REVISION
December 1998
Process Industry Practices
Vessels
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication
Specification
ASME Code Section VIII, Divisions 1 and 2
PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES
In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these
technical requirements into a single set of Practices, administrative, application, and
engineering costs to both the purchaser and the manufacturer should be reduced. While
this Practice is expected to incorporate the majority of requirements of most users,
individual applications may involve requirements that will be appended to and take
precedence over this Practice. Determinations concerning fitness for purpose and
particular matters or application of the Practice to particular project or engineering
situations should not be made solely on information contained in these materials. The
use of trade names from time to time should not be viewed as an expression of
preference but rather recognized as normal usage in the trade. Other brands having the
same specifications are equally correct and may be substituted for those named. All
practices or guidelines are intended to be consistent with applicable laws and
regulations including OSHA requirements. To the extent these practices or guidelines
should conflict with OSHA or other applicable laws or regulations, such laws or
regulations must be followed. Consult an appropriate professional before applying or
acting on any material contained in or suggested by the Practice.
©Process Industry Practices (PIP), Construction Industry Institute, The
University of Texas at Austin, 3208 Red River Street, Suite 300, Austin,
Texas 78705. PIP member companies may copy this practice for their
internal use.
9/97
Issued
12/98 Revision
Not printed with State funds
REVISION
December 1998
Process Industry Practices
Vessels
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication
Specification
ASME Code Section VIII, Divisions 1 and 2
Table of Contents
1. General Requirements.................3
1.1 Purpose ................................................3
1.2 Scope ...................................................3
1.3 Alternative Design Proposals ...............3
2. References....................................4
2.1 Process Industry Practices (PIP) .........4
2.2 Industry Codes and Standards.............4
2.3 Other References.................................5
3. Definitions.....................................5
4. Responsibilities............................6
4.1 Manufacturer’s Responsibilities ...........6
4.2 Disclaimers...........................................6
4.3 Conflicts ...............................................6
4.4 Documentation to be Provided by the
Manufacturer........................................6
5. Fabrication Requirements ...........7
5.2.5 External Attachments .............10
5.2.6 Temporary Welded
Attachments ............................11
5.2.7 Vapor Belts .............................11
5.3 Shop Fabrication ................................11
5.3.7 Finish ......................................12
5.3.8 Prevention of Stress Raisers
in Impact Tested Materials.....12
5.3.9 Flanged Pressure Boundary
Joint Assembly.......................12
5.3.10 Tube-to-Tubesheet Joints.......12
5.3.11 Fixed Tubesheet Thickness ...14
5.3.12 Pass Partition Plates...............14
5.3.13 Dummy Tubes ........................14
5.3.14 Seal Strips ..............................14
5.3.15 Skid Bars ................................14
5.3.16 Removable Component
Marking ..................................14
5.4 Tolerances .........................................15
5.5 Welding ..............................................15
5.6 Postweld Heat Treatment...................16
5.1 Materials...............................................7
5.2 Design ..................................................9
5.2.1 General .......................................9
5.2.2 Vessel Layout .............................9
5.2.4 Nozzles and Reinforcing Pads 10
Process Industry Practices
Page 1 of 22
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
6. Nondestructive Examination,
Inspection and Testing ............. 17
6.1 Nondestructive Examination .............. 17
6.2 Inspection .......................................... 18
6.3 Pressure Testing................................ 18
6.3.8 Test Temperature .................... 1 9
6.4 Leak Testing ...................................... 20
7. Preparation for Shipping .......... 21
December 1998
Appendices
Appendix A
Appendix B
Appendix C
Appendix D
Quality Overview Plan
Documentation Schedule
and Manufacturer’s Data
Package
Flanged Pressure Boundary
Joint Assembly
Manufacturer’s Drawing
Information
7.1 Cleaning and Painting........................ 21
7.2 Preservation and Preparation for
Shipment ........................................... 21
7.2.3 Closure of Openings ................ 21
Page 2 of 22
Process Industry Practices
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
1.
General Requirements
Note to Readers: This Practice contains fabrication criteria for pressure vessels and shelland-tube heat exchangers. Corresponding subject matter for pressure vessels and shell-andtube heat exchangers is covered by paragraphs identically numbered. Paragraphs pertaining
to pressure vessels are preceded by [V]. Paragraphs pertaining to shell-and-tube heat
exchangers are preceded by [E]. Paragraphs pertaining to both are preceded by [V/E]. In
addition, ASME Boiler and Pressure Vessel Code Section VIII, Division 2 requirements are
shown in braces { }.
This Practice should be used for pressure vessels built to Division 1 or Division 2 of the
ASME Boiler and Pressure Vessel Code. Shell-and-tube heat exchangers are limited to
Division 1 in this Practice.
1.1
Purpose
[V/E] This Practice describes the general fabrication, examination, inspection,
testing, and documentation requirements for pressure vessels and shell-and-tube heat
exchangers to be constructed in accordance with Section VIII, Division 1 {or 2} of
the ASME Boiler and Pressure Vessel Code, henceforth referred to as the Code.
[E] This Practice describes the additional requirements for shell-and-tube heat
exchangers to be constructed in accordance with TEMA Standards of the Tubular
Exchanger Manufacturers Association.
1.2
1.3
Scope
1.2.1
[V/E] This Practice is to be used in conjunction with design drawings or
Data Sheets, and for project-specific design criteria that may supersede the
requirements of this Practice but not take exception to the requirements of
the Code.
1.2.2
[V/E] Total compliance with the Code, including stamping, shall be a basic
requirement of all vessels ordered to this Practice. Unless otherwise
specified in the purchase order or the drawings, all “U-” {U2-} stamped
vessels shall be National Board (NB) registered.
1.2.3
[V/E] Deviations from this Practice require written approval by the User.
Alternative Design Proposals
[V/E] The Manufacturer shall provide a base bid in full compliance with the
Purchaser’s request for quotation. The Manufacturer may submit an alternative
design if, in the Manufacturer’s judgment, economy and/or improved schedule can
be realized without loss of capability and without shortening the anticipated life of
the vessel. The Manufacturer shall comply with the following requirements when
submitting an alternate bid:
a. Alternative design quotations shall be accompanied by the base quotation and
be clearly noted as an alternate.
Process Industry Practices
Page 3 of 22
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
b. Alternative designs shall be fully and clearly described and substantiated by
sketches or drawings. Specific exceptions should be identified as such.
c. An alternative design shall not be used unless approved in writing by the User.
2.
References
The following documents are only those specifically referenced in this Practice. In
applications where laws or regulations issued by municipal, state, provincial, or federal
authorities cover pressure vessels, those laws or regulations should be reviewed prior to the
initiation of design work since the requirements may be different or more restrictive than
those included in this Practice. Short titles will be used herein when appropriate.
2.1
Process Industry Practices (PIP)
The latest edition of the following reference documents in effect on the date of
contract award shall be used.
– PIP VECV1001 - Vessel/S&T Heat Exchanger Design Criteria, ASME Code
Section VIII, Divisions 1 and 2
– PIP VEDST003 - Shell and Tube Heat Exchanger Specification Sheet
– PIP VEDV1003 - Vessel Drawing/Data Sheet and Instructions
– PIP VEFV1100 - Vessel Standard Details (27 Details and Index)
PIP VEFV1102 - Vessel; Tolerances (Orientation)
PIP VEFV1103 - Vessel; Grounding Lug
2.2
Industry Codes and Standards
For the following reference documents, if Table U-3 {AG-150.1} of the Code lists an
edition or addenda different than the latest edition issued, the edition in Table U-3
{AG-150.1} shall be used. For documents not listed in Table U-3 {AG-150.1}, the
latest edition or addenda issued at the date of contract award shall be used.
