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Indian Oil Corporation LTD. (IOCL)

SPECIFICATION
Plant
Naphtha Cracker Unit

Location
Panipat, Haryana, India

REV.

11-03-2005

FPM

DIS

JHWO

DATE

For Feed Package

DESCRIPTION

04184
D-612

Dept./Sect.
Project
Specification

Doc. No.
04184-120211-D-612

PREPARED

CHECKED

Rev. 0

Specification For:

HEAVY WALL CARBON AND LOW-ALLOY STEEL VESSELS

APPROVED

Page 1 of 8

Indian Oil Corporation LTD. (IOCL)

SPECIFICATION
Plant

Naphtha Cracker Unit

Location

Panipat, Haryana,India

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INDEX
SECTION

PAGE

1.

SCOPE

2.

GENERAL

DESIGN

4.

MATERIALS

5.

WELDING

6.

INSPECTION

7.

HYDROSTATIC TESTING

Page 2 of 8

Indian Oil Corporation LTD. (IOCL)

SPECIFICATION
Plant

Naphtha Cracker Unit

Location

Panipat, Harayana, India

1.

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SCOPE
This specification covers the minimum technical requirements for the design, fabrication, inspection,
testing and documentation of pressure vessels, and supplements the code under which the vessels are
to be supplied.

1.1

DEFINITIONS
For this specification the following definitions are applicable
Vessels
Code
Requisition
Client
Contractor
Buyer
Seller

is the collective name for the category of equipment, which is to be in

accordance with this specification.
means any code or standard listed under section 2.
means the Requisition including all attachments.
is Indian Oil Company Limited (IOCL) or his representative.
carries out all or part of the design, engineering, procurement,
construction and commissioning for the project.
is either Client or Contractor.
is the party responsible for the delivering the goods in accordance with the
requisition. This shall also mean rendering all services forming part of the
delivery.

This specification covers the general requirements for pressure vessels of the following materials:
1. Heavy wall CS (over 38 mm thick), or
2. Low-alloy Cr-Mo steels (all thicknesses)
Herewith refered Specifications and Directive as listed in para. 8 are also part of this specification.
2.

GENERAL

2.1

Code Conformance
This specification requires applying some of the nondestructive examinations and quality assurance
required by ASME code VIII Div 2 to vessels designed and fabricated according to ASME code VIII Div 1.

DESIGN

3.1

WELDED JOINTS
In addition to the requirements of Welding specification SW-0612, the following requirements are
applicable:

3.2

All Category A and B weld joints shall be double butt welded (Type 1), or an acceptable equivalent
agreed to by the Contractor.

3.3

Integrally forged, weld neck flange joints are required, unless specifically approved otherwise by the
Contractor.

3.4

All Category D nozzle welds shall be double welded and have full penetration.

3.5

Dissimilar metal welds are prohibited for all Categories A, B, C, and D weld joints, unless specifically
approved by the Contractor.

Indian Oil Corporation LTD. (IOCL)

SPECIFICATION
Plant

Naphtha Cracker Unit

Location

Panipat, Harayana, India

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3.6

All plate and sheet cut by shearing shall be ground to have shear damaged material removed from all
edges.

3.7

On horizontal vessels, no Category A weld joint shall be located more than 30-degrees below the
horizontal center line.

3.8

Weld joints between the support skirt and the vessel shall be as shown on the vessel drawing or data
sheet. Other longitudinal and circumferential weld joints shall be in accordance with Paragraph 3.2.

3.9

ATTACHMENTS

3.9.1

External pads and saddles shall be circular, or have a corner radius at least equal to the pad thickness.
(Where practical, corner radii of five times the pad thickness are preferred).

3.9.2

External attachments shall not cover nor intersect pressure containing welds in the vessel without
specific Contractor approval, with the exception that stiffening (vacuum rings) and insulation support
rings can intersect Category A welds.

3.9.3

Internal attachments shall be continuously welded to the vessel, with the exception that a 25 mm skip in
the weld at the bottom of an internal pad shall be made for a vent.

3.9.4

Internal pads shall be circular, or have corner radius of at least five times the pad thickness.

3.9.5

Efforts shall be made to avoid covering or intersecting pressure containing welds in the vessel with
internal attachments

4.

MATERIALS

4.1

PRESSURE CONTAINING PARTS

4.2

All plate grades of material 4-inch thick or greater shall be ultrasonically examined in accordance with
the requirements of the ASME Code VIII Div 2, section AM 203.1.

4.3

All forgings shall be forged as close as practicable to the finished shape and size to develop metal flow
in a direction most favorable for resisting the stresses encountered in service.

4.4

All forgings 4-inch thick and thicker shall be ultrasonically examined in accordance with the requirements
of ASME Code VIII Div. 2, Section AM 203.2.

