TECHNICAL SPECIFICATION
CLIENT:
N°.
I-ET-3010.00-1200-540-P4X-001
SHEET:
SRGE
JOB:
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AREA:
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TITLE:
DDP-SRGE
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MICROSOFT WORD / V.2010 / I-ET-3010.00-1200-540-P4X-001_B.DOCX
INDEX OF REVISIONS
REV.
DESCRIPTION AND/OR REVISED SHEETS
0
ORIGINAL ISSUE
A
ITEMS: 2;4.1; 4.2; 4.3; 4.4.5; 4.5.1; 4.5.2; 5.1; 5.9; 8.1.14; 8.1.15 and 15 ADDED;
ITEMS1; 2.3; 4.9; 5.3.2.2 ; 5.6; 6.1.4; 6.1.7; Table 8.3; 13.1.2 and 17 REVIEWED;
ITEM 5.7 EXCLUDED.
B
GENERAL REVISION ACCORDING TO THE REQUIREMENTS OF IOGP S-619.
THIS TECHNICAL SPECIFICATION ALSO INCLUDES THE REQUIREMENTS
FROM I-ET-3010.00-1200-540-PX4-002 (REQUIREMENTS FOR PRESSURE
VESSELS FABRICATION).
DATE
DESIGN
EXECUTION
CHECK
APPROVAL
REV. 0
REV. A
REV. B
AGO/13/18
APR/01/19
JUL/20/20
ESUP
ESUP
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PONTE
PONTE
DANISCHMIDT
ESTEVES
DANISCHMIDT
PONTE
JUVENTINO
JUVENTINO
GONZALEZ
REV. C
REV. D
REV. E
INFORMATION IN THIS DOCUMENT IS PROPERTY OF PETROBRAS, BEING PROHIBITED OUTSIDE OF THEIR PURPOSE.
FORM OWNED TO PETROBRAS N-0381 REV.L.
REV. F
REV. G
REV. H
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WORKING GROUP RESPONSIBLE FOR REVISION B
NAME
DEPARTMENT
KEY
Alexandre Esteves e Cunha
SRGE/ESUP/EEA/EEAT
CJW2
André Mariano
SRGE/ESUP/EEA
CSM0
André Roberto Nisgoski
SRGE/ESUP/EEA/EEAT
ASWG
Daniela Gomes Schmidt
SRGE/ESUP/EEA
CJX4
Nilson Manoel Pires Bomfim Silva
SRGE/ESUP/EEA/EEAT
QM66
Pedro Jacinto Vivas Ponte
SRGE/ESUP/EEA/EEAT
HR7W
Ricardo Luiz Fernandes de Carvalho
SRGE/ESUP/EEA/EEAT
U3CI
TECHNICAL SPECIFICATION
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SUMMARY
OBJECTIVE ................................................................................................... 5
SECTION I – COMPLEMENTARY REQUIREMENTS TO IOGP S-619 ......... 5
1 SCOPE ....................................................................................................... 5
2 NORMATIVE REFERENCES...................................................................... 5
3 TERMS AND DEFINITIONS ....................................................................... 8
4 VENDOR’S DATA....................................................................................... 8
5 DESIGN .................................................................................................... 10
6 MATERIAL................................................................................................ 17
7 FABRICATION.......................................................................................... 20
8 HEAT TREATMENT ................................................................................. 23
9 NON-DESTRUCTIVE EXAMINATION ...................................................... 24
10 PRESSURE TESTING ............................................................................ 28
11 COATING AND PAINTING ..................................................................... 30
12 PREPARATION FOR SHIPMENT .......................................................... 31
ANNEX A – ADDITIONAL REQUIREMENTS FOR SOUR SERVICE
VESSELS..................................................................................................... 32
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ANNEX B – ADDITIONAL REQUIREMENTS FOR INTEGRALLY CLAD
AND WELD OVERLAY VESSELS .............................................................. 33