American Society of Mechanical Engineers (ASME)
– ASME Boiler and Pressure Vessel Code
Section V - Nondestructive Examination
Section VIII - Pressure Vessels, Divisions 1 and 2
Section IX - Welding and Brazing Qualifications
– ASME B16.5 - Pipe Flanges and Flange Fittings, Sizes NPS 1/2 through
NPS 24
– ASME SA-263 - Corrosion-Resisting Chromium, Steel-Clad Plate, Sheet and
Strip
– ASME SA-264 - Stainless Chromium-Nickel, Steel-Clad Plate, Sheet and Strip
– ASME SA-265 - Nickel and Nickel-Based Alloy-Clad Steel Plate
– ASME SA-578 - Straight-Beam Ultrasonic Examination of Plain and Clad
Page 4 of 22
Process Industry Practices
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
Steel Plates for Special Applications
– ASME SA-745 - Ultrasonic Examination of Austenitic Steel Forgings
American Welding Society (AWS)
– AWS A2.4 - Welding and Brazing and Nondestructive Examination
Tubular Exchanger Manufacturers Association (TEMA)
– Standards of the Tubular Exchanger Manufacturers Association
Welding Research Council (WRC)
– WRC Bulletin 107 - Local Stresses in Spherical and Cylindrical Shells Due to
External Loadings
2.3
Other References
Association for Information and Image Management (AIIM)
– ANSI/AIIM MS32 - Microrecording of Engineering Source Documents on
35-mm Microfilm
3.
Definitions
Approved Equal: A substitution to a specified product that has been approved in writing by
the Purchaser
Code: ASME Boiler and Pressure Vessel Code Section VIII, Division 1 {or 2}. References
to Division 2 are identified in braces { }.
Designer: The party responsible for defining and specifying the mechanical design
requirements (e.g., Vessel Drawing/Data Sheet) consistent with User criteria for use by the
Manufacturer. The Designer is frequently an engineering contractor, but could be the User,
third party consultant, or the Manufacturer.
Manufacturer: The party entering into a contract with the Purchaser to construct a vessel in
accordance with the purchase order
National Board: The National Board of Boiler and Pressure Vessel Inspectors, an
organization comprised of chief inspectors of various governmental jurisdictions in the
United States and Canada. Vessels meeting requirements of the Code, except those stamped
with the Code UM-symbol, can be registered with the National Board.
Purchaser: The party actually placing the order for the vessel or vessel components. This
may be the User or the User’s Designated Agent.
User: The party responsible for establishing construction criteria consistent with the Code
philosophy and service hazards. “User” refers to the owner and/or operator of the equipment.
Vessel: This term may be used as a non-specific reference to a pressure vessel or a shell-andtube heat exchanger
Process Industry Practices
Page 5 of 22
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
4.
REVISION
December 1998
Responsibilities
4.1
Manufacturer’s Responsibilities
[V/E] The Manufacturer is responsible for the construction of the vessel(s) in
conformance with this Practice and the documents referenced herein. Review of
Manufacturer’s documentation (e.g., fabrication drawings or weld procedures) by the
Purchaser or User does not alter this responsibility.
4.2
Disclaimers
[V/E] Specified Design: When a vessel or vessel component design is specified on
the User’s vessel design drawings, the Manufacturer is in no way relieved of his
obligations and/or responsibilities to comply with the purchase specifications.
[V/E] Welding: Welded fabrication shall not be sublet by the Manufacturer without
prior approval of the Purchaser. Standard pressure parts covered under the provisions
of Code Paragraph UG-11 are exempted, as are multi-piece formed heads with a
Code part stamp.
[V/E] Inspection: Release for shipment by Purchaser’s or User’s inspector does not
relieve the Manufacturer of any responsibility for complying with the Code,
specifications and/or drawings.
4.3
Conflicts
[V/E] If the Manufacturer finds a conflict between this Practice, the design drawings
or Data Sheet, referenced codes and standards, or any supplementary specification,
the Manufacturer shall obtain written clarification from the Purchaser prior to
proceeding with any work.
4.4
Documentation to be Provided by the Manufacturer
[V/E] The Manufacturer shall provide the following documentation to the User, in
quantities and at dates indicated on the Documentation Schedule in Appendix B.
Reproducible materials are to be of suitable quality to be microfilmed, per
ANSI/AIIM MS32.
4.4.1
[V/E] Design calculations shall include relevant formulas and source
paragraphs from the Code, values used in the formulas, calculated results,
and comparisons with acceptable values. Where calculations are based on
formulas other than those in the Code, the source of the formulas shall be
referenced. Where calculations are done by a computer program, a program
description shall be given, including name and version of the program. If the
program is not commercially available to industry, the Manufacturer shall
maintain and provide program documentation, upon request. (See Foreword
of the Code for Cautionary Note regarding responsibility for the use of
computer programs.)
Calculations shall include:
a. Code calculations
Page 6 of 22
Process Industry Practices
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
b. Wind and earthquake calculations, as applicable
c. Support calculations
d. Calculations associated with lifting and erection of the vessel
e. Nozzle load analysis for local and gross effect, per WRC 107 or other
approved method, when required
f.
Design of attachments, internal and external, including PIP or any
other standard details used
g. Fatigue analysis as applicable for fatigue services (see PIP
VECV1001, Section 5.5)
5.
4.4.2
[V/E] Manufacturer’s Data Package shall include the documents listed in
Appendices A and B. Final Manufacturer’s Data Package shall be printed or
folded to 8-1/2" x 11" size and suitably bound.
4.4.3
[V/E] Manufacturer’s drawings should include, but are not limited to, the
items listed in Appendix D.
Fabrication Requirements
5.1
Materials
5.1.1
[V/E] Attachments welded to pressure-resisting vessel components (e.g.,
skirts, stiffening rings, saddles, clips, pads, brackets, and supports) shall be
considered critical to the structural integrity of the vessel for evaluation of
impact test requirements (see Code Paragraph UCS-66a) {AM-204}.
5.1.2
[V/E] All impact test values shall be reported in the material supplier’s
certified test reports.
5.1.3
[V/E] No galvanized clips or attachments shall be welded to a vessel.
5.1.4
[V/E] Postweld Heat Treatment (PWHT) of test specimens shall be in
accordance with Code requirements. PWHT shall include one extra PWHT
cycle for potential future field repair as specified by the Designer on the
Data Sheet.
5.1.5
[V/E] Rolled plate for flat covers and blind flanges (blind flanges per ASME
B16.5 excluded) exceeding 3 inches in thickness shall be examined after
cutting to final size per ASME SA-578 Acceptance Standard - Level 1.
Note: This article shall apply to carbon, low-alloy, and high-alloy steel
plates.
5.1.6
[V/E] All carbon, low-alloy, and high-alloy steel forgings exceeding 3
inches in thickness (flanges per ASME B16.5 excluded) shall be examined
ultrasonically per ASME SA-578 with the following requirements:
1. Quality levels for straight beam examinations from flat surfaces shall
be:
Process Industry Practices
Page 7 of 22
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
THICKNESS
Inches
>3 < 8
>8 < 12
>12
5.1.7
QUALITY
LEVEL
QL-2
QL-3
QL-4
2. Quality level for straight beam examinations from curved surfaces shall
be QL-5.
3. Quality level for all angle beam examinations shall be QA-1. Notch
depth shall be per QA-1 or 1/4 inch, whichever is less.
Sleeve liners shall not be used in lieu of providing clad or weld overlay.
5.1.8
[V/E] Integrally clad plate for vessels designed for vacuum service and for
vessels whose design calculations include the cladding shall be examined per
ASME SA-578 Acceptance Standard - Level 1 and Supplementary
Requirement S6.
5.1.9
[V/E] The heat treatment of integrally clad plate conforming to ASME
SA-263, ASME SA-264, and ASME SA-265 shall be done by the plate
manufacturer.
5.1.10 [V/E] All integrally clad plate, including explosion clad plate, conforming to
ASME SA-263, ASME SA-264, and ASME SA-265 shall be cold flattened, if
required, after final heat treatment and descaling.
