Revision A Page 2 CONTENTS 1.0 2.0 3.0 4.0 5.

0
5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14

Introduction Custodian Purpose Application Design

General External Loadings Earthquake Design Shipping Loads Jacketed Vessels Corrosion Allowance Shell and Heads Supports Nozzles and Other Connections Manways and Other Inspection Openings Mist Eliminators Equipment Davits Ladders and Platforms Grounding Lugs

6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0

Materials Fabrication Inspection and Testing Repairs Stamping and Recording Painting and Preparation for Shipment Pressure Vessels with Special Design and Fabrication Requirements Approval to Deviate Revision History Glossary Bibliography

Revision A Page 3 Appendices Appendix 1 Requirements for the Contractor or Purchaser

Revision A Page 4 1.0 Introduction

This Design Guide provides the minimum requirements for the design, materials, fabrication, inspection and testing of welded unfired pressure vessels. Pressure vessels shall conform to the requirements of the job specifications and this guide. However, any more restrictive statutory rules or governmental regulations shall have precedence. Requirements for the contractor or purchaser that are not intended for the direct use of the fabricator are included in the Appendix 1. Design decisions based upon the Appendix 1 must be clearly indicated on the Vessel Technical Data Sheets (TDS) or in the job specifications.

2.0

Custodian
The Custodian of this guideline is EE, who is responsible for the accuracy and quality of its contents and for its future revisions, where these are required to reflect industry trends or changes to QGPC business practices.

3.0

Purpose
This Design Guide defines the minimum technical requirements for the design, materials, fabrication, inspection and testing of unfired pressure vessels designed for an internal pressure greater than 103 kPag or for vacuum conditions, for onshore and offshore production and processing facilities.

4.0

Application
This guideline shall be used by project teams, business units and Contractors or Consultants employed by them. This guide shall form part of the procurement specification when ordering new pressure vessels.

5.0
5.1 5.1.1

Design
General Unfired pressure vessels shall conform to the requirements of ASME SEC VIII D1, and Sections 5 through 11 of this guide, except as follows: 1) Vessels shall conform to ASME SEC VIII D2 if both of the following conditions are met: The Division 2 (D2) design results in lower overall cost than the Division 1 (D1) basis No fatigue analysis is required, as determined by ASME SEC VIII D2 Paragraph AD-160.

2) Vessels shall also conform to the requirements of Section 12 for any of the following

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conditions: 5.1.2 When the vessel shell is made of quenched and tempered steel or when the specified minimum yield strength exceeds 360 MPa When the vessel shell thickness is greater than 50 mm When ASME SEC VIII D2 design is used When cyclic service may render the vessel fatigue sensitive For design pressure, exceeding 20,700 kPag

Pressure vessels shall be designed for combined loading applicable to the erection, operation, shutdown, and test conditions. These shall include loads due to wind, loadout, erection lift, dead weight, static pressure and moment from piping. Pressure vessel shall be self-supporting with supports designed to withstand the greatest loading of the following cases: a) Design wind load on an empty vessel (fully corroded). b) Hydrotest (new), plus 75% Design wind load. c) Design wind load with vessel at maximum normal operating conditions (fully corroded). d) Loadout accelerating conditions (new)

5.1.3

5.1.4 5.1.5

Design wind and loadout loading conditions shall be considered non-coincidental For all nozzle connections attached to piping systems the stresses in the vessel wall due to the piping loads combined with the pressure stress intensity shall be evaluated. These local stresses can be assessed using the method as indicated in BS5500 Appendix G. When vessels are stacked, intermediate head must be designed for the maximum differential pressure in accordance with corresponding compartment assuming either compartment depressurised except when designed for differential pressure. Design of pressure part for differential pressure shall be specified on drawing. The requirements of this guide do not apply to vessels that are excluded from the scope of ASME SEC VIII D1 by Paragraph U-1(c) 5, provided they conform to the requirements of ASME B31.3. This exclusion shall not apply to vessels larger than 610 mm diameter or to vessel shells thicker than 25 mm. Pressure vessels for design pressures over 20.7 MPa, when designed to Division 1, shall be constructed in conformance with the intent of Paragraph U-1 (d). Vessels of proprietary design (non-code construction), layered vessels, and vessels with intermediate heads shall not be used without QGPC approval. When specified on the TDS, quick opening closures shall be used. Detailed drawings and calculations, including safety devices, shall be submitted to QGPC for approval.

5.1.6

5.1.7

5.1.8

5.1.9

5.1.10

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5.1.11 Stiffening and insulation rings on parts of vertical vessels with normal operating temperatures below 149oC or in intermittent service shall have cutouts at their inner face for drainage. These drain slots shall be a minimum of 16 mm wide by 150 mm circumferentially long and spaced at no more than 1 m on center. Welds attaching non pressure parts to the pressure containing shell and welds to highly loaded parts such as skirts or supports for major internal, such as grids, should be designed using the same allowable stresses as used for the pressure parts. Horizontal vessels supported by two saddles shall be investigated using the Zick method in BS 5500 for assessing the localised stresses. Basic allowable stresses for non pressure parts are 1/3 of the ultimate tensile strength, 2/3 of the yield strength, or that stress which produces a creep rate of 1 percent in 10,000 hours, whichever is lowest (all stresses being taken at design metal temperature of the part) External Loadings Wind Design Onshore Wind design must be in accordance with BS CP3, Chapter V, Part 2 Topography factor S1 = 1.0 Ground roughness factor S2 from table 3 of BS CP3 Category 1 Class B. Open country with no obstructions. Factor S3 = 1.0 Design wind speed; 38 m/s for structures less than 15 m above grade and 45 m/s for structures more than 15 m above grade. Force coefficient C shall be: As per table 14 of BS CP3 for shell and attached piping C = 1 for platforms and ladders