ANNEX C – ADDITIONAL REQUIREMENTS FOR CARBON STEEL
VESSELS..................................................................................................... 35
ANNEX
D
-
ADDITIONAL
REQUIREMENTS
FOR
AUSTENITIC
STAINLESS STEEL, 22CR AND 25CR DUPLEX VESSELS ...................... 36
ANNEX E - VESSEL TOLERANCES ........................................................... 37
ANNEX F - REQUIREMENTS FOR MAXIMUM ALLOWABLE CORROSION
ALLOWANCE (MACA) ................................................................................ 38
ANNEX G – REQUIREMENTS FOR NAMEPLATES................................... 39
SECTION II - IOGP S-619 SPECIFICATION FOR UNFIRED, FUSION
WELDED PRESSURE VESSEL .................................................................. 42
SECTION III – IOGP S-619D DATASHEET FOR UNFIRED, FUSION
WELDED PRESSURE VESSEL .................................................................. 42
SECTION IV – IOGP S-619L INFORMATION REQUIREMENTS FOR
UNFIRED, FUSION WELDED PRESSURE VESSEL .................................. 42
SECTION V – IOGP S-619L QUALITY REQUIREMENTS FOR UNFIRED,
FUSION WELDED PRESSURE VESSEL .................................................... 42
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OBJECTIVE
This Specification establishes the technical requirements for the execution of the
mechanical design of pressure vessels to be supplied to PETROBRAS’ FPSOs. This
specification complements IOGP S-619 and its amendments (IOGP S-619D, IOGP S-619L
and IOGP S-619Q).
This technical specification is written as an overlay to IOGP S-619 (version 1.0, December
2018), matching the same numbers of section and subsections. If the section (or
subsection) of the document IOGP S-619 is not mentioned in this technical specification, it
means that, the requirements of this section are mandatory and does not need a
supplementary requirement or modification. If the section (or subsection) of the document
IOGP S-619 needs a modification, this specific section is identified with: Add (add to
section or add new section), Replace (part of or entire section) or Delete.
In addition to the requirements of this technical specification, CONTRACTOR shall follow
all the requirements of the Exhibit I (Scope of Work), as well as Exhibit III (Directives for
Engineering Execution), Exhibit IV (Directives for Construction and Assembly), Exhibit V
(Directives for Procurement), Exhibit VI (Directives for Planning and Control), Exhibit VII
(Directives for Quality Management System) and Exhibit VIII (Directives for
Commissioning Process).
SECTION I – COMPLEMENTARY REQUIREMENTS TO IOGP S-619
1 SCOPE
1.1 GENERAL
Add to Section
Pressure vessels design shall be according ASME BPVC Section VIII Divisions 1 and 2.
Other internationally recognized standards or code can be used only with the prior
OWNER approval.
When the vessel is a component part of steam generation equipment, it shall be designed
according to ASME BPVC Section I.
The requirements herein listed are applicable to all players performing such related
activities within the scope of this unit, including manufacturer, packager, main contractor,
subcontractors, suppliers, sub suppliers, integrators, constructors, and all technical
personnel involved. Within the scope of this document, they are all referred to as being a
CONTRACTOR.
1.2 MATERIALS
Add to List
e. other materials not indicated here and referenced in Datasheets.