5.1.11 [V/E] Where weld overlay is specified, the deposited weld overlay shall
have a nominal composition that corresponds to that of the alloy in the vessel
to the depth specified on the Data Sheet.
5.1.12 [V/E] Vessel internals constructed of alloy pipe up to and including Nominal
Pipe Size (NPS) 12 shall be a minimum of Schedule 10S. Larger than NPS
12, use at least 3/16 inch nominal wall pipe or fabricate from plate. The
material shall be the same nominal composition as the cladding, weld
overlay, or alloy shell.
5.1.13 [V/E] Carbon and low-alloy steel material for separate nozzle reinforcing
pads, as well as stiffening rings and other attachments which are welded to
pressure-retaining components, shall not limit the Minimum Design Metal
Temperature (MDMT). Use Code Paragraph UCS-66 for determining the
MDMT. For high-alloy steel shells and heads where stresses due to
differential thermal expansion must be considered, the use of carbon or lowalloy steel for nozzle reinforcing pads, stiffening rings, and other
attachments welded to pressure retaining components shall require written
agreement between the Purchaser and the Manufacturer.
5.1.14 [V/E] Gaskets specified in the purchase order or on the drawings shall be
supplied by the Manufacturer unless otherwise specifically noted. For test
gaskets, see Section 6.3.16; for spare gaskets, see Section 7.2.2.
5.1.15 [E] Heat exchanger tubes shall be formed from one continuous length of
tubing. Circumferential welds are not permitted.
Page 8 of 22
Process Industry Practices
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
5.1.16 [E] Rolled plate for tubesheets exceeding 3 inches in thickness shall be
examined after cutting to final size per ASME SA-578 Acceptance Standard Level 1 and Supplementary Requirement S1.
Note: This article shall apply to carbon, low-alloy, and high-alloy steel
plates.
5.1.17 [E] Integrally clad plate for tubesheets shall be examined per ASME SA-578
Acceptance Standard - Level 1 and Supplementary Requirement S7.
5.2
Design
5.2.1
General
[V/E] The vessel design by the Manufacturer shall comply with the
applicable requirements in PIP VECV1001, the Code, {User’s Design
Specification,} this Practice, the Vessel Data Sheet, and all other
requirements in the purchase specification. Vessel-related design performed
by the Designer does not relieve the Manufacturer from this responsibility.
[V/E] The Manufacturer is responsible for determining the size and quantity
of anchor bolts and base plate details. Refer to PIP VECV1001, Section 5.16
for allowable stresses.
5.2.2
Vessel Layout
[V/E] Vessel layout shall include consideration of the following:
a. Saddles shall be continuously welded to the shell. Welded seams under
the saddle or wear plate are not permitted. Longitudinal weld seams in
the shell shall not be located within 15 degrees of the horn of the
saddle, since this is a location of high stress.
b. Plate layouts shall be arranged so that, to the maximum extent
possible, longitudinal and circumferential weld seams clear all
nozzles, manways, and their reinforcing pads by 2 inches minimum,
measured from weld edge to weld edge.
c. When nozzles must penetrate weld seams, or when nozzle reinforcing
pads must cover weld seams, the seam shall be ground flush and
radiographically examined before welding the nozzle. The seam shall
be radiographed per Code Paragraph UW-51 {Table AF-241, Article
I-5} as required in Code Paragraph UW-14 {AD-502}.
d. Structural attachment welds (e.g., internal support rings or clips,
external stiffening rings, insulation support rings, and ladder, platform
or pipe support clips) shall clear weld seams by a minimum of 2
inches. If overlap of pad type structural attachments and weld seams is
unavoidable, the portion of the seam to be covered shall be ground
flush and radiographically examined before the attachment is welded
on. The seam shall be radiographed per Code Paragraph UW-51
{Article I-5} for a minimum distance of 2 inches beyond the edge of
the overlapping attachment. Radiographic examination of weld seams
Process Industry Practices
Page 9 of 22
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
is not required when single-plate edge-type attachments such as tray
support rings, downcomer bolting bars, stiffening rings, insulation
support rings, ladder, platform, or pipe support clips cross weld seams.
e. The layout of seams shall be, to the maximum extent possible, such
that the longitudinal seams are not within the downcomer area of trays
or behind any obstruction that prevents inspection of these welds.
Circumferential seams shall not fall on a tray ring, and shall be located
not less than 2 inches above or below the tray ring.
f.
Bolt holes in all fixed flanges and studding outlets shall straddle the
natural centerlines. For nozzles in heads, the bolt holes shall straddle
centerlines parallel to, or coincident with, the natural vessel
centerlines.
5.2.3
{Intentionally Left Blank}
5.2.4
Nozzles and Reinforcing Pads
5.2.4.1
[V] All inside nozzle neck edges shall be rounded to 1/8 inch
minimum radius. Nozzles for pressure relief devices and for
drainage shall be flush with the inside wall of the shell or head.
[E] All inside nozzle neck edges shall be rounded to 1/8 inch
minimum radius. Nozzles shall be flush with the inside wall.
5.2.5
5.2.4.2
[V/E] Nozzle reinforcing pads shall be external and, when
constructed in segments, shall have the segments joined with full
penetration butt welds, the location of which shall be at least 45
degrees from the longitudinal axis of the vessel (see Code Figure
UG-37 {Figure AD-520.1}). Each pad segment shall have one
American Standard Taper Pipe Thread (NPT) 1/4 inch telltale hole
for testing purposes.
5.2.4.3
[V/E] Nozzle reinforcing pads and all attachment pads, if not
circular, shall have rounded corners of 2 inches minimum radius.
External Attachments
[V/E] The Manufacturer shall furnish and install all clips, brackets, and
other items which are welded to the outside surface of the vessel or skirt, as
listed on the User’s drawings and specifications including:
a. The Manufacturer’s nameplate shall be made either of a 300 series
stainless steel or of a nickel-copper alloy UNS N04400 or equivalent
(Monel), and shall be attached securely on a support bracket. The
nameplate support bracket shall conform to PIP VEFV1100. See the
Vessel Data Sheet for Code nameplate contents.
b. Lifting attachments, as designed by the Manufacturer or as specified
on User drawings
c. A grounding lug in accordance with PIP VEFV1103
Page 10 of 22
Process Industry Practices
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
5.2.6
5.2.7
Temporary Welded Attachments
5.2.6.1
[V/E] 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.
5.2.6.2
[V/E] All temporary attachments shall be designed for removal
prior to hydrotest.
5.2.6.3
[V/E] Temporary attachments shall be removed flush with the
vessel shell and nondestructively examined (MT or PT), in
addition to visual examination, to ensure no cracks have been
generated.
5.2.6.4
[V/E] Temporary welds shall be made in accordance with Section
5.5.2.
Vapor Belts
[E] When a vapor belt annular distributor is required, provide 1/2 inch
minimum radii on the corners of the distribution slots.
5.3
Shop Fabrication
5.3.1
[V/E] Machining shall be performed after welding or heat treatment if such
operations change machined surface characteristics or geometry (e.g., flange
face flatness). For all flanges (except ASME B16.5 flanges) and shopfabricated lap rings, the gasket contact surface flatness tolerance, in both the
radial and circumferential directions, shall be 0.006 inch total indicator
reading. Measurement shall be made by a dial indicator after all other
operations have been completed with regard to the fabrication and heat
treatment of the flange or lap ring and its attachment to the shell or nozzle
neck that can affect flatness tolerance. The total circumferential tolerance
shall not occur in less than 20 degrees arc.
5.3.2
[V/E] When forming any austenitic stainless or nonferrous plate, care shall
be taken to prevent carbon pickup or contamination of formed material.
5.3.3
[V/E] Only stainless steel brushes and clean, iron-free sand, ceramic or
stainless steel grit shall be used for cleaning high-alloy surfaces. Cleaning
tools or materials shall not have been previously used on carbon steel.