5.1.12

5.1.13

5.1.14

5.2 5.2.1

Towers shall be designed to be self supporting 5.2.2 Wind Design Offshore Design wind speed shall be 45 m/s; Values for S1, S2 and S3 shall be as per 5.2.1 5.2.3 Wind induced vibration caused by vortex shedding shall be evaluated for slender towers having total height to diameter ratio greater than 15. Vortex shedding may be inhibited by external helical spoilers or other types of spoilers, subject to QGPC approval. Deflection due to wind shall be calculated for towers having total height to diameter ratio exceeding 15. The maximum allowable lateral deflection of vertical vessels due to wind shall not exceed the following:

5.2.4

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Columns with internal trays Other vessels = = H/300 H/100

Where H is the total height of the vessel with support 5.3 Earthquake Design Vessels to be designed for earthquake according to Uniform Building Code (UBC) with applicable Zone number as 1 (one). Earthquake loads may govern the design of process and utilities equipment and supports. It is therefore recommended that earthquake design requirements be issued to designers and fabricators responsible for this equipment. 5.4 Shipping Loads Vessel shall be designed adequately to withstand transportation and erection loads. The vessel fabricator shall provide lifting and tailing lugs as required, designed for an impact load of not less than 1.5. All vessels shall be designed to withstand forces, which may be encountered during transportation. A one-third increase in basic allowable stresses will be acceptable for this case. In addition, all equipment shall be designed to withstand earthquake forces, which may be encountered during the life of the facility, without catastrophic failure of the vessel or its supports. Allowable stresses may be increased by a factor 1.7 for the earthquake case. Design shall be based on the following minimum conditions: Loading Condition Transport Case Earthquake Case Lateral 0.35g 0.15g Vertical 0.50g 0.07g

Relaxation of these minimum requirements will require QGPC approval. 5.5 Jacketed Vessels Both the vessel and jacket shall be designed in accordance with this guide and ASME SEC VIII, regardless of design pressure. No credit for pressure or vacuum in the jacket shall be taken to reduce the pressure for which the vessel is designed. 5.6 Corrosion Allowance Corrosion allowance shall be determined from the process requirements as specified on the TDS, with minimum corrosion allowances given in Table 5.6.1. If corrosion allowance is required, it shall be added to all surfaces of pressure parts, nonrenewable internals, and major removable internal structural parts that are exposed to the process. For minor removable parts, only one-half the minimum corrosion allowance shall be added to the exposed surfaces when the specified minimum corrosion allowance exceeds 2.5 mm. The minimum corroded thickness of tray support rings, downcomer bolting bars, and other major load-bearing internals shall be 5 mm.

Revision A Page 8
5.6.1 Corrosion Allowance for Vessel Parts Vessel Part Pressure Material of Part Minimum Corrosion Allowance 1.5 mm (f) 0.0 mm Thickness of Alloy Protection (b) 0.0 mm (e)

Carbon/Low Alloy Steels (a) High-Alloy Steels and Non Structural Non-Removable Ferrous Major Removable (c) Alloy Lined Steels (Clad or Weld Overlaid) Minor Structural All Materials (a) Removables (d) Notes: a)

For non-removable structural parts and for major and minor removable structural parts, high alloy steel should be considered if the specified corrosion allowance is 5 mm or greater. All structural internals shall be of the same material as the lining, with a corrosion allowance only if specified. Parts include bed support beams, bed support gratings, demister support beams, and so forth. Parts include pipe guides, bolted clips, vortex breakers, non pressure distributor piping, and similar devices not welded to the vessel. Parts need not have corrosion allowance added unless the specified minimum corrosion allowance exceeds 2.5 mm. Typical minimum corrosion allowances in mildly corrosive or non-corrosive environments are 1.5 mm to 3.0 mm.

b)

c)

d)

e)

f)

5.7 5.7.1

Shell and Heads The minimum fabricated thickness of the pressure containing shell and heads shall be the greater of the following: a) D/1000 + 2.5 mm, where D is the diameter in mm b) 5 mm plus corrosion allowance

5.7.2

Acceptable head shapes are torispherical, 2:1 ellipsoidal or hemispherical. Do not use torispherical heads when any of the following conditions apply: Design pressure over 690 kPag Bottom heads of vertical vessels having height-to-diameter ratios exceeding 12 Head diameters 3.6 m and larger

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Code approved weld caps may be used as heads on vessels with outside diameters of 600 mm or smaller. 5.7.3 Stresses shall be calculated in the knuckle region of torispherical heads with a thickness-todiameter ratio less than 0.002, to assure stability against buckling. In addition to the standard code requirements, all elliptical heads with D/t greater than 200 for carbon steel and greater than 70 for stainless steel must be checked for head knuckle wrinkling during hydrotest. The check is to be performed using the methods of ASME Section VIII, Division 2, paragraph AD-204-2. The new (uncorroded) dimensions are to be used. The pressure used in the equation is to be the hydrotest pressure plus any applicable hydrostatic head. The allowable stress to be used is 90% of the yield stress for the top head, and 1.325 x Division 2 allowable stress for bottom head. The AD-204-3 requirement for minimum straight flange length at the minimum head thickness must also be followed. Cylinder to cone transitions shall be toriconical sections when any of the following conditions apply: 5.7.6 The section is subject to a major support reaction (for example, skirt to cone attachment) Shell thickness is over 32 mm Cone apex angle exceeds 60 degrees