2 NORMATIVE REFERENCES
TECHNICAL SPECIFICATION
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Add to List
ASME BPVC Section I
-
Rules for Constructions of Power Boilers
-
Materials - Part D: Properties
-
Rules for Constructions of Pressure Vessels
ABNT NBR 6123
-
Forças devidas ao Vento em Edificações
API Spec 6A
-
Specification for Wellhead and Christmas Tree Equipment
-
Pipe Flanges and Flanged Fittings NPS ½ Through NPS 24
ASME BPVC Section II
Part D
ASME BPVC Section VIII
Div.1
ASME B 16.5
ASME B16.47
Metric/Inch Standard
-
Large Diameter Steel Flanges NPS 26 Through NPS 60
Metric/Inch Standard
BSI PD 5500:2009
-
Specification for Unfired Fusion Welded Pressure Vessels
IOGP S-619
-
Specification for Unfired, Fusion Welded Pressure Vessels
IOGP S-619D
-
Datasheet for Unfired Fusion Welded Pressure Vessels
-
Information requirements for Unfired Fusion Welded Pressure
IOGP S-619L
IOGP S-619Q
ISO 21457
Vessels
-
Quality requirements for Unfired Fusion Welded Pressure
Vessels
-
Materials selection and corrosion control for oil and gas
production systems
ISO 27509
-
Compact flanged connections with IX seal ring
WRC-368
-
Stresses in Intersecting Cylinders Subjected to Pressure
Add to Section
2.1 CLASSIFICATION SOCIETY
CONTRACTOR shall perform the work in accordance with the requirements of
Classification Society.
CONTRACTOR is responsible for submitting
documentation in compliance with stated Rules.
2.2 GOVERNMENTAL REGULATION
to
the
Classification
Society
all
TECHNICAL SPECIFICATION
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NR 13
-
Norma Regulamentadora N° 13 (NR-13) - "CALDEIRAS, VASOS DE
PRESSÃO,
TUBULAÇÕES
E
TANQUES
METÁLICOS
DE
ARMAZENAMENTO"
*Note: Government codes, regulations, ordinances or rules applicable to the equipment in
Brazil shall prevail over the requirements of this specification, including reference codes and
standards, only if more stringent.
2.3 REFERENCE DOCUMENTS
DR-ENGP-I-1.15
-
COLOR CODING
I-ET-3000.00-1200-940-P4X-001
-
TAGGING PROCEDURE
UNITS DESIGN.
I-ET-3010.00-1200-251-P4X-001
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BOLT MATERIALS
I-ET-3010.00-1200-200-P4X-116
-
REQUIREMENTS
FOR
BOLTED
ASSEMBLY AND MANAGEMENT
I-ET-3010.00-1200-955-P4X-001
-
WELDING
I-ET-3010.00-1000-970-P4X-002
-
REQUIREMENTS FOR NDT
I-ET-3010.00-1200-956-P4X-002
-
GENERAL PAINTING
I-ET-3010.00-1200-956-P4X-003
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THERMAL SPRAY
ALUMINUM
I-ET-3000.00-1200-431-P4X-001
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THERMAL
INSULATION
INSTALLATION
I-ET-3010.00-0000-970-P4X-001
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REQUIREMENTS
PERSONNEL
CERTIFICATION
I-ET-3010.00-1200-955-P4X-001
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REQUIREMENTS FOR INITIAL SERVICE SAFETY
INSPECTIONS
I-ET-3010.00-1200-940-P4X-002
-
GENERAL TECHNICAL TERMS
•
FOR
COATING
PRODUCTION
JOINTS
APPLICATION
FOR
MARITME
FOR PROCEDURES
QUALIFICATION
AND
AND
Specific Documents to be supplied by OWNER:
-
METOCEAN DATA
-
MOTION ANALYSIS
-
PROCESS DATASHEET
-
GENERAL ARRANGEMENT
-
GENERAL AREA CLASSIFICATION
-
MATERIAL SPECIFICATION FOR PRESSURE VESSELS
2.4 CONFLICTING REQUIREMENTS
In case of conflicting requirements between this technical specification and the referred
applicable standards, the most stringent requirement shall prevail. In case of conflicting
information between this Specification and other specific OWNER’s document, a formal
technical query shall be issued to OWNER, seeking clarification.
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3 TERMS AND DEFINITIONS
3.1 DEFINITIONS
Add to Section
Terms and definitions are also established in I-ET-3010.00-1200-940-P4X-002 –
GENERAL TECHNICAL TERMS.
3.1.1
Add to Section
Only flanges not available in ASME B16.5, ASME B16.47, API Spec 6A and ISO 27509
shall be calculated according to ASME BPVC Section VIII.