5.3.4
[V/E] Materials that may cause corrosive attack when the vessel part is
heated shall not be used, including:
Process Industry Practices
Marking inks (containing halogens)
Lubricants
Crayons
Adhesives, except as required in Appendix C
Tapes (e.g., duct tape)
Coatings to prevent adhesion of weld spatter
Paints containing sulfur
Page 11 of 22
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
REVISION
December 1998
Chlorine compounds (which will decompose to hydrogen chloride)
Carbon
Harmful metal or metal salts such as zinc, lead, or copper
[E] The flatness of tubesheet gasket contact surfaces shall be measured after
the tube-to-tubesheet joints have been welded and/or expanded.
5.3.5
5.3.6
[E] All longitudinal and circumferential welds of shells for other than kettle
type units shall be finished flush with the inner contour for ease of tubebundle insertion and withdrawal. For kettle type units, this requirement is
waived for welds in the enlarged section that are not in the bottom quadrant
of the shell.
5.3.7
Finish
[V/E] When polishing or special finishing is specified, the acceptance of the
final finish is subject to the approval of the User. To reach agreement on the
finish required:
1. The Manufacturer will prepare and submit, prior to fabrication, two
halves of a polished sample to illustrate the minimum proposed finish.
2. Polished samples shall contain welds similar to welds of the
equipment which are the most difficult to polish.
3. One half of the sample will be returned to the Manufacturer for use as
the Manufacturer’s reference standard. The other half will be sent to
the User’s inspector as the User’s standard.
5.3.8
Prevention of Stress Raisers in Impact Tested Materials
[V/E] Special care shall be taken to prevent stress raisers which might cause
low impact strength due to notch effect or abrupt change in section.
Welder’s and welding operator’s symbols and reference lines may be
stamped on the material in accordance with the provisions of Code
Paragraph UW-37{AF-235}, provided that a round-nose stamp is employed
and the symbol is located at least 1 inch from the edge of the weld.
5.3.9
Flanged Pressure Boundary Joint Assembly
[V/E] Joints shall be assembled in accordance with Appendix C of this
Practice.
5.3.10 Tube-to-Tubesheet Joints
5.3.10.1 [E] Tube holes in tubesheets shall be deburred by chamfering 1/32
inch maximum on both sides of the tubesheet.
5.3.10.2 [E] Tubesheet expansion depth shall be in accordance with TEMA,
except that expansion shall not begin closer than 1/8 inch from a
tube-to-tubesheet weld.
5.3.10.3 [E] Expansion of tubes and any tube-to-tubesheet welding shall be
performed after any PWHT affecting tube-to-tubesheet joints.
Page 12 of 22
Process Industry Practices
REVISION
December 1998
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
5.3.10.4 Seal Welded Tube-to-Tubesheet Joints
5.3.10.4.1 [E] In addition to TEMA requirements for expanded
tube-to-tubesheet joints, when seal welds are specified
they shall be in accordance with Code Paragraph
UW-20. Tubes shall be secured (locked) in position
prior to welding. Tubes shall not be fully expanded
prior to welding or leak testing. The bore of the tubes
shall be free of deposited weld metal.
5.3.10.4.2 [E] After welding and prior to expanding and pressure
testing, a leak test in accordance with Code Section V,
Article 10 and Appendix I is required.
5.3.10.4.3 [E] Penetrant Testing (PT) shall be performed on the
tube-to-tubesheet welds after expansion. Examination
shall be per Code Appendix 8. Repair any
unacceptable welds and re-examine per this
Paragraph.
5.3.10.5 Strength Welded Tube-to-Tubesheet Joints
5.3.10.5.1 [E] Strength welds shall be in accordance with Code
Paragraph UW-20 and tested in accordance with Code
Appendix A. The bore of the tubes shall be free of
deposited weld metal. Tubes shall not be expanded
prior to welding or leak testing.
5.3.10.5.2 [E] The proposed strength welding procedure
(including cleaning, assembly, welding, testing, other
inspection procedures, and tube expansion) shall be
submitted to the Purchaser for review. A shear load
test in accordance with Code Appendix A-3 to prove
the tube-to-tubesheet joint procedure shall be
completed before start of fabrication. The factor of
efficiency, fr, as calculated in accordance with Code
Appendix A-4 shall not be less than 1.0. The thickness
of the mock-up tubesheet shall be the lesser of the
thickness of the production tubesheet, or 1-1/2 inches.
The test results shall be certified by the Manufacturer
and submitted with the data reports to the Purchaser.
At least two of the tube-to-tubesheet joints adjacent to
the tube tested shall be sectioned, polished, and etched
to visually examine the weld. The weld sizes
determined from the etched sections shall meet the
requirements of Code UW-20. Photographs of the
etched sections (10X magnification) shall be
submitted to the Purchaser.
Process Industry Practices
Page 13 of 22
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
REVISION
December 1998
5.3.10.5.3 [E] After welding and prior to expanding and pressure
testing, a leak test in accordance with Code Section V,
Articles 10 and Appendix I is required.
5.3.10.5.4 [E] Penetrant Testing (PT) shall be performed on the
tube-to-tubesheet welds after expansion. Examination
shall be per Code Appendix 8. Repair any
unacceptable welds and re-examine per this
Paragraph.
5.3.11 Fixed Tubesheet Thickness
[E] Fixed tubesheet thickness shall not exceed the specified thickness by
more than that allowed in Code Appendix A-A.
5.3.12 Pass Partition Plates
[E] Pass partition plates shall have full penetration welds for a minimum of 2
inches from the gasket face of each flange. The balance of the length shall be
continuously fillet welded on both sides of the plate.
5.3.13 Dummy Tubes
[E] Dummy tubes shall be sealed at one end only. Dummy tubes shall be
welded to every other baffle on one side of the baffle.
5.3.14 Seal Strips
[E] Seal strips shall be continuously welded to one side of each baffle from
the Outside Diameter (OD) of the baffle to the base of the seal strip.
5.3.15 Skid Bars
5.3.15.1 [E] The outer edge shall be ground to match the baffle/support
OD. The leading and tailing ends of the skid bars shall be radiused
or beveled.
5.3.15.2 [E] The skid bars shall be welded with a continuous fillet weld to
each baffle (when possible), support, or stationary tubesheet.
5.3.16 Removable Component Marking
[E] Removable bundle stationary tubesheets and channels (bonnets)/shells
shall be match marked with a single weld bead (1/8 inch min. height x 1/2
inch length) on each part. Match marks shall be on the top for horizontal
exchangers and the same orientation as the nearest shell inlet/outlet nozzle
for vertical exchangers.
[E] All removable exchanger components (bonnet, channel cover, test
covers, etc.), except the shell, shall be stamped on its perimeter with the
User’s identification number.
Page 14 of 22
Process Industry Practices
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
5.4
Tolerances
[V] All equipment shall meet the manufacturing tolerances as shown in the purchase
order or on the drawings. Tolerances on fabricated equipment as shown on PIP
VEFV1102 shall apply to the completed vessel after pressure test.
[E] Tolerances for heat exchangers shall be per TEMA.
5.5
Welding
5.5.1
[V/E] Selection of welded pressure joint requirements from the variety of
Code options is the Designer’s responsibility (see PIP VECV1001, Section
5.6). See Section 5.5.8 of this Practice for minimum requirements when not
specified by the Designer.
5.5.2
[V/E] All welds, including those for nonpressure parts and attachments
(including temporary attachments), shall be made by welders, welding
operators, and welding procedures qualified under the provisions of Code
Section IX. Welds shall meet the supplementary provisions of the Code, plus
recognized and generally accepted good welding practices (including, but
not limited to, the use of clean and dry materials, good techniques, and the
proper chemistry).
5.5.3
[V/E] Shielded metal arc electrodes used for pressure-resisting welds shall
be of the low-hydrogen type and shall have a minimum tensile strength
nominally equal to the weaker of the base materials being joined. Use of
higher strength weld materials for all welding processes is prohibited except
as specifically approved in writing by the User.