5.7.4

5.7.5

For toriconical transitions in vacuum service, stiffening rings in the adjacent cylindrical sections shall be provided. Where stiffeners are required by the design code for vacuum vessels they shall be continuous and preferably external. The rings shall be positioned at least 100mm clear of circumferential seams, vessel branches and other permanent attachments unless otherwise agreed by QGPC. Unless otherwise specified stiffeners shall be welded to shell with continuous weld seams.

5.7.7

5.8 5.8.1

Supports Skirts on vessels, 1.5 m or less in diameter shall have at least one access opening. Skirts on vessels exceeding 1.5 m in diameter shall have two access openings. The openings shall be suitably reinforced. The minimum size access openings shall be as follows: For vessels under 3 m in diameter, the access openings shall be at least 610 mm in diameter, or 430 mm x 915 mm obround (unless otherwise noted on the technical data sheet). For vessels exceeding 3 m in diameter, the access openings shall be at least 760 mm in diameter. No piping shall pass through access openings.

5.8.2

The design of skirt shall be arranged to ensure that the temperature of any supporting concrete will stay below 100o C. A minimum of four DN 50 nipples shall be located near the top of the skirt to vent the space

5.8.3

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at the bottom head intersection. Similar nipples shall be located at the bottom of the skirt if the skirt cannot otherwise drain. 5.8.4 Skirts shall be attached to the underside of heads so that the skirt and shell plate centerlines coincide. In no case shall a skirt be positioned so that a vessel girth seam is covered. Horizontal vessels shall be supported on two saddles covering at least 120 degrees of the vessel circumference. When the vessel temperature is less than 121C, the shell in contact with the saddle shall be protected from corrosion by the use of a steel pad. This pad shall be between the vessel shell and the support surface, continuously welded to the shell and vented. Saddles and pads shall not cover vessel shell seams. One of the saddle bearing plates shall have slotted holes to allow for thermal expansion of the vessel. Vessel supports and skirts shall have a minimum thickness of 6.4 mm. Baseplates shall have a minimum thickness of 12.7 mm. Skirt attachment welds to bottom head, base ring and compression ring shall be continuous. For alloy vessels, the top 610 mm of the skirt for vertical vessels, or the saddle wear plates for horizontal vessels, shall be the same material as the vessel. Anchor bolts shall be supplied in multiples of four with a minimum of eight for skirt supported vessels. Anchor bolt to be minimum size of M20. Allowable anchor bolt stress shall be 103 MPa calculated on the root area of the bolt. Nozzles and Other Connections All openings and branch connections shall be flanged unless otherwise specified. Branch connections DN 50 or larger are preferred, and in no case shall the branch diameter at the vessel wall be less than DN 40. All connections smaller than DN 50 shall be provided with two stiffening gussets located at right angles unless the nozzle is a long weld neck type construction. For all nozzles and connections, except manways and other openings intended solely for access or inspection, the vendor shall determine the stresses in the vessel resulting from the worst combination of any internal pressure up to the maximum operating pressure and the externally applied forces and moments specified on the data sheet. Where the external nozzle loads have not been specified, the vendor shall assume the forces and moments in the following Table acting in the worst combination, at the nozzle to shell junction.

5.8.5

5.8.6

5.8.7

5.8.8

5.9 5.9.1 5.9.2

5.9.3

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5.9.4 Nozzle Loadings Nozzle DN (mm) 150
Force kN Moment kN m Force kN