3.1.4
Replace section with
Flanges dimensioned and manufacturer in conformance with ASME B16.5, ASME B16.47,
API Spec 6A, ISO 27509 or equivalent standard.
3.2 ABBREVIATIONS
Add to List
P&ID:
-
Piping & Instrumentation Diagram
FPSO
-
Floating Production Storage and Offloading
LPG
-
Liquefied Petroleum Gas
SSC
-
Sulphide Stress Corrosion
TSA
-
Thermal Spray Aluminium
IOGP
-
International Association of Oil & Gas Producers
4 VENDOR’S DATA
4.2 DRAWINGS AND OTHER INFORMATION REQUIRED
Add to List
z. weld-repair map
aa. All documents required by NR-13.
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Add to section
Documents mentioned above as well as the following ones shall be submitted to the
inspector for examination before the beginning of the corresponding activity:
a. Fabrication drawings approved for execution;
b. Material quality certificates;
c. Certificates of consumable material quality;
d. WPQR´s;
e. Welders/Weld operators qualification records;
f. Report indicating procedures and inspectors and/or qualified non-destructive testing
operators and qualified welding inspectors;
g. Report of welding record.
Add new section
4.3 MANUFACTURING RECORD BOOK (MRB)
CONTRACTOR shall furnish a complete set of technical fabrication data books for each
equipment containing at least the following documents:
a. Certified mechanical design and fabrication drawings and documents;
b. Technical specifications;
c. Data sheets;
d. Material quality certificates of pressure parts, internals and equipment supporting parts;
e. Quality certificates of welding consumables, including drying control;
f. Traceability map of materials and welding consumables;
g. Report with NDE´s results;
h. Drawing with radiography spot positions;
i. Map of repaired defects;
j. PMI report;
k. Production test reports;
l. Report of dimensional inspection, including dimensions measured;
m. PWHT report, including temperature chart;
n. Pressure test report;
o. Pneumatic test report;
p. Hardness test report;
q. Hydrostatic test report, including pressure chart;
r. Report of ferrite content examination;
s. Report of internal coating/clad inspection;
t. Report of external coating inspection;
u. Report of insulation inspection;
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v. Report of nonconformities, if any;
w. Hibernation procedure;
x. Assembly procedure.
y. Data files (soft copies) of recordable NDT´s (automated UT and digitalized radiographic
films);
z. All documents required by NR-13.
Add new section
4.4 FILES
CONTRACTOR shall keep the information required below in an organized file, making it
available for OWNER´s examination (or its authorized representative) at any time within a
period of 5 years from the equipment shipping date:
a. Mill certificates for shell components: the certificate shall contain a specification to which
the material conforms, the heat number, the treatment undergone by the material and the
results of the chemical analysis and mechanical tests.
b. Certificates of compliance for materials obtained from sub-suppliers and for which mill
certificates are unavailable: when it is not possible to prove the material specification, the
manufacturer shall carry out tests and analyses and issue certificates of compliance.
c. For piping accessories and flanges manufactured in accordance with an approved
standard, certificates are not required, provided they are marked as required by code
ASME BPVC Section VIII. Certificates are required when markings are removed.
d. Registers of qualified welding procedures, registers of qualification of welders and weld
operators.
e. Radiographic films and UT digital records, when is required.
f. Non-destructive test certificates.
g. Charts and/or certificates of hydrostatic and pneumatic tests and other tests.
h. Temperature recording charts and other heat treatment registers.
5 DESIGN
5.1 GENERAL
5.1.2
Replace section with
Unless otherwise specified, CONTRACTOR shall design and fabricate the complete
equipment for a minimum service life of 30 years.
5.1.4
Replace section with
The use of ASME code cases is not permitted, except the use of Code Case 2235 for
ultrasonic in lieu of radiographic examination and as allowed in 5.8.3.
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5.1.6
Replace section with
During the hydrotest, the general primary membrane stress in any pressure part shall not
exceed 90% of the material minimum specified yield strength, unless otherwise specified
by the design code.