5.5.4
[V/E] The responsibility for welding to be used in Code construction rests
with the Manufacturer. The Manufacturer’s responsibility includes the
following, with the documents referenced made available for use by the
welders/welding operators and for reference by the Code Authorized
Inspector and the User:
1. Selecting and preparing the Welding Procedure Specification(s)
(WPS) suitable to the need
2. Preparing and providing a Procedure Qualification Record (PQR)
documenting proof of the weldability of the variables described in the
WPS
3. Preparing and providing a Welder Performance Qualification (WPQ)
documenting proof of the welder’s ability to deposit sound weld metal
within the range of WPS parameters being used
5.5.5
[V/E] The Manufacturer is responsible for complying with all applicable
Code requirements relating to welding and associated considerations,
spanning from the design of the welded joint, consumables control and
preheat, to final nondestructive examination of the joints.
5.5.6
[V/E] Should the User request review of the WPS(s) prior to the start of
production welding, the return of this document to the Manufacturer with or
Process Industry Practices
Page 15 of 22
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
REVISION
December 1998
without comments does not constitute approval. The responsibility for
welding shall be part of the overall construction responsibility of the
Manufacturer.
5.5.7
[V/E] When requested by the User, a detailed weld map shall be provided as
part of the review and Manufacturer’s Data Package submitted to the User.
The weld map shall include, as a minimum, a sketch of all weld joints,
welding symbols used (per AWS A2.4), and associated weld procedure
numbers.
5.5.8
[V/E] Pressure boundary butt-weld seams shall be in accordance with Type
No. 1 of Code Table UW-12 {Table AF-241.1} only (i.e., butt joints as
attained by double-welding or by other means that will obtain the same
quality of deposited weld metal on the inside and outside weld surfaces to
agree with the requirements of Code Paragraph UW-35 {AF-221}). Welds
using permanent metal backing strips are not permitted. Butt-weld seams
shall be accessible for examination, inspection, and/or repair with welded
attachments in place. For joints inaccessible from the inside, the
Manufacturer shall submit an alternative method for obtaining a full
penetration and full fusion weld from one side. (Refer to the Welded
Pressure Joint Requirements Form in Appendix B {not applicable} of PIP
VECV1001.)
5.5.9
[V/E] No tack welding is permitted between heads and skirts on the inside of
skirts. The skirt-to-base ring attachments shall be two continuous fillet
welds, one outside and one inside. All seams in the skirt shall be Type No. 1
of Code Table UW-12 {Table AF-241.1}. Alignment tolerance at plate edges
to be butt-welded shall be per Code Paragraph UW-33 {AF-221.3}.
5.5.10 [V/E] All external supports, support rings, pads, and structural brackets
attached to the vessel shall be seal-welded all around to prevent corrosion
between the vessel and attachments. When seal welding all around is not
practical, provision for drainage shall be made (e.g., a gap in the low-point
weld).
5.6
Page 16 of 22
Postweld Heat Treatment
5.6.1
[V/E] Where PWHT is required, PWHT shall be performed after all welding
(including repairs) and nondestructive examination is completed, but prior to
any hydrotest or other load test.
5.6.2
[V/E] Alternative PWHT Requirements of Code Table UCS-56.1 {AF402.2} for carbon and low-alloy steels shall not be employed.
5.6.3
[V/E] Furnaces used for PWHT shall be constructed so as to prevent flame
impingement on the work.
5.6.4
[V/E] A sufficient number of thermocouples (attached directly to the unit
being heat-treated) shall be used to accurately indicate the temperature of the
work and detect uneven heating.
Process Industry Practices
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
5.6.5
6.
[V/E] The equipment shall be adequately supported during the PWHT to
avoid distortion.
Nondestructive Examination, Inspection and Testing
6.1
Nondestructive Examination
6.1.1
[V/E] The extent of examination and special documentation, over and above
the minimum requirements of the Code, will be specified in the purchase
specification.
6.1.2
[V/E] {Not applicable} For specific welded pressure joint examination
requirements, see the Welded Pressure Joint Requirements Form in
Appendix B of PIP VECV1001.
6.1.3
[V/E] Welded joints that will be inaccessible after assembly (e.g., joints
covered by lap-type flanges) shall be examined by PT and repaired as
required, prior to painting, assembly, and testing, as follows:
6.1.4
1. Examine the root pass and its opposite side after back-chipping to
sound metal.
2. After any required machining or grinding, examine the finished
surfaces of the weld with the following additional requirement: all
indications on the finished weld surfaces shall be removed by grinding
or welding prior to the required pressure test.
[V/E] If an examination reveals an unacceptable imperfection, the
imperfection shall be repaired, and the repair shall, as a minimum, be
examined by the same method, to the same extent, and by the same
acceptance criteria that revealed the condition.
6.1.5
[E] Welded tubes shall be examined by the electromagnetic (eddy current)
nondestructive examination technique after final heat treatment in
accordance with applicable Code Material Specifications.
6.1.6
[E] For heat exchangers larger than 24 inches nominal diameter, or for any
size having design pressure on the tubesheet attachment side exceeding 300
psig, non-butt type joints attaching tubesheets to shells or channels shall be
examined as follows:
1. Before welding, examine the cut surfaces per Code Paragraph UG93(d)(4).
2. For joints per Code Paragraph UW-13.2(f), (j), or (k), examine the
deposited groove weld surfaces after machining weld flush with
tubesheet.
3. For double-welded joints, after back-chipping the reverse side of weld
metal first deposited and before additional welding, examine the backchipped surfaces.
4. Examine all accessible surfaces of completed weld.
5. After welding, re-examine all cut edges examined per item 1 above that
remain exposed.
Process Industry Practices
Page 17 of 22
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
6.2
6.3
Inspection
6.2.1
[V/E] If inspection by the Purchaser is specified in the purchase order, the
Purchaser’s quality assurance representative will contact the Manufacturer to
schedule inspection visits. The Manufacturer shall notify the Purchaser’s
Quality Assurance Organization at least five working days before an
inspection is required. Appendix A, or equivalent form, shall be utilized by
the Designer to convey inspection and associated documentation
requirements.
6.2.2
[V/E] The Manufacturer shall make a complete set of certified fabrication
drawings available to the Purchaser’s Quality Assurance Representative at
the time quality surveillance activities are being conducted.
6.2.3
[V/E] If major components or services are obtained from sub-suppliers, the
Purchaser’s Quality Assurance Representative shall be notified and given the
option of inspecting those items at their point of manufacture. The
Manufacturer is responsible for including the Purchaser’s quality
surveillance and notification requirements in suborders. The Manufacturer is
also responsible for arranging for certified drawings for use by the
Purchaser’s representative at the sub-supplier’s location.
6.2.4
[V/E] The Manufacturer retains overall responsibility for ensuring, either
directly or through sub-suppliers, that the inspections necessary for
conformance to the purchase specifications are conducted. The performance
of quality surveillance by the User’s representative does not relieve the
Manufacturer or sub-suppliers of responsibility for meeting the specification
requirements.
6.2.5
[E] After any required heat treatment, heat exchangers (except kettle type
units) shall have the inside diameter and out-of-roundness of the completed
shell checked using a rigid template. The template shall consist of two
concentric disks having an OD equal to the actual baffle OD rigidly mounted
perpendicularly on a shaft and spaced 18 inches apart. The template shall
pass completely through the shell without binding. This template shall also
be used to verify the baffle-to-shell clearance.
6.2.6
[E] When two or more heat exchangers are stacked, the entire stack shall be
shop-assembled and checked for accuracy of saddle and nozzle fit-up
utilizing service gaskets. One or more shims may be used. Each shim shall
be one-piece construction of the same size (excluding thickness) as the
saddle base plate. The bolts, nuts, washers, and shims shall be supplied by
the Manufacturer and shall be shipped bolted in place on the lower
intermediate supports.