Nozzle Rating 300

Moment kN m Force kN

600
Moment kN m Force kN

900
Moment kN m

1500
Force kN Moment kN m

50 80 100 150 200 250 300 350 400 450 500 600

1.5 3 3.5 6 7 9 12 13 16 17 17 22

0.5 1 2 6 9 13 19 21 26 31 32 41

1.5 3 3.5 6 7 9 12 13 16 20 21 29

0.5 1 2 6 9 13 19 21 29 38 40 54

2 3.5 4 8 12 15 21 22 29 36 39 55

0.5 1.5 2.5 7 14 22 32 36 50 65 70 98

2 4 5 10 14 18 25 28 35 44 48 68

0.5 1.5 3.5 9 16 25 39 43 58 77 84 118

2 5 6 12 20 27 30 40 52 -

0.5 2 3.5 10 21 34 53 60 81 -

Unless otherwise specified, for vessels manufactured from stainless steel or non-ferrous alloy, with no corrosion allowance specified, the loadings in Table 5.9.4 for nozzle ratings of 150, 300 and 600 may be reduced by 50%. Where accommodation of the nozzle loads, as specified or as assumed in accordance with Table 5.9.4, would require the shell thickness of the vessel to be increased, the Vendor shall inform the Purchaser accordingly. The Purchaser may consider reducing the nozzle loadings by, for example, recalculating the piping loads allowing for any flexibility in the vessel nozzles. To facilitate this, the Vendor shall provide information on the nozzle/shell flexibility. On no account shall the Vendor assume nozzle loads less than those specified or determined from Table 5.9.4 without the prior agreement of the Purchaser. 5.9.5 Reinforcement and reinforcing pads shall be as follows: 1) Reinforcement for manways and nozzles over DN 50 shall be 100 percent area replacement for the full uncorroded shell or head thickness. For example, reinforcement shall be equal in area to the nozzle inside diameter (corroded) multiplied by the nominal uncorroded thickness of the shell or head. No credit shall be taken for excess head or shell material provided for factors such as corrosion allowance and joint efficiency. 2) Integral reinforcement shall be required for multiple nozzles in heads and spheres, where the distance between reinforcing pad edges would be less than 2.5 (Rt)1/2 (R and t being the head or sphere radius and thickness, respectively). When integral reinforcing is provided on nozzles 150 mm and greater, the ratio of nozzle wall thickness to shell wall thickness shall not be greater than 2. 3) Each reinforcing pad or segment thereof, shall be provided with a NPT 6 mm threaded "telltale" hole filled with grease, only after testing.

Revision A Page 12
4) Reinforcing pad shall not be used in the following services: a) Operating temperature above 300o C b) Operating temperature below -50o C 5.9.6 Flanges shall be designed for displaying the pressure and temperature on the vessel nameplate, in accordance with the ASME SEC VIII and the following requirements: 1) Flanges in sizes of DN 600 and smaller shall conform to the requirements of ASME B16.5. For sizes DN 650 through DN 1500 steel flanges dimensions and ratings shall conform to ASME B 16.47 Series B. Lap-joint and slip-on flanges require QGPC approval. 2) Plate or forged flanges with no hub shall only be used for internal non-pressure connections. The minimum flange thickness is 9.5 mm plus corrosion allowance. 3) Bolting on flanges shall clear vessel insulation by not less than the distance required to insert and operate a box wrench. 4) Where corrosion is a problem, nozzle flanges should be located as near the vessel as possible. Extended nozzles in this service present code problem if repairs are required in the piping of the extended nozzle. 5.9.7 5.9.8 Threaded connections are not allowed. Bottom head connections that are brought through a skirt shall be of butt-welded construction, and fabricated of pipe and pipe components of at least schedule 80. Openings in the skirt shall be reinforced with a sleeve at least 2 pipe diameters larger than the connection. Piping shall be supported through the sleeve, and sleeves shall be welded both sides with a continuous fillet weld. Nozzles and their reinforcing pads shall not be located in the knuckle region of a torispherical head. Nor, without QGPC approval, closer than 2.5 (RT)1/2 (R and T being the shell radius and thickness, respectively) from a cone-to-cylinder junction. When the technical data sheets for a pressure vessel require a corrosion resistant alloy lining, all nozzles 152.4 mm and smaller shall be solid alloy of the same material as the lining. Manways and Other Inspection Openings Handgrips at manhole shall be provided where entry is made horizontally through the manholes. If the bottom manhole is more than 1500 mm from the crown of the bottom head, internal ladder rungs shall also be provided. Manway covers shall be equipped with davits or hinges to facilitate handling. Only davits shall be used with vertical manway covers. Flange facing for manways and hand holes shall be raised face, with a finish conforming to ASME B16.5, unless otherwise specified. Trayed columns shall have at least one manway at the top and one in the bottom section. Generally, manways shall not be spaced more than 30 trays apart. Additional manways shall

5.9.9

5.9.10

5.10 5.10.1

5.10.2

5.10.3

5.10.4

Revision A Page 13
be provided as required by service conditions and maintenance. 5.11 5.11.1 Mist Eliminators Wire mesh for corrosion resistant alloy clad vessels shall be of the same material as the vessel cladding. The wire diameter shall be 0.28 mm, bulk density shall be 144 Kg/m3, and the element thickness not less than 150 mm. On non clad vessels, mesh shall be supported, above and below, by carbon steel grids, unless the corrosion allowance exceeds 3 mm, in which case stainless steel grids shall be used. In either case, the mesh shall be wired in place with stainless steel wire. On clad vessels, mesh shall be supported, above and below, by grids manufactured of the same material as the vessel cladding. The mesh shall be held in place with wire of the same material as the vessel cladding. The elements shall be removable in sections through the vessel manway. Mist elimination can also be achieved by use of vanes or cyclones instead of wire mesh. Equipment Davits Davits shall be provided for handling equipment weighing more than 34 kg. For example, safety valves and internals those are subject to removal for periodic repair or replacement. The davits shall be designed to swing equipment clear of the vessel. 5.13 5.13.1 Ladders and Platforms If specified, vendor shall provide ladders and platforms. Ladders, platforms, and all accessories shall be furnished with a hot-dipped galvanized coating in accordance with ASTM A153. After fabrication, ladders and platforms, including all bolts and nuts, shall be completely assembled to the vessel in the shop to insure fit, then disassembled and shipped separately, unless otherwise noted on the technical data sheet. Insulation support rings shall be 12.7 mm less in width than the thickness of the insulation and spaced at 3.7 m intervals starting at the top tangent line. Insulated vertical vessels shall be furnished with 12.7 mm square nuts welded on edge to the inside of the skirt on approximately 305 mm centers. Grounding Lugs Two grounding lugs shall be provided on each vessel. The lugs shall be welded to the vessel support

