CRA material. Carbon steel tools or other steel tools dedicated to different materials shall not be used.
11.2 Tolerances
a. Tolerances shall be in conformance to drawing number PIP VEFV1102M sheets 1 and 2. b. Tolerances shall be specified on the fabrication drawings in either the main dimensions or
as an additional tolerance drawing.
c. Allowable flatness tolerances of gasket contact surfaces of flanged shell girth joints, after PWHT if required, shall be as shown in Table 9 for the designated service condition.
Table 9 - Flatness tolerances of gasket contact surface
Vessel diameter mm (in) Allowable tolerance mm (in) (1) Normal service Special service (2)
< 380 (15) 0,8 (0,03) 0,08 (0,003)
> 380 (15) to 760 (30) 0,8 (0,03) 0,150 (0,006)
> 760 (30) to 1 140 (45) 0,8 (0,03) 0,225 (0,009)
> 1 140 (45) 0,8 (0,03) 0,300 (0,012)
Notes:
1. Total tolerance on peripheral gasket contact surface shall not occur on less than a 0,35 radian (20 degree) arc.
2. Design temperatures greater than 454°C (850°F), or a flange rating greater than ISO PN 110 (ASME Class 600).
11.3 Joints
11.3.1 General
a. Location of all longitudinal and circumferential joints shall be shown on the fabrication drawings.
b. If two sections of unequal thickness are butt welded together, the inside (process face) shall be flush.
1. If thermal cutting is performed, the joint surfaces shall be ground to sound metal prior to welding.
2. Preheat requirements for thermal cutting shall be the same as specified in the WPS. d. Except as permitted in 11.3.1e, longitudinal joints shall be located to clear nozzle
openings, nozzle attachment welds, and reinforcing pad attachment welds by at least 50 mm (2 in), measured weld toe to weld toe.
e. The following shall apply if a nozzle opening, nozzle attachment weld, reinforcing plate, or reinforcement plate weld is located on a longitudinal or circumferential weld.
1. It shall be demonstrated to Company that plates cannot be re-orientated or relocated in instances where the required weld toe clearance is not achieved.
2. Alignment of the butted plates under the reinforcement plate shall be flush. 3. Longitudinal or circumferential weld shall be ground flush and given 100%
volumetric and surface examination for a length equal to three times the diameter of the opening before attachment of pad.
4. Location of the nozzle and weld seam shall be agreed by Company.
f. Welds subject to severe forming, where ratio of thickness to local radius is greater than 5%, shall have full volumetric examination before forming and full surface examination after forming.
11.3.2 Longitudinal joints
a. Longitudinal seams shall not fall within the tray-downcomer area of trays or behind other large obstruction that prevents inspection of the welds.
b. Longitudinal joints shall be offset between courses by at least five times the plate thickness, or 150 mm (6 in), whichever is greater.
c. Longitudinal joints shall be located to maximise access for internal visual inspection, consistent with the presence of the internals.
d. Longitudinal joints in horizontal vessels shall not be located: 1. Under the saddle or saddle wear plate.
2. Within 50 mm (2 in) of the saddle or saddle wear plate attachment welds. 3. Within 15 degrees of the horn of the saddle or saddle wear plate.
11.3.3 Circumferential joints
a. Circumferential joints shall be located at least 50 mm (2 in) above or below the tray ring attachment welds.
b. Circumferential joints shall be located at least 50 mm (2 in) away from horizontal vessel saddle or saddle wear plate attachment welds.
11.4 Welding
11.4.1 General
a. Butt joints shall be full penetrations.
b. For butt joints inaccessible from the inside, a method for obtaining a full penetration and full fusion weld from one side shall be submitted for Company review and agreement. c. Butt joints shall not use permanent backing strips.
d. All welds, including internals, non-pressure parts and attachments, temporary attachments and shipping attachments, shall be made by welders, welding operators, and welding procedures qualified under the provisions of the pressure vessel code and agreed by Company.
e. The following documents shall be provided to Company for review and agreement before the start of fabrication:
1. Welding procedure specification. 2. Procedure qualification record. 3. Welder performance qualification. 4. Detailed weld map.