Pressure Testing
6.3.1
Page 18 of 22
REVISION
December 1998
[V/E] This Practice is oriented to the use of water as the test fluid. Fluids
other than water may be used for hydrostatic testing as described in the
Code, if so directed by the purchase specification.
Process Industry Practices
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
6.3.2
6.3.3
[V/E] Vessels shall not be painted or controlled shot peened prior to the
Code pressure test, with the following exceptions:
1. Surfaces that are required to be painted and which will be inaccessible
after assembly (e.g., mating surfaces of lap-joint stub ends, flanges and
nozzle necks, flange bolt holes, welded joints, etc.) shall be painted
prior to assembly and pressure testing.
2. Welded joints that will be inaccessible after assembly (e.g., joints
covered by lap-type flanges) shall be examined by PT and repaired as
required, prior to painting, assembly, and pressure testing (see Section
6.1.3).
[V/E] The test pressure shall be measured at the high point of the vessel in
the test position.
6.3.4
[V/E] All welds shall be sufficiently cleaned and free of scale or paint prior
to hydrostatic testing to permit proper examination for defects.
6.3.5
[V/E] Testing of vessels shall be conducted with test water that is clean and
free of debris. Potable water as delivered through municipal systems is
acceptable for carbon or chrome steel. Brackish or untreated water shall not
be used.
6.3.6
[V/E] Testing of vessels or components made of austenitic stainless steel
materials shall be conducted with water containing no more than 50 ppm
chloride. Water containing more than 50 ppm chloride but no more than 250
ppm may be used only if the duration of the test procedure is 72 hours or less
and includes rinsing with water containing less than 50 ppm chloride (see
Section 6.3.8).
6.3.7
[V/E] The Manufacturer shall provide all facilities and materials, such as
blinds, bolting, and gaskets.
6.3.8
Test Temperature
6.3.9
6.3.8.1
[V/E] Before application of the test pressure, the test water and the
vessel material shall be allowed to equalize to approximately the
same temperature.
6.3.8.2
[V/E] The temperature of the pressure resisting components
during the pressure test, regardless of test media, shall be at least
30º F warmer than the minimum design metal temperature to be
stamped on the nameplate, but need not exceed 120º F.
[V/E] The final pressure test shall be held for a minimum of one hour, or as
specified on the drawings and/or purchase specification. Except for leakage
that might occur at temporary closures for those openings intended for
welded connections, leakage is not allowed at the time of the required
inspection. Leakage from temporary seals shall be directed away so as to
avoid masking leaks from other joints.
6.3.10 [V/E] After completion of the hydrostatic test, the vessel shall be drained,
dried (including drying internals), and closed as quickly as practicable. Test
Process Industry Practices
Page 19 of 22
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
REVISION
December 1998
water shall not be in contact with austenitic stainless steel for more than 72
hours unless treated with an appropriate biocide.
6.3.11 [V/E] If field assembly/erection is involved, the final pressure test shall be
on the User’s site. The Manufacturer shall provide the Purchaser a detailed
test procedure for review prior to testing.
6.3.12 [V/E] Pneumatic testing, when required in the field on the User’s site, shall
be so stated in the purchase specification. The detailed procedure for
pneumatic testing shall be submitted in writing by the Manufacturer for the
User’s written approval.
6.3.13 [V/E] A horizontal vessel, designed to support a full weight load of water,
shall be tested while resting on its support saddles without additional
supports or cribbing.
6.3.14 [V/E] Tall vertical vessels may be shop-tested in the horizontal position.
These vessels must be adequately supported during the test to prevent
damage.
6.3.15 [V/E] No welding, burning or grinding (including cosmetic grinding) of
pressure resisting welds shall be performed on vessels that have been
pressure tested unless approved by the User. This includes, but is not limited
to, welds for shipping attachments, refractory or insulation clips, stiffeners,
spiders, or grinding for surface preparation.
6.3.16 [V/E] Any flanged joint for which the service gasket is to be furnished by
the Manufacturer and which will not be disassembled after testing shall be
tested with the specified service gasket. If the joint is to be disassembled
after testing and employs flanges per ASME B16.5, the test gasket may be
selected by the Manufacturer. If the joint is to be disassembled after testing,
employs nonstandard flanges (other than ASME B16.5), and the service
gasket is not specified, the test gasket shall be approved by the Purchaser.
6.3.16.1 [V/E] In no case shall the nominal thickness of sheet or laminate
service gasketing be greater than 1/16 inch.
6.3.16.2 [V/E] No joint sealing compound or gasket lubricant shall be used
unless specified for the service condition.
6.3.16.3 [V/E] Flanged joint assemblies specified to be furnished with
service gaskets (e.g., main body flange joints, manways, blind
flanged nozzles) and which are disassembled following tests shall
be reassembled using new service gaskets. If such joints are
shipped unassembled, new service gaskets for field installation
shall be suitably packaged, marked, and shipped with the vessel.
(See Section 7.2.2.)
6.4
Leak Testing
6.4.1
Page 20 of 22
[V/E] Leak tightness demonstrated by a gas/pneumatic test, if to be a part of
the acceptance criteria, shall be defined in the purchase specification.
Process Industry Practices
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
6.4.2
7.
[V/E] Reinforcing pad attachment welds and accessible surfaces of inside
nozzle to vessel wall welds shall be tested for the absence of leaks with a
gauge pressure of 15 psig dry air or nitrogen and bubble forming solution.
This test shall be prior to the final hydrostatic or pneumatic test as
applicable.
Preparation for Shipping
7.1
Cleaning and Painting
7.1.1
[V/E] Before shipping, the vessel shall be thoroughly cleaned inside and
outside. Grit, scale, oil, grease, weld rod stub ends, sand, water, free
moisture, and all other foreign material shall be carefully removed from the
vessel. Painting shall be complete as required by the purchase specification.
(See Section 6.3.2.)
7.1.2
[V/E] All PWHT vessels shall have the following notice painted on two
sides of the shell and insulation covering, if present, in three-inch high letters
visible in the shipping position from grade:
POSTWELD HEAT TREATED - DO NOT BURN OR WELD
7.1.3
[V/E] All vessels with non-metallic linings shall have the following notice
painted on two sides of the shell and insulation covering, if present, in threeinch high letters visible in the shipping position from grade:
LINED VESSEL - DO NOT BURN OR WELD
7.2
Preservation and Preparation for Shipment
7.2.1
[V/E] Machined surfaces, flange faces, threaded surfaces, and other finished
or delicate parts shall be well-greased and protected against rusting and
damage during shipment. Telltale holes in reinforcing pads shall be plugged
with Room Temperature Vulcanizing (RTV) silicone sealer or rust
preventative grease.
7.2.2
[V/E] For flanged joints specified to be furnished with service gaskets, a
spare gasket (in addition to any required for initial field assembly in Section
6.3.16.2) shall be furnished and suitably packaged, marked, and shipped with
the vessel for the following joints: flanged joints having other than ASME
B16.5 flanges with other than commercially available sheet or laminate
gaskets. Unless otherwise specified, one set of unused service gaskets shall
be furnished by the Manufacturer for non-ANSI body flanges and other nonstandard flanges. Service gaskets used for testing shall be left installed for all
blind flanged connections.
7.2.3
Closure of Openings
7.2.3.1
Process Industry Practices
[V/E] Blind flanged connections, including manways, shall have
the blinds attached with a full complement of new bolts.
Page 21 of 22
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
Page 22 of 22
REVISION
December 1998
7.2.3.2
[V/E] All flange faces other than those furnished with permanent
blinds shall be covered with 1/2 inch thick wood or 1/8 inch thick
steel plate, no smaller than the flange OD and secured with a
minimum 25% complement of (but no fewer than 4) bolts.
7.2.3.3
[V/E] Welding stub ends shall be provided with bevel protecting
caps.