5.11.2

5.11.3

5.11.4

5.11.5 5.11.6 5.12

5.13.2

5.13.3

5.14

Revision A Page 14 6.0

6.1 6.1.1

Materials
Pressure Parts Materials of construction for pressure parts shall be in accordance with any one of the appropriate specifications listed in ASME SEC II-A and ASME SEC II-B, except as follows: SA-36, SA-283, and other structural quality steel shall not be used Castings shall not be used for pressure parts Other equivalent materials meeting the requirements of this specification may be used, with QGPC approval. The nomenclature and complete chemical and physical properties of the proposed material shall be stated along with the ASME equivalent. Any added requirements (such as fully killed, fine grain practice, and inspection practices) for equivalency shall also be stated Quenched and tempered steel is limited to a maximum tensile strength of 690 MPa and an actual yield-to-tensile strength ratio of <0.85 When service is specified as sour on the technical data sheet, materials of construction shall be in accordance with QGPC Standard 153 (Material for Sour Service), together with NACE Standard MR-01-75

6.1.2

To promote good weldability, the chemical composition of carbon and carbon-manganese steels to be used for vessels (pressure parts and attachments directly welded to the pressure parts) shall comply with the following: Carbon content shall not exceed 0.23%, except for forgings, where this may be relaxed to 0.25% The carbon equivalent (CE) shall be 0.45% maximum (ladle analysis) based on the following formula:
CE = C +

Mn
6

Cr + Mo + V
5

Ni + Cu
15

6.1.3

In addition to the CE restrictions, SA 105 forgings shall be normalised

Materials shall be represented by test specimens that have been subjected to the same heat treatment as the completed vessel. The term "heat treatment" shall also include any heating above the critical range for hot forming. Substitution of material used for pressure parts requires QGPC approval. Austenitic stainless steel pressure parts exposed to the weather on offshore platforms shall be used only with QGPC approval. External Attachments and Supports Attachments that are essential to the structural integrity of the vessel, (for example, supports and stiffening rings) as well as pipe and platform clips, shall be of material meeting the toughness requirements of the ASME SEC II-A. Lightly loaded attachments, such as

6.1.4 6.1.5

6.2

Revision A Page 15
insulation supports, shall meet ASME SEC II-A requirements for minimum design metal temperatures lower than -10C. 6.3 External Bolting Where solid alloy vessel nozzles are required by paragraph 5.9 of this guide, bolting shall be ASTM A-453 Gr 660B. Where carbon steel nozzles are required by paragraph 5.9, bolting shall be SA 193-B7M and nuts shall be SA 194-2HM. All bolting shall be cadmium plated to BS 1706. 6.4 6.4.1 Alloy Linings Alloy linings shall be one of the following types: 1) Integral Clad: a) Hot rolled - QGPC approved manufacturer b) Explosion bonded - QGPC approved manufacturer 2) Alloy Weld Overlay

Integrally clad plates shall be ultrasonically examined per SA 578 with the acceptance criteria of S7. 6.4.2 Alloy lining shall not be included in the calculations of the vessel wall thickness required for pressure. Connections, manways, and inspection openings in alloy lined portions of vessels shall conform to one of the following methods of construction (loose sleeve liners are not permitted): 6.5 Connections in all sizes may be fabricated from integrally clad plate or protected with deposited alloy weld metal Solid, alloy nozzles and other connections may be welded to ferritic base material, subject to QGPC approval Ferritic base material flanges with alloy weld overlay may be welded to alloy nozzles

6.4.3

Gaskets Unless specified otherwise, raised face flange gaskets shall be stainless steel Grade 316 or 316L spiral wound graphite filled, with external stainless steel guide ring. Gaskets shall be supplied in accordance with API 601. The minimum width of spiral wound gasket for sizes outside scope of API 601 shall be 25 mm and minimum thickness shall be 7.2 mm.

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7.1 7.1.1

Fabrication
Welding All pressure containing welds and skirt welds shall be full fusion, full penetration butt joints. Wherever practical, these welds should be made using double-side techniques. The skirt shellto-baseplate joint shall be continuous fillet weld both inside and outside. Nozzles inserted through a hole cut in the vessel shall be full penetration welded, including the reinforcing pad. Nozzles inserted through cover plates shall be full penetration or partial penetration double welded. Attachment by fillet welds only is not permissible. Set-on connections having a nozzle inside diameter equal to the diameter of the opening in the vessel wall are limited to a maximum diameter of DN 100. Before welding, the plate below the nozzle weld shall be ultrasonically examined. The weld attaching the nozzle to the vessel shall penetrate completely through the nozzle neck and may be either single or double welded. Forming of Shells and Heads When a difference in thickness exists between shell sections or shells and heads, the inside surfaces shall be aligned. Cold-formed ferritic pressure parts with a ratio of thickness to local radius greater than 5 percent shall be stress-relieved after forming and prior to any welding. Connections All manways and nozzles that do not extend into the vessel for internal connections shall be finished flush with the inside of the shell. The inner edge shall be rounded to a minimum radius of 6 mm. 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 fillet weld. Openings for connections shall not pass through main vessel seams. Any portion of the weld, which unavoidably must be covered by a reinforcing pad, shall be ground flush with the surface of the shell plates and examined by radiographic and magnetic particle techniques (or dye penetrant, where appropriate), prior to the installation of the pad. All gauge glasses, level controls, and alarms having two connections shall be set with jigs. Heat Treatment Local heat treating requires QGPC approval. The complete post weld heat treating procedure, including temperature and holding time, shall be submitted to QGPC for approval. Machined surfaces shall be protected against scaling during heat treatment. Non-pressure Attachments In corrosive services, welded attachments inside carbon steel vessels shall be completely