5. Welding procedures. 6. Fabrication drawings.
f. The detailed weld map shall include, as a minimum, a sketch of all weld joints, welding symbols used in conformance to AWS A2.4, and associated weld procedure numbers. g. Arc strikes shall be conditioned to eliminate surface stress concentrations.
h. Defects found from arc strikes shall be removed and the surface shall be repaired and re-examined.
i. Significant weld repairs shall be subject to agreement by Company.
j. Removable start-up and run-off tabs may be used for longitudinal welds. The tab materials shall be of the same material specification and grade as the base metal.
k. Unless specifically agreed by Company, use of weld materials with strengths higher than that of low-hydrogen weld materials for any welding processes shall not be permitted. l. Welding consumables shall:
1. Be the same nominal composition as the parent metal.
2. Not contain addition of alloys via the flux, other than that required to make up for losses (e.g., in the arc).
3. Filler wire shall conform to GIS 18-012.
4. Have material properties such as, tensile strength or yield strength, equal to or greater than the minimum requirements for the base metal at ambient and design temperature. m. A local DHT shall be performed for butt-welds and corner joint welds (i.e., ASME weld
category A, B, and C) that are 50 mm (2 in) and greater in thickness (See Annex E).
11.4.2 Welding processes
a. The following welding processes shall not be used: 1. Self-shielded flux-cored arc (FCAW).
2. Welding process agreed by Company for a different Purchase Order, but not submitted or agreed for the subject Purchase Order and item.
b. Manual shielded metal arc with covered electrode (SMAW) of carbon and low alloy steels shall be made using low hydrogen electrodes.
c. Semi-automatically submerged arc (SAW) may be used. d. Gas metal arc using solid wire (GMAW) may be used.
1. The type of metal transfer (short-circuiting arc, globular or spray transfer) shall be specified on the WPS under electrical characteristics.
2. The process is applicable to carbon steel and weld overlay if a satisfactory level of dilution is demonstrated.
3. GMAW using a short-circuiting arc shall only be used for depositing metal that is subsequently removed.
4. Field welding is subject to Company agreement.
e. Gas tungsten arc, manual or automatic (GTAW) may be used. f. Gas shielded flux-cored arc (FCAW) may be used.
1. The type of metal transfer shall be specified on the WPS. Globular or spray is permitted but using a short-circuiting arc is prohibited.
2. Rutile wire may be used for welding carbon and low alloy steels and stainless steel. FCAW shall not be used for other alloys.
3. Basic cored wires may only be used for the deposition of fill passes in butt welds in the 1G and 1GR position.
4. For welds subject to PWHT and requiring impact testing, the FCAW brand name for rutile wires shall be an essential variable.
5. Fillet welding procedures in 1F and 2F positions shall be separately qualified for leg length greater than 6 mm (1/4 in).
g. The use of metal cored wires is subject to specific agreement by Company.
11.4.3 Weld procedure and welder qualification
a. Changes to the agreed WPS or PQR shall also be submitted for review and agreement by Company.
b. The WPQ shall be made available for review upon request.
c. Repair procedures shall be submitted for review and agreement if the repairs could be detrimental to the material (either in terms of mechanical performance of corrosion performance in service) or delivery of the vessel.
d. Unless otherwise agreed, the position of the impact test specimens for tests of weld metal and HAZ shall be:
1. Weld metal centreline. 2. Fusion line.
3. Fusion line plus 2 mm (1/16 in). 4. Fusion line plus 5 mm (1/4 in).
11.4.4 Dissimilar welds between austenitic stainless steels and ferritic steels
a. Welds joining austenitic stainless steels to ferritic steels shall be made with filler metal as follows:
1. For services not exceeding 340°C (650°F), one of the following shall be used: a) ASME SFA-5.4 classification E309L.
b) SFA-5.9 classification ER309L.
c) The filler metals given in 11.4.4a.2 below.