5.1.8
Replace section with
All welds subjected to pressure loads, in the shell and heads, shall be double-butt welded,
full penetration type and allow radiography. When the internal weld is impracticable, only
the external weld may be done, adopting a method that guarantees the quality of the weld
root, meeting that:
a. All welded joints of the shell and heads shall be designed to allow radiographic
inspection, even in those cases where the design Code does not require it.
b. All welded joints of the shell and heads shall be, as a minimum, examined by spot
radiography.
5.2 CORROSION ALLOWANCE
5.2.2
Add to the section before first sentence
Unless otherwise specified on the datasheet, the following minimum values shall be
adopted for corrosion allowance, for parts made of carbon-steel or low alloy steels:
a. Towers, vessels and heat exchangers for hydrocarbon service: 3 mm;
b. Sumps for the above vessels: 6 mm;
c. Vessels and filters containing fresh water: 3 mm
d. General pressure vessels for either vapour or air: 1,5 mm;
e. LPG storage vessels: 1,5 mm.
For carbon-steel or low alloy steel parts, a minimum corrosion allowance of 1,5 mm shall
be adopted, even if the estimated corrosion is lesser than this value.
Corrosion allowances shall be based on the service life, as specified in this Technical
Specification. As a general rule, when the expected corrosion rate exceeds 0,24 mm/year,
or when the corrosion allowance exceeds 6 mm, other materials with a higher corrosion
resistance should be used.
5.3 WIND, SEISMIC AND SNOW LOADS
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5.3.1
Add to the end of section
Wind loads shall be calculated according to ABNT NBR 6123 with wind basic velocity of 45
m/s. Another standard may be used with previous OWNER´s approval.
Add new section
5.3.5
The equipment shall be suitable for the environment and range of ambient conditions,
defined in METOCEAN DATA specification [document supplied by OWNER].
Add new section
5.3.6
The necessary design data and information on motion requirements of the floating unit are
given in MOTION ANALYSIS report[document supplied by OWNER].
5.4 DESIGN LOADS AND LOAD COMBINATIONS
5.4.1
Add to the end of section
For field (or future) hydrostatic test condition, motion induced loads (L14) shall be
considered, in addition to the other related items of table 1, in Design load combination.
5.6 LOCAL LOADS
5.6.1
Add to the end of section
For nozzles not connected to pipes, such as manways, the evaluation shall be performed
according to finite element method (FEM) or WRC 368, provided its limitations for use are
met.
For all nozzles, the effect of pressure thrust shall be considered in stress analysis.
5.7 NOZZLES, MANWAYS AND REINFORCEMENTS
5.7.1
Replace section with
The use of set-on nozzles is not allowed.
5.7.3
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All nozzle connections shall be either weld neck or long weld neck. The use of stub-end
shall not be permitted for pressure vessels.
Slip-on flanges (SO) may be used for inspection openings and manways, since all the
following requirements are met:
-
Nozzles flanges pressure up to 300;
Service with following fluids: compressed air, inert gases or water;
Corrosion allowance up to 3 mm;
Impact test is not required;
PWHT is not required.
5.7.4
Replace first sentence with
Flanged nozzles DN 40 (NPS 1 1/2) and DN 50 (NPS 2) shall be long weld neck flanges or
fabricated from seamless pipe with at least nominal wall thickness per Table 3.
5.7.8
Add to section
The use of two inspections holes, instead of a manhole or bolted head, is also acceptable
for pressure vessels without internals and with internal diameter less than 1000 mm. For
vessels with internal diameter greater than 1000mm, at least one manway is mandatory.
5.7.10
Replace section with
Nozzle to vessel wall joints, including manhole, shall have full penetration welds.
5.7.15
Replace section with
Unless otherwise specified, flanges face finishing, gasket, studs and nuts of each flange
on nozzles including manways and access opening shall be according to piping
specification applicable to the section of the vessel where they are located.
Add new section
5.7.19
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All vessels shall have nozzles for vent, drain and pressure inlet connections. They shall be
used for hydrostatic test, cleaning or maintenance. These connections shall have easy
access.