7.1.2

7.1.3

7.2 7.2.1

7.2.2

7.3 7.3.1

7.3.2

7.3.3

7.3.4 7.4 7.4.1 7.4.2

7.4.3 7.5 7.5.1

Revision A Page 17
welded to prevent corrosion behind the attachment. Intermittent welding may be used in noncorrosive services and in high-alloy and alloy-lined vessels, where seal welding is not required. Seal welding is required on the top side of support rings for trays, baffles, and pans in vertical vessels, and on downcomer bolting bars. 7.5.2 All attachments shall be welded to vessels in the shop and prior to final post weld heat treatment. Dimensional Tolerances The out-of-level tolerance for tray support rings is 3 mm for vessels up to 3660 mm in diameter and 5 mm for larger diameter vessels. This tolerance shall be measured from a level plane passing through the low or high point of the ring. Rings shall be perpendicular to the vessel wall and shall not deviate from the perpendicular by more than 1.6 mm at the inner edge of the ring. The maximum tolerance permitted for the dimension between adjacent tray rings is 3 mm.

7.6

8.0
8.1

Inspection and Testing

Full radiography is required for vessels with shell thickness >19 mm, and spot radiography is required for thinner vessels. All shop fabricated vessels shall be given a shop hydrostatic test prior to any painting in accordance with the basis set forth in ASME SEC VIII D1, Paragraph UG-99c and the following strictures: The test pressure shall be based on the as fabricated, fully reinforced, (refer to Section 5.9.1) uncorroded shell and heads, except as otherwise limited by the nozzle flange ratings The test pressure shall be maintained for a period of not less than one hour per inch of thickness, but not less than one hour. The thickness of the head or shell, whichever is greater, shall be used to determine the length of the test period The minimum metal temperature during initial pressure testing of ferritic vessels with shell or head thicknesses greater than 13 mm shall not be lower than the following: a) Where base metal impact tests have been conducted, the impact test temperature plus 17C b) Where base metal impact tests have not been conducted, both the test water and the metal temperature shall be a minimum of +15o C, however the test temperature shall not exceed 49C Fresh water shall be used for hydrotesting vessels. The chloride content of water shall not exceed 50 ppm for testing vessels fabricated of, or lined with, austenitic stainless steel.

8.2

8.3 8.4

Pneumatic or hydro-pneumatic tests are not permitted. All reinforcing pad welds shall be tested to 103 kPag minimum, with dry air or light oil, before PWHT.

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8.5 Gaskets supplied by the fabricator shall be new and not those used for shop hydrostatic testing. Gaskets shall be separately boxed, shipped with each vessel, and clearly identified for field installation.

9.0
9.1

Repairs
Defects shall be removed and rewelded using qualified welding procedures. The repair weld shall be re-examined by the original method to ensure freedom from defects. Prior QGPC approval is required for the following: Weld repair depth exceeding 9.5 mm or 1/2 the weld thickness Where defects in plates or forgings are observed The second and subsequent repairs in the same area Repairs after PWHT All repairs in quenched and tempered material, or when the specified minimum yield strength exceeds 360 MPa.

10.0
10.1

Stamping and Record

Stamping Manufacturer shall securely fasten a stainless steel name plate to a carbon steel bracket that is seal welded to the vessel. The name plate shall bear the following, as a minimum: All applicable code symbols Manufacturer's name Manufacturer's serial number Date of manufacture Maximum allowable working pressure and corresponding temperature (corroded condition) Corrosion allowance, and shell and head thickness Hydrostatic test pressure QGPC purchase order number and QGPC equipment number Vessel size - OD x T/T length Minimum design metal temperature Capacity

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Erection weight PWHT Radiography

Steel stamping of vessels with a minimum design metal temperature below 15C shall be done with low stress stamps. 10.2 Records Records to confirm compliance of materials and fabrication with the requirements of this guide shall be retained by the fabricator for review by QGPC. Upon completion of fabrication, the fabricator shall supply QGPC with copies of final drawings and data as specified, including: Assembly and detail drawings showing as-built dimensions, weights, and details ASME Code Form U-1 Manufacturer's Data Report Certified record showing location, heat numbers, chemical and physical properties of all materials used Copy of post weld heat treatment recording charts Copy of hydrostatic test chart Copy of non-destructive examination test results

11.0
11.1

Painting and Preparation for Shipment

All external surfaces of vessel except machined surfaces shall be cleaned , primed and finsh painted in accordance with the QGPC standards ESQ12 (Specification for Painting and Wrapping of Metal Surfaces) Before shipment all vessels shall be dried, perfectly cleaned and free from all foreign matters. The equipment shall be suitably preserved to maintain in good condition throughout the phases of storage until ready to be operated. Internal surfaces of stainless steel vessels shall be pickled and passivated. All equipment shall be suitably protected for shipment and securely anchored during transit. Vessel shall be clearly identified by painting or stencilling in a conspicuous place, the vessel description and the purchase order number. Separate or loose parts shall be completely boxed with identification tag.

11.2 11.3

11.4 11.5 11.6

11.7

Revision A Page 20 12.0

12.1

Pressure Vessels with Special Design and Fabrication Requirements

General The following are additional requirements for vessels covered under Section 5.1.1.

12.2 12.2.1

Design Connections Connection reinforcement shall be integral and no pads shall be used. In cyclic service, connections shall be such that their attaching weld can be readily radiographed.