7.2.4
[V/E] Internals which cannot be safely shipped in place shall be identified,
tagged, and shipped separately. For those internals which have specified
clearances or tolerances, the Manufacturer shall trial assemble at least one of
each type (e.g., tray type or distributor type) into the vessel to ensure proper
fit prior to shipment.
7.2.5
[V/E] All bolting and other loose parts shall be suitably packaged and
identified to the purchase order. 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.
Process Industry Practices
APPENDIX A
Quality Overview Plan
for
Section VIII, Divisions 1 and 2 Vessels/S&T Heat Exchangers
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
APPENDIX A
Quality Overview Plan
for
Section VIII, Divisions 1 and 2 Vessels/S&T Heat Exchangers
Equip. No. _______________________________________
Equip. Description
Project Engineer
Inspection Contact
P. O. No.
S. O. No.
Phone No.
Phone No.
Activities checked apply to the above item (see Quality Overview Notes). In most cases, the User/Purchaser representative will require five (5)
days notification to make arrangements for hold point inspections.
References are either to Division 1 Code paragraphs or
applicable Code Table U-3 {AG-150.1} reference standards. All
additional requirements covered by the purchase specifications
also apply.
QUALITY OVERVIEW ACTIVITY
REVIEW
Yes
No.
1.
Material Receipt (Prior to Fab)
2.
MTR's/Certificate of Compliance (Prior to Fab) (UG-93
{AF-101})
3.
Positive Material Identification (PMI)
4.
Impact Test Values
5.
Lap Joint Flange (ASME B16.5)
6.
Machined Surfaces (Prior to Assembly)
7.
WPS/Welder/Welding Operator Qualifications (UW-28 &
UW-29 {AF-210})
8.
Weld Map
9.
Inside Nozzle Corners Rounded [UG-36(a)(2) {AD-600}]
10.
Welded Joint Fit-Up (UW-33 {AF-221.3}, UG-76
{AF-112.2}, UG-77 {AF-102})
11.
Initial Welding (UW-32 {AF-141}, UW-37 {AF-210})
12.
Final Welding (UW-35 {AF-142}, UW-36 {AF-225},
UW-37 {AF-210})
13.
Machined Surfaces (After Assembly & Welding)
14.
Magnetic Particle Examination (MT) (App. 6 {Art. 9-1} )
15.
Liquid Penetrant Examination (PT) (App. 8 {Art. 9-2} )
16.
Radiographic Examination (RT) (UW-11 {App. 8} )
Page A-2
No
DOCUMENTATION
WITNESS
INSPECT
HOLD POINT
Yes
Yes
Yes
No
No
No
REQUIRED
Yes
Process Industry Practices
No
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
References are either to Division 1 Code paragraphs or
applicable Code Table U-3 {AG-150.1} reference
standards. All additional requirements covered by the
purchase specifications also apply.
QUALITY OVERVIEW ACTIVITY
REVIEW
Yes
No.
17.
Ultrasonic Examination (UT) (App. 12 {Art. 9-3})
18.
Other NDE
19.
Material Repairs (UG-78 {AF-104}
20.
Weld Repairs (UW-38 {AF-250})
21.
Out-of-Roundness (UG-80 {AF-130}, TEMA)
22.
Peaked Seam [UG-79(b) {AF-120}]
23.
Weld Reinforcement/Weld Contour (UW-35
{AF-142})
24.
Dimensional Check
25.
Installation of Internals
26.
Internal Inspection (Prior to Pressure Test)
27.
PWHT (UW-40 {AF-635})
28.
NDE (After PWHT, When Required)
29.
Machined Surfaces (After PWHT)
30.
Gasket/Gasket Installation/Bolted Joint Assembly
31.
Nameplate Bracket
32.
Pressure Test (UG-99 {Art. T-3}, UG-100 {Art. T-4})
33.
Gas Leak Test
34.
Formed Head Knuckle (After Pressure Test)
35.
Internal Inspection (After Pressure Test)
36.
Coating Inspection
37.
Final Dimensional Check
38.
Description of Nonconformance(s)
39.
Preparation for Shipment
40.
Bundles Insertion (for exchangers)
41.
Tube Expansion (for exchangers)
42.
Tube-to-Tubesheet Welding (for exchangers)
No
WITNESS
Yes
No
INSPECT
Yes
No
DOCUMENTATION
HOLD POINT
Yes
No
REQUIRED
Yes
43.
Process Industry Practices
Page A-3
No
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
REVISION
December 1998
Quality Overview Notes
1. The User or the User’s Designated Agent will provide the Manufacturer with a completed Quality
Overview Plan.
2. The Manufacturer is to provide the User with the documents for review, witness/hold point activity
notification, and inspection opportunity as indicated by the User on the Plan, as follows:
2.1 Review: Manufacturer is to provide documentation, the review of which will allow the User to
verify that the referenced construction activity has been performed as specified. Other
construction requirements may be verified/audited.
2.2 Witness: Manufacturer is to notify User not later than five days before performing the
referenced construction activity so that the User may exercise the option to observe. Other
construction requirements may be verified/audited.
2.3 Inspect: Manufacturer is to provide User access to physically conduct internal/external
inspection of the referenced item. Other construction requirements may be verified/audited.
2.4 Hold Point: Manufacturer must notify User not later than five days before performing the
referenced construction activity and must receive authorization from the User before
performing the activity. Other construction requirements may be verified/audited.
3. Some of the items in this Quality Overview Plan are covered elsewhere in this Practice.
4. If a work item is not checked, then there is no requirement to provide documentation or notification
to the User. However, the work item itself is still required to be performed if specified elsewhere in
this Practice, the Data Sheet, the purchase order, the Code, etc.
Page A-4
Process Industry Practices
APPENDIX B
Documentation Schedule and
Manufacturer’s Data Package
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
APPENDIX B
Documentation Schedule
Equip. No. ____________________________ P.O. No. ___________________________ S.O. No. ______________________
Equip. Description ____________________________________________________________________________________
Project Engineer __________________________________________ Phone No. ___________________________________
“WKS”
“P”
“T”
Column = Number of Weeks Required from P.O. Date
Column = Number of Legible Prints Required
Column = Number of Transparencies Required
WITH
BID
ITEM
T
FOR
APPROVAL
P
WKS
FROM
PO
T
FINAL (2)
CERTIFIED
P
WKS
FROM
PO
T
DATA (3)
BOOKS
P
WKS
FROM
PO
WITH
EQUIP
P
P
ALLOW FOR
USER
APPROVAL
WEEKS FROM
DATE OF DATA
RECEIPT
Completed Data Sheets
Vessel Dimension Outlines
Vessel Details
Vessel Structural Attachments for
Ladders, Platforms, etc.
Column Tray and Downcomer
Support Details
Weld Procedures with Weld Maps
Nondestructive Examination and
PWHT Procedures
Design Calculations
Shipping Diagram and Rigging
Instructions
Manufacturer's Data Package
(See Page B-3)
Fabrication Sequence and
Schedule
Sub-Supplier List
Progress Report (Monthly)
NOTES:
1. Drawings and data are to be mailed to _____________________________________________
unless submitted with quotation.
2. Final certified drawings are to be submitted within two (2) weeks of receipt of “Approved” or “Approved As Noted” prints.
3. All data must be supplied prior to submission of final invoice.
4. All questions of a technical nature shall be directed to _________________________________.
5. Sepias and original film drawings shall not be folded for mailing.
6. Each copy of all data (e.g., drawings, manuals) must be certified by Manufacturer with equipment or instrument Tag
Number and Purchase Order Number written or typed on the face of each copy.