4.5

All surfaces of forgings, regardless of thickness, shall be magnetic particle examined in accordance with
the requirements of ASME Code VIII Div 2, Appendix 9, article 9-1 after finish machining.

4.6

The tensile and Cv-impact tests required for certification of all plate, forging, and pipe grades of material
according to ASME Code VIII Div 2, section AF-101 shall represent the vessel in the completed
condition.

4.7

For ASME Code VIII Div 2 vessels, compliance with section AF-101 shall be verified by subjecting
specimens for tensile and Cv-impact tests to the total thermal history that will be required for fabrication
of the vessel.
The thermal history shall include all heat treatments, hot forming, heat treatments after hot forming,
PWHT and at least 2 additional heat treatment cycles to allow for shop or field repairs.

Indian Oil Corporation LTD. (IOCL)

SPECIFICATION
Plant

Naphtha Cracker Unit

Location

Panipat, Harayana, India

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Note: Compliance with these tensile and impact requirements can be met by including additional testing
of the base metals in the weld procedure qualification or production test plates requirements with the
approval of the Contractor.
4.8

For cold formed components for both ASME Code VIII Division 1 and division 2 vessels, stress relief
heat treatment is required if fiber elongation according to ASME Code VIII Division 1, paragraph UCS-79
is between 5% and 10% for carbon steel, or 3% and 10% for low alloy steel. Complete heat treatment in
accordance with the materials specification is required if fiber elongation exceeds 10%.

4.9

Cold sizing is permitted after stress relief heat treatment, if necessary to correct for distortion, providing
maximum fiber elongation does not exceed 5% for CS, or 3% for low-alloy steel.

4.10

For hot formed components, complete reheat treatment in accordance with the materials specifications is
required if the temperature of hot forming exceeds the normalizing temperature for normalized material,
or the tempering temperature for normalized and tempered or quenched and tempered material.

4.11

Components that will require reheat treatment by the seller need not be obtained from the materials
supplier in the final heat treatment condition.

4.12

Seller shall prepare a flow chart showing the sequence of all forming, welding, heat treating, and
inspection operations for review by the Contractor prior to the start of production.

4.13

All plate, forging, and pipe grades of material shall meet the Cv-impact test requirements of the
applicable design codes at the minimum design metal temperature shown on the data sheet or vessel
drawing.

4.14

When Cv-impact tests are required, the minimum Cv-impact test energy required is 27 J, unless
stringent values are required according to applicable Design Code.

4.15

Cv-impact testing is required for minimum design temperatures of 0 C, or lower when indicated on
equipment data sheets.

4.16

Cv-impact specimens shall be oriented transverse to the direction of major working with the notch
perpendicular to the surface.

5.

WELDING

5.1

Post Weld heat Treatment (Stress Relief)

5.1.1

Final Post Weld Heat Treatment (PWHT) for ASME P-1 material (carbon steel) shall be 593 650 C.
The minimum holding time shall not less than specified in ASME Code VIII Div 2, Table AF-402.2.

5.1.2

Postweld heat treatment shall meet or exceed the minimum temperature and the minimum time required
by ASME Code VIII Div 2, Paragraph AF-402. Table AF- 402.2 for applying the postweld heat treatment
at a lower temperature for an increased length of time is not acceptable.

5.1.3

Postweld heat treatment of the completed vessel as a whole is preferred. Local heat treatment is
permitted for Category B girth welds only, and the procedures must be submitted to the Contractor for
approval. Nozzles are not permitted in the locally heated band.

5.1.4

No welding shall be done on the pressure-containing parts of the vessel after PWHT or hydrostatic
testing.

Indian Oil Corporation LTD. (IOCL)

SPECIFICATION
Plant

Naphtha Cracker Unit

Location

Panipat, Harayana, India

5.1.5

6.
6.1

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During postweld heat treatment, vessels shall be blocked and supported as necessary to avoid any
deformation or damage.
INSPECTION
RADIOGRAPHY
All radiographic examinations for both ASME Code VIII Div. 1 and Div. 2 vessels shall be made in
accordance with ASME Code Div. 2, Article I-5, and the acceptance standard shall be in accordance with
ASME Code VIII Div. 2, Appendix 8.

6.1.1

All Category A, B and C weld joints, including nozzles, shall receive full coverage radiographic
examination after final postweld heat treatment.

6.1.2

With Contractor approval, radiographic examination may be performed before final postweld heat
treatment when ultrasonic examination is performed after final postweld heat treatment in accordance as
per section 6.3 of this specification.

6.1.3

Category D nozzle welds shall receive full coverage radiographic examination after final postweld heat
treatment. All Category D welds that cannot receive full coverage radiographic examination shall receive
full coverage ultrasonic examination after final postweld heat treatment.