12.2.1

Attachments and Supports Welds attaching non-pressure parts to pressure parts shall be full penetration welds. For quenched and tempered steel vessels, or when SMYS exceeds 360 MPa, skirts that exceed 19 mm in thickness at their point of attachment shall be attached in accordance with Figures 1 and 2 below:

Revision A Page 21 Figure 1: Skirt Attachment Details Forging Detail

Revision A Page 22 Figure 2: Skirt Attachment Details Weld Buildup Detail

12.3 12.3.1

Materials The following apply to test specimens and coupons for ferritic plates and forgings thicker than 50 mm, when cooled faster than still-air cooling, as part of any heat treatment: Specimens shall be taken a minimum of 1/4 t from the surface and 1 t from an edge, where t is the plate or forging thickness. Where a separate test coupon is used, it shall accompany the product during any heat treatment and be at least 3t x 3t x t, with specimen locations as specified above.

12.4 12.4.1 12.4.2 12.5 12.5.1

Fabrication The welded joint between the shell and skirt shall merge smoothly with the shell. Maximum allowable offset in butt-welded joints shall not exceed 6 mm. Heat Treating Forming temperatures for ferritic materials shall be as follows: 1) Hot bending or roll forming: 900C to 1093C

Revision A Page 23
2) Closed die or press forming: 900C to 1093C 3) Cold sizing, rounding out, or roll forming plate: a) Up to: 50 mm thick: 93C minimum b) 100 mm: 149C minimum 12.6 12.6.1 Inspection and Testing Plate over 50 mm in thickness that has not been vacuum degassed, and all plate and forgings over 102 mm thick, shall be ultrasonically examined. Plate ultrasonic examination shall be in accordance with ASME SEC II-A SA-578. Forging ultrasonic examination shall be in accordance with ASME SEC II-A SA-388. Plate and forgings shall be straight-beam, ultrasonically examined in accordance with ASME SEC II-A SA-578, with supplemental requirements S1, S2.2, and ASME SEC II-A SA-388 enforced, respectively. Any area with one or more discontinuities, which produce a continuous total loss of back reflection and cannot be encompassed within a 25 mm diameter circle, is unacceptable. The recording of indications shall apply to all thicknesses. Recordable indications shall be reported in sketch form. The sketch shall mirror the geometry of the plate, and dimension the location and depth (from the test surface) of the recordable indications. Cut edges of base materials, after final edge preparation, shall be examined by the magnetic particle method or liquid penetrate method. Refer to the footnotes to Table 12.7. All shop fabricated vessels designed in accordance with the ASME SEC VIII D2, shall be given a shop hydrostatic test in accordance with Paragraph AT-301 of that Division. Weld Inspection Type of Joint Longitudinal and circumferential in shells, heads, and connections Connections to shell or head Attachments Weld build-up for skirts and weld A (see Figure 1) Weld repairs: a. Minor b. Major - depth of repair 9.5 mm or 1/2 weld thickness Notes:
*

12.6.2

12.6.3

12.6.4

12.6.5

12.6.6

12.7

Before Final PWHT RT, UT, and MT RT*, UT, and MT MT or PT RT or UT and MT

After Final PWHT UT and MT UT and MT MT or PT UT and MT

Original inspection methods

UT and MT

Use UT only for non-radiographic welds.

RT = Radiography MT = Magnetic Particle

Revision A Page 24
PT = Liquid Penetrant (use only for austenitic stainless steel, non-ferrous metals and 5 through 9 percent NI steels). UT = Ultrasonic

13.0

Approval to Deviate
Strict compliance with this standard guideline is required. Any deviation must obtain prior written approval from its custodian.

14.0

Revision History
A log is kept of the revision history of this document, and incorporated in the electronic readme file (ES.5.06.0003R).

15.0

Glossary
Within the context of this Design Guide the following words shall have the meanings stated: "must/shall" "should" "may" "approval" QGPC Purchaser - indicates a mandatory requirement. - indicates a preferred course of action. - indicates one acceptable course of action. - indicates agreement/sanction and shall be in writing only. - Qatar General Petroleum Corporation - The organisation responsible for performing the purchasing function, e.g. QGPC or a QGPC appointed Contractor, Consultant or Agent. - The supplier or a potential supplier of materials or equipment not necessarily the Manufacturer. - The company responsible for the manufacture - not necessarily the Vendor. - The QGPC appointed main Contractor for a defined piece of work. - A company awarded a contract by QGPC for the company to advise or give guidance on specific subjects. The Scope of Work may include instructions to act as an Agent for QGPC (see Agent). - The legal status of any person or company authorised by QGPC to act on QGPC's behalf on the matters specified in the agency agreement or contract. Third parties can usually rely on the Agent

Vendor

Manufacturer

Contractor

Consultant

Agent

Revision A Page 25
as acting on behalf of and with the authority of QGPC, provided that the Agent acts within the scope of his apparent authority from QGPC.

16.0

Bibliography
The following standards, codes and specifications shall, to the extent specified herein, form a part of this Engineering Guide. Except where a specific edition or revision is identified by date or revision/edition number, the edition in effect at the time of the contract shall govern.