Add new section
5.7.20
Manholes on the horizontal plane opening downward shall be avoided; in those cases, in
which they are inevitable, a safe device shall be provided to remove and handle its blind
flange.
Vessels with the manhole on the vertical plane shall be provided with stairs on the inside,
except when internals preclude access to the manhole or make those stairs unnecessary.
Add new section
5.7.21
For vertical vessels with a single manhole, it shall be located in the cylindrical shell at the
lowest possible position, unless otherwise defined in respective datasheet. When the
vertical vessel has 2 manholes, the second manhole shall be located above the upper tray
or at the highest possible position. For vertical vessels with 3 or more manholes, additional
manholes shall be equally spaced wherever possible along the length of the vessel and
preferably located next to inlet nozzles and internal piping systems.
For horizontal vessels, the manhole shall be preferably located on one of the heads; the
second manhole, if any, shall be located on the top part of the shell, near the opposite end.
Horizontal vessels more than 10 m long shall have 2 manholes.
Add new section
5.7.22
Manways shall be provided with davits for its blind flange removal. Hinges might be use for
manways pressure class 150 NPS up to 24.
5.8 CUSTOM DESIGNED FLANGES
Add new section
5.8.6
Custom flanges designed according to ASME BPVC Section VIII, just as flanges in
compliance with ISO 27509 or API 6A shall be supplied with companion flanges.
5.9 FLANGE BOLTING
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5.9.4
Studs, bolts, tightening bolts and nuts shall be according I-ET-3010.00-1200-251-P4X-001
– BOLT MATERIALS.
Add new section
5.9.5
For flanged joints connecting two equipment parts or flanged joints designed according
ASME BPVC sec. VIII (e.g.: heat exchanger flanged joints) the CONTRACTOR shall
submit to OWNER approval the completely tightening report containing at least the
following information: lubricant, bolt/stud torque, gasket type and flange calculation report.
In these cases, CONTRACTOR shall design the flange to be able to a bolt tightening loads
at least equal to a 60% of the bolt yield stress.
Add new section
5.9.6
For pressure vessels operating with gas, CONTRACTOR shall evaluate bolt material
considering the possibility of temperature reduction due to flange leakage. When not
previously informed, CONTRACTOR shall submit a study informing the minimum expected
temperature and the bolt material selected for such case.
5.10 SKIRT SUPPORT
5.10.2
Replace section with
Access openings shall be provided in skirts. The minimum diameter of these access
openings shall be the same as specified for pressure vessel. No piping shall run through
access openings.
5.10.3
Replace section with
No flanged connection or valve shall be allowed inside the skirt.
5.10.5
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Provision shall be made for venting and draining of the skirt. The location of the vent shall
be as close as possible to the junction with the head, in the amounts and diameters
specified in Table 5.
Table 5 - Skirt Vents
Vessel Internal Diameter, [mm]
Number of Vents
Vent Diameter
Up to 914
2
3” Sch. 40
915 – 1 830
4
3” Sch. 40
1 831 – 2 740
6
4” Sch. 40
2 741 – 3 660
8
4” Sch. 40
3 661 – 4 570
10
4” Sch. 40
4 571 – 5 490
12
4” Sch. 40
5.11 LEGS
5.11.1
Replace first sentence with
Small, cylindrical, vertical vessels [di ≤ 1 000 mm (40 in.)] may be supported by legs or
lugs, if all of the following conditions are met:
5.12 SADDLES
5.12.1
Add to sentence
Saddles shall be placed symmetrically in relation to the midpoint of length between tangent
lines and shall cover at least 120° of the vessel circumference.
Saddles shall be joined to the vessel shell by a continuous weld.
When the operating weight of vessel is greater than 200 kN (20 t) PTFE, or other low
friction material, sliding plates shall be used in the mobile saddle in accordance with Figure
4.