Page B-2
Process Industry Practices
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
Manufacturer’s Data Package
The Manufacturer’s Data Package is to include:
1. Final certified fabrication drawings per PIP VESV1002, as shown on the following sheets
2. Manufacturer’s Data Report (U Forms)
3. Plate material (mill) test reports and/or certificates of compliance (provide index when
appropriate)
4. Impact test values including production weld test results
5. Heat treatment charts (time/temperature record)
6. Pressure test charts (time/pressure/water temperature record)
7. Nondestructive examination records and reports (PT, MT, RT, BHN, PMI chemistry)
8. Nameplate facsimile
9. If requested, weld procedures, qualifications, and weld maps
10. Description of non-conformities accepted by the User, if any
11. Required bolted joint assembly procedures including bolt preload for custom flanges
12. Any other documentation required on Appendix A
13. Operating instructions, performance data, and parts list (when applicable)
Process Industry Practices
Page B-3
APPENDIX C
Flanged Pressure Boundary Joint Assembly
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
APPENDIX C
Flanged Pressure Boundary Joint Assembly
For blinding prior to hydrotest or for final joint assembly, all bolted joints shall be assembled and
tightened in accordance with the following:
1. All “working” surfaces must be cleaned and inspected before assembly is started.
a. Clean gasket seating surfaces to remove all grease and dirt. Gasket seating surfaces
shall be free from any scratches, nicks, burrs, weld spatter, or similar defects.
b. External and internal threaded surfaces shall be inspected for damage. Replace
questionable parts.
c.
Inspect nut-bearing surfaces for scores, burrs, etc. Remove protrusions; spot face if
required.
2. Install new gasket.
a. Handle gaskets carefully to avoid damage. Do not remove any gasket shipping/handling
protector until ready to use the gasket.
b. Examine gasket for defects or damage.
c.
Place new gasket in position. Make sure that the gasket is in proper alignment with the
gasket surfaces on the flanges or lap-joint stub ends.
d. Use a light dusting of 3M 77, or equal, spray adhesive if required to hold gasket in place
during assembly.
3. Liberally coat all external and internal threaded surfaces of fasteners (bolts, nuts, and threaded
holes, as applicable) with the lubricant specified on the vessel data sheet. Lubrication is not
required for new PTFE-coated bolts. If the lubricant is not specified on the vessel data sheet,
the lubricant shall be approved by Purchaser.
4. Align flange or stub end faces carefully before bolting up. Fasteners shall fit loosely in bolt holes.
Do not use fasteners to spring flanges for alignment.
5. Install fasteners with nuts hand tight, then snug up at 10 to 20 ft-lbs.
6. Tighten bolts carefully to specified torque level using a cross-bolting technique and step-wise
tightening to increase loading about 1/4 to 1/3 of total preload per step.
Page C-2
Process Industry Practices
APPENDIX D
Manufacturer’s Drawing Information
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
REVISION
December 1998
APPENDIX D
Manufacturer’s Drawing Information
Manufacturer shall provide certified assembly and working drawings for all vessels. Drawings shall be
complete and shall include, but not necessarily be limited to, the following information:
1. Maximum allowable working pressure {design pressure} and coincident maximum design
temperature (see PIP VECV1001, Section 5.2) (internal and external if applicable)
2. Minimum design metal temperature and coincident maximum allowable working pressure (see
PIP VECV1001, Section 5.3)
3. Design specific gravity, maximum liquid level, and other operating loads
4. Reference to Code Section VIII, Division 1 or 2, Edition, and Addenda. Include any Code Cases
used and special service restrictions.
5. Special service notes (e.g., “for cyclic service” followed by a description of the cyclic loadings
and number of cycles used in the design)
6. Applicable Code paragraphs for impact test exemption [e.g., UG-20(f), UCS-66(a), UCS-66(b),
UCS-66(c)] or for impact test requirements (e.g., UHA-51 or UHT-6)
7. National Board registration number (U- or U2-symbol stamped vessels)
8. ASME material specifications for all pressure-resisting components and all attachments to
pressure-resisting components
9. Wind/seismic design criteria
10. Corrosion allowance. When a corrosion allowance is specified and the service is specified on
Data Sheet Item 13 as non-corrosive, the notation “for non-corrosive service” shall be added to
the drawing notes.
11. Weld details. All welds shall be either detailed or identified by use of the standard welding
symbols of the American Welding Society.
12. Nondestructive examination requirements of welded pressure joints
13. Joint efficiency for each butt-welded joint (or seamless equivalent) in the vessel, including
nozzles and communicating chambers. A joint efficiency map may be useful.
14. Nondestructive examination of non-pressure-resisting welds
15. Postweld heat treatment requirements
16. Hydrostatic or pneumatic test pressures, as applicable:
a. Shop test in horizontal position (referenced to top of vessel)
b. Shop test in vertical position (referenced to top of vessel) (except for horizontal vessels)
c.
Future test in operating position (referenced to top of vessel) (in the corroded condition for
vessels having a corrosion allowance)
17. Minimum permissible metal temperature during hydrostatic testing
18. Sensitive leak tests, if any
19. Nominal thickness of all components [minimum thickness after forming (includes corrosion
allowance) for formed heads]
20. All pertinent dimensions, including location of weld seams, location and projection of nozzles,
location of vessel and insulation supports, and any other information necessary for a complete
description of the vessel
21. Manufacturer’s drawings shall have the same designation for nozzles, manways, skirt openings,
and column trays as shown on Purchaser’s drawings.
Page D-2
Process Industry Practices
REVISION
PIP VESV1002
Vessel/S&T Heat Exchanger Fabrication Specification
ASME Code Section VIII, Divisions 1 and 2
December 1998
22. Complete description of all vessel flanges (including both standard and custom design),
pressure bolting, and gaskets
23. Relevant fabrication, inspection, testing, and painting requirements
24. Vessel support details
25. Surface preparation and painting or other protective coating specifications
26. Estimated weight of vessel: empty, operating, full of water, shipping and removable tube bundle
(when applicable)
27. Capacity of vessel (or each compartment), in gallons
28. Facsimiles of Manufacturer’s nameplate as stamped by Manufacturer
29. Purchaser’s vessel identification number(s)
30. Reference to specifications. Manufacturer shall include on drawings a reference to all applicable
codes, standards, and specifications, including date of issue. References shall include all
applicable PIP Practices and any applicable Manufacturer standards. When reference is made
to Manufacturer’s own standards, copies of such standards shall be included with the submitted
working drawings.
31. Tube bending schedule for U-tubes (center to center dimension of bends)
32. Expansion joint drawings shall include the following information: maximum design pressure and
temperature (when applicable), spring constant (lb/inch), maximum axial movement (opening or
closing), total life cycles, materials of construction; and for flanged and flued expansion joints,
provide radius dimensions of corners.
Special Notes
Manufacturer’s drawings shall also include the following notes as applicable:
1. All Vessels - the following note: “Substances containing chlorine or which will decompose to
hydrogen chloride (e.g., coatings to prevent adhesion of weld spatter) shall not be applied to any
part of the vessel.”
2. Stainless Steel or Nickel-Alloy Vessels - the following note: “Zinc-coated (galvanized or painted)
components shall not be in contact (welded, bolted, or loose) with any alloy parts of the vessel.”
3. Hastelloy, Monel, Nickel, or Nickel-Alloy Vessels - the following note: “Substances
containing sulfur (e.g., lubricants to aid machining) shall not be applied to alloy parts of the
vessel.”
4. Clad-Steel Vessels - Drawing notes shall specify whether or not the thickness of cladding metal
has been included in the design calculations for strength.
5. Balance point location - for horizontal equipment, the balance point location shall be noted and
dimensioned from a permanent reference point (e.g., main body flange, tubesheet, etc.).
6. All PWHT vessels shall have the following notice painted on two sides of the shell and insulation
covering, if present, (and/or channel) in three inch high letters visible in the shipping position
from grade:
POSTWELD HEAT TREATED - DO NOT BURN OR WELD
7. All vessels with non-metallic linings shall have the following notice painted on two sides of the
shell and insulation covering, if present, (and/or channel) in three inch high letters visible in the
shipping position from grade:
LINED VESSEL - DO NOT BURN OR WELD
Process Industry Practices
Page D-3