2. For services exceeding 340°C (650°F), one of the following shall be used: a) ASME SFA-5.14 classification ER NiCr-3.
c) Another filler metal as specified on the data sheets.
d) Company agreement is required for dissimilar welds in services exceeding 340°C (650°F).
b. Preheat shall be based on the ferritic material.
c. The first layer of weld overlay deposits shall be made using the preheat required for the base plate.
d. Subsequent weld layers may use the preheat required for the alloy deposits.
e. Proposals for dissimilar welds that require a PWHT shall be submitted to Company for review and approval
11.5 Temporary welded attachments
a. Attachment point of spiders, braces, or other temporary attachments shall be of the same material alloy as the point on the vessel to which it is attached.
b. Temporary welds shall conform to 11.4.1d.
c. Temporary clips, brackets and other fabrication aids shall be removed flush with vessel without damage to base metals.
1. Gouges from cutting tools shall be welded with an agreed procedure and ground flush to a finish in conformance to the pressure vessel welding code.
2. Areas where attachments have been removed shall be subjected to examination by PT/MT, in addition to visual examination, to ensure no cracks have been generated. 3. Temporary attachment removal and repairs shall be performed prior to PWHT and
hydrotest.
4. Peening shall not be used.
12
Examination requirements
12.1 General
a. The extent of examination and special documentation, in addition to the minimum requirements of the design code, shall be as specified in the Purchase Order documents. b. All specified NDE shall be performed in conformance to the design code.
c. For specific welded pressure joint examination requirements, see the data sheets. d. The minimum degree of examination of welded butt joints shall be spot radiography. e. Accessible surfaces of completed corner joint welds shall be examined by MT, PT, UT, or
other non-destructive methods in conformance to Company’s Purchase Order documents. f. Welded joints that are inaccessible after assembly shall be examined by PT or MT in
conformance to the following instructions, and repaired as required before painting, assembly, and testing:
1. After back-chipping to sound metal, the root pass and its opposite side shall be examined.
2. After any required machining or grinding, the finished surfaces of the weld shall be examined, and all indications on the finished weld surfaces shall be repaired by grinding or welding before pressure testing.
g. Imperfections shown to be unacceptable during examination shall be repaired and then, as a minimum, the repair shall be examined by the same method, to the same extent, and by the same acceptance criteria that revealed the condition.
h. The following items shall be examined by MT or PT:
1. The following surfaces of butt-type joints greater than 50 mm (2 in) thick:
a) The surface of sound metal after back-chipping or gouging root pass to metal surface.
b) All accessible surfaces of completed weld.
2. The following surfaces of non-butt type joints, including surfaces in nozzles and manways, if the vessel section or head is designed using a joint efficiency of 1.00: a) The surface of sound metal after back-chipping or gouging root pass to metal
surface.
b) All accessible surfaces of completed weld.
3. The cut edge of openings in vessel walls greater than 13 mm (1/2 in) thick into which nozzles and manways are attached with a full penetration weld through the nozzle or manway wall.
a) Examination shall be performed before nozzle attachment, and a re-examination performed after attachment if accessible.
4. All accessible surfaces of completed welds for the following:
a) Internal and external welds if the thickness of the pressure part is greater than 50 mm (2 in).
b) Welds attaching vertical vessel supports. c) Welds attaching vessel lifting lugs. d) Welds attaching manway davits.
i. Fracture mechanics assessment of weld flaws shall not be used to justify weld defects not permitted by the design code.
12.2 Preparation
a. The NDE schedule and NDE procedures shall be submitted to Company for review and agreement.
b. Personnel concerned with inspection, interpretation, and NDE shall be qualified to at least PCN Level 2 or ASNT Level 2 if the qualification has been obtained through examination