Add new section
5.13 SUPPORT´S DESIGN
Supports shall be designed in accordance with Part 4.15 of ASME BPVC Section VIII
Division 2. For pressure vessels designed according to ASME BPVC Section VIII Division
1, PD 5500 may be used, except that allowable stresses shall in any case be according to
ASME BPVC Section VIII Division 1.
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Figure 4 – Details of Saddle, Support Members and Sliding Plates.
6 MATERIAL
6.1
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Pressure vessels material selection shall be according to MATERIAL SPECIFICATION
FOR PRESSURE VESSELS [document supplied by OWNER]. Only if the material
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selection is not specified by OWNER, CONTRACTOR shall define the complete pressure
vessel’s material considering the minimum design lifetime, the requirements of ISO 21457
and the statements of Table 6 and its complements.
Table 6 – Criteria for specification of Materials of Vessel Components
Class of the Vessel
Part under
Consideration
Vessel´s Base Material
Carbon Steel
Low
Temperature
Carbon Steel
Alloy Steels, Stainless
Steels and Nonferrous
Metals
I
Same material
as for shell.
Same material as Same material as for
for shell.
shell.
II
Same material
as for shell.
Material having the
Same material as
same “P-number” as
for shell.
shell material.
III
Structural
carbon-steel.
Low-temperature
carbon steel.
IV
Materials
specified for
each case.
Materials
Materials specified for
specified for each
each case.
case.
V
Structural
carbon-steel.
Structural carbon
steel.
Structural carbon steel.
VI
Structural
carbon-steel.
Structural carbon
steel.
Material having the
same “P-number” as
shell material.
Material having the
same “P-number” as
shell material (Note)
Class I
Parts of the pressure wall of the vessel in contact with the process fluid (e.g.: shells,
heads, nozzle necks, flanges, blind flanges and others) and other pressure parts in contact
with the process fluid (e.g.: tubesheets). This class also includes internal parts welded to
vessels and subject to primary stress (e.g.: rings, plates and other elements for supporting
trays, gratings, internal heads and others). This class also includes reinforcements (any
type) of openings on the vessel pressure wall.
Class II
Parts of the vessel pressure wall not in contact with the process fluid such as external
reinforcements, vacuum reinforcements and others, except reinforcements of openings
(included in Class I).
Class III
Internal parts welded to the vessel but not subject to primary stress (e.g.: baffles, vortex
breakers, weir plates and others). External parts welded to the vessel subject to stress
during operation, such as any type of support (e.g.: skirts, columns, saddles etc.),
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supporting elements for ladders, platforms, external piping and others. For supports, this
class only includes the parts of supports directly welded to the vessel or very close to it.
Note: The supports shall have a section 1000 mm long from the attachment to the vessel,
with the same shell material in the following cases:
-
design temperature lower than or equal to 15 °C;
design temperature over 340 °C;
service with hydrogen;
vessels made of alloy steel, stainless steels and nonferrous materials.
Class IV
Internal removable parts (not welded to the vessel), such as trays, bubble caps, gratings,
supporting beams, distributors, tube bundles and others.
Class V
Parts of supports of any type not included in Classes III and IV. For all parts of this class,
the design temperature is always the ambient temperature.
Class VI
All external parts subject to loads only during assembly, maintenance, disassembly and
others, such as lifting eyes, davits and others. For all parts of this class, the design
temperature is always the ambient temperature.
These external parts shall not be welded directly to the vessel. A reinforcement pad of the
same material as vessel shall be provided prior to welding.
6.6
Add to section before first sentence
Repairs of warped parts due to welding, among other factors, shall be done according to a
repair procedure previously approved by OWNER and preferably done in the cold
condition. After unwarping of warped parts, the higher strain regions in these parts shall be
examined with penetrant liquid or magnetic particles.
6.7
Add to section before first sentence
The materials used shall be perfectly identified according to the fabrication drawing of the
equipment and to the material certificate, using the criteria of code ASME Section VIII.