6.2

ULTRASONIC EXAMINATION
All ultrasonic examinations shall be made in accordance with ASME Code VIII Div. 2, Appendix 9, Article
9-3, and the acceptance / rejection standard of Article 9-3, Paragraph 9-320 shall be applied.

6.2.1

All Category A, B, C, and, D weld joints in shell components with a thickness above 50 mm shall receive
full coverage ultrasonic examination after final postweld heat treatment. Above 100 mm thickness, semimechanized pulse echo or time of flight diffraction (TOFD) technique shall be used. Procedure shall be
submitted for approval.

6.2.2

Ultrasonic examination of Category D welds additionally requires prior approval of detailed UT

procedures including weld and nozzle configuration, mode of the UT wave, refractionation angle,
scanning position, and calibration blocks.

6.2.3

All weld pad buildups for attachment of internal or external components and supports shall receive an
ultrasonic examination.

6.2.4

All skirt-to-vessel welds shall receive an ultrasonic examination unless another type of examination is
approved by Contractor. Where possible, skirt to vessel welds shall be designed to permit ultrasonic
inspection. If not designed such that ultrasonic examination can be applied, refer to paragraph 6.4.3.

6.3 MAGNETIC PARTICLE EXAMINATION

Magnetic particle examinations shall be made in accordance with ASME Code VIII Div. 2, Appendix 9,
Article 9-1 and the acceptance standard in Article 9-1, Paragraph 9-130 shall be applied. Examinations
shall be made by the wet fluorescent technique. All production burns on vessels that receive a postweld
heat treatment shall be removed by grinding, unless the final postweld heat treatment will be performed
after the magnetic particle examination.
6.3.1

All weld bevels with a shell component thickness of 50 mm or greater shall receive a magnetic particle
examination prior to welding. All indications of linear flaws shall be removed by grinding or chipping and

Indian Oil Corporation LTD. (IOCL)

SPECIFICATION
Plant

Naphtha Cracker Unit

Location

Panipat, Harayana, India

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the area shall be re-examined to assure satisfactory removal of the flaw. Repairs shall be made with a
welding procedure qualification.
6.3.2

All Category A, B, C and double welded root areas shall receive a magnetic particle examination after
back gouging or back chipping. A dry powder technique may be used when the magnetic particle
examination is done with welding preheat applied.

6.3.3

Skirt-to-vessel welds that cannot be ultrasonically examined according to Section 6.3.4 shall receive a
magnetic particle examination after root pass is completed and for every third layer thereafter. A drypowder technique can be used when a preheat for welding is required.

6.3.4

When Magnetic particle testing is specified on the vessel drawing or datasheet, all accessible internal
surfaces of welds shall receive a magnetic particle examination after hydrotest.

6.3.5

All internal and external attachment welds to low alloy vessels shall receive a magnetic particle
examination after PWHT.

6.3.6

All surfaces where temporary attachments have been removed shall receive a magnetic particle
examination after grinding.

7.

HYDROSTATIC TESTING

7.1

PREPARATION

7.1.1

Seller shall furnish all test materials and facilities, including blinds, bolts and gaskets.

7.1.2

The vessel shall be cleaned internally and externally of dirt, debris, welding slag and weld spatter before
the hydrotest.

7.1.3

No paint or primer shall be applied to the vessel prior to hydrotesting.

7.1.4

Contractor shall be notified 5 days in advance so that the hydrostatic test can be witnessed.

7.2

REQUIRED STRESS LEVELS

The hydrostatic test pressure shall be the pressure calculated to stress the full thickness, including
corrosion allowance if any, of the strongest Category A weld to the applicable design code allowable
stress for the material at the test temperature, provided that no component of the vessel is stressed
above 90% of the minimum yield strength. If the hydrostatic test pressure so calculated will stress
components of the vessel above 90% of the minimum yield strength, then the pressure shall be reduced
by the least amount necessary to avoid overstressing weaker Category A welds.
The hydrostatic test pressure shall also full fill the requirements specified by PED 97/23/EC Pressure
Equipment Directive and local law regulations.

Indian Oil Corporation LTD. (IOCL)

SPECIFICATION
Plant

Naphtha Cracker Unit

Location

Panipat, Harayana, India

8.0

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REFERENCES
Reference Specifications and Directives:

D-611

Pressure Vessels

EA-601

Shell and Tube Heat Exchangers

SW - 0612

Equipment With Welding of Carbon Steel, Low-alloy,

Austenitic and Duplex Stainless- Steel.

SM-0622

Wet H2S Corrosion.

PED 97/23/EC

Pressure Equipment Directive

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