16.1

National/International Standards ASME Section VIII ASME Section II ASME B31.3 BS 5500 API 601 NACE MR-01-75 - Boiler and Pressure Vessel Code Rules for Construction of Pressure Vessels - Boiler and Pressure Vessel Code Material Specifications, Part A, B and D - Process Piping - Unfired Fusion Welded Pressure Vessels - Metallic Gaskets for Piping - Sulphide Stress Cracking Resistant Metallic Materials for Oil Field Equipment

16.2

QGPC Documents ES.5.06.0001 QGPC. STD. ESQ12 QGPC. STD. 153 - Design Guidelines for Engineering of Pressure Vessels - Specification for Painting and Wrapping of Metal Surfaces

- Engineering Std. - Material for Sour Service

Revision A Page 26 Appendix 1 Requirements for the Contractor or Purchaser A-1.0 General
Decisions based on these requirements must be clearly indicated on the vessel Technical Data Sheets (TDS) and in the job specifications. This Appendix therefore need not be submitted to the vessel fabricator, but must be submitted to the vendor of package units involving pressure vessels. QGPC approval of subvendors for package units is required prior to award of the contract.

A-2.0
A-2.1

Design
Design Pressures The design pressure shall be a minimum of 10 percent above the maximum operating pressure for vessels protected by conventional safety relief valves. For vessels with safety relief valves with pilot operators or adapters providing bubble tight operation, a minimum of 5 percent shall suffice. In no case, however, shall the margin between design and maximum operating pressure be less than 173 kPag. When vessels are dually protected by a high pressure shutdown system and safety relief valves, the design pressure shall be a minimum of 15 percent above the maximum operating pressure. Only those pressure vessels that will be subjected to vacuum conditions during operation (including startup and shutdown) shall be designed for such conditions. If the internal pressure is 34 kPa, absolute or less, the vessel shall be designed for a full vacuum. Pressure vessels normally will not be designed for a vacuum condition caused by emptying water, after water filling or by other non-operating conditions. However, the maximum external pressure, which each vessel or vessel compartment can withstand at 149C, shall be calculated for corroded conditions, and shown on the vessel TDS and the assembly drawing. Pressure vessels without safety relief devices, but with an outlet that may be completely blocked off, shall be designed for the maximum pressure that can be developed in the vessel.

A-2.2

Design Temperatures The maximum design temperature shall not be less than the maximum operating temperature of the contained fluid, after quenching or flashing. However, the design metal temperature for vessel parts, such as inlets and the adjacent area, shall be the temperature of the fluid (before quenching or flashing) or the design metal temperature of the vessel, whichever is higher. The minimum design temperature (MDMT) shall be the minimum metal temperature expected in service. Process and ambient temperatures during start-up, normal operation, upset, holding, auto refrigeration, or shutdown conditions shall be considered in determining metal temperatures. These pressure-temperature conditions shall establish whether ambient conditions shall be used to determine the MDMT. The ambient temperature shall be the lowest one-day mean ambient temperature for the location unless otherwise specified. No account

Revision A Page 27
shall be taken of external insulation as protection from low ambient temperatures. The effect of internal insulation (castable linings) in slowing the warm-up of the shell during start-up pressurisation shall be taken into consideration. A-2.3 Supports Vertical vessels shall be self-supporting units. Skirts shall be used unless otherwise specified. A-2.4 Nozzles and Other Connections

A-2.4.1 Engineers should ensure that nozzle projections are clear of vessel insulation with sufficient space to permit flange bolting. Typical flanged nozzles equal to or less than 305 mm in diameter shall project a minimum of 203 mm from the outside surface of the shell, reinforcing pad, or insulation, as applicable. For manways and nozzles greater than 305 mm in diameter, the projection shall be a minimum of 254 mm. A-2.4.2 Flange boltholes shall straddle the vessels natural centerlines. A-2.4.3 No flanges connections shall be located within a skirt. A-2.5 Manways and Other Inspection Openings Vessels 915 mm in diameter and larger shall have at least one manway with a 457 mm minimum inside diameter. Smaller vessels with replaceable internals shall have a flanged head, and such vessels without replaceable internals shall have two inspection openings, as required by ASME SEC VIII. Flanged connections for instrumentation or piping of the same or larger size may be considered as inspection openings. Horizontal vessels shall have a manway in one head or on the top centerline of the vessel, preferably at the end opposite the vent. Manways on towers shall be located above the top tray, at the normal feed tray, and below the bottom tray. In towers containing packed beds, manways shall be provided above and below each bed. A-2.6 Instrument Connections, Drains, Vents, and Steamouts Connections for internal displacement liquid level devices shall be DN 100, and DN 100 stilling well shall be provided for the float. The nozzle shall be located so as to provide maximum stilling well length with no interference. Connections for external displacement liquid level devices shall DN 50, with ASME Class 300 flanges as a minimum. Each vessel shall have a drain of DN 80 minimum size, except that vessels 610 mm in diameter and smaller may have a DN 40 drain. Drains shall be sized so as to empty the vessel filled with water within an eight-hour period. The minimum size nozzle for vents shall be DN 50. Vents shall be located at the highest point of one end of each separate compartment. Consideration shall be given to proper provision of ventilation throughout the vessel during internal inspection or maintenance. Normally this is achieved by locating the vent nozzle and manway at opposite ends of the vessel to provide an adequate fresh airflow.

Revision A Page 28
Process nozzles shall not be used for level instrument connections.

A-3.0

Materials
Quenched and tempered steels and steel where SMYS exceeds 360 MPa, shall not be used for moist H2S service. C-1/2 Mo steels shall not be used.