6.8
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Unless otherwise specified, pressure components shall undergo the PMI examination
when they are received, except for carbon steel material. Inspection in 100 % of lot. Noncomplying parts shall be identified and disposed.
Fixing elements (studs/bolts and nuts) and equipment internals shall undergo the PMI
examination, by sampling in 20 % of its lot at the receiving, except for carbon steel
materials. Sampling acceptance criteria: 100 %. In case of non-compliance, the sampling
shall be extended to 100 %. Non-complying parts shall be identified and disposed.
Add new section
6.9
Optical emission spectroscopy shall be used in cases where the PMI technique is not able
to identify the alloy steel material.
Add new section
6.10
Pressure vessels in which heat conservation is necessary and pressure vessels subjected
to temperature of 60ºC and above shall be thermal insulated according to I-ET-3010.001200-431-P4X-501 – THERMAL INSULATION FOR MARITME INSTALLATIONS.
Thermal insulation shall be applied after the hydrostatic test and approval of NDT’s.
7 FABRICATION
7.1 GENERAL
7.1.1
Add to section before first sentence
All welds of parts externally attached to the vessels shall have continuous weld bead.
Add to sentence
Nozzles NPS 10 and greater shall have two holes diametrically opposite. After tests, these
holes shall be left open and filled with grease.
7.1.5
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The distance between main seam welds (longitudinal and circumferential joints) and
nozzles, reinforcement or other welded attachments shall be in any case 3 times the
thickness of the thinnest plate and at least 50 mm (2 in), measured weld toe to weld toe.
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7.1.6
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Whenever possible, welds of the shell and heads shall be arranged in such a manner as
not to interfere with vessel supports and nozzles, manholes, lifting lugs and their
respective reinforcements.
7.1.9
Add to sentence
For dished heads and other pressed or formed parts, provision shall be made for a
minimum increase in the plate thickness to compensate the thickness loss in pressing or
forming, so that the final thickness of the finished part be at least equal to the calculated
value or the value shown on the drawings.
7.1.10
Replace sentence with
Permanent marking is not allowed on the pressure boundary.
7.1.11
Add to section before first sentence
The thickness of all manufactured sections shall be checked. Special attention is drawn to
regions of higher strain, such as the toroidal region of torispherical heads. The measured
thickness shall have the thickness defined in fabrication drawing or above.
Add new section
7.1.13
Welds of the shell and heads shall not interfere with internal parts welded to the vessel.
For horizontal vessels, longitudinal welds of the shell on the bottom generatrix of the
vessel, where they interfere with the saddle, shall not be allowed.
For vertical vessels, the weld of the skirt to the vessel shell shall be located so as not to
interfere with the weld of the shell to the bottom head and to allow inspection of the weld.
For horizontal vessels, saddles shall also be located in such a manner as not to interfere
with the circumferential welds of the vessel and allow the inspection of these welds.
Add new section
7.1.14
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For vessels less than 2000 mm in diameter, only a single longitudinal weld per shell
section is allowed. For diameters equal to or greater than 2000 mm, commercial length
plates shall be used and smaller plates shall only be allowed for adjustment purposes .
Add new section
7.1.15
Longitudinal welds of adjacent rings shall be at least 45º apart from each other.
Add new section
7.1.16
The same corrosion allowance specified for the vessel shall be added to the minimum
dimension of the throat of the fillet welds.
Add new section
7.1.17
For all vessels to be postweld heat treated, all welds shall be of the full penetration type,
excepting for the weld of slip-on flanges and nozzles pads, where gas escape and
pressure relief holes shall be provided.
Add new section
7.1.18
7.1.18.1
Bevels shall be dimensionally and visually checked for cleanliness and absence of the
following defects:
a. lamellar de-cohesion;
b. pores;
c. cutting irregularities;
d. dents;
e. cracks;
f. discontinuities crosswise to the surface;
g. discontinuities parallel to the surface, over 25 mm in length.
Note: Paragraphs e., f. and g. shall be verified by non-destructive tests, when there is
suspicion of those defects’ existence.
7.1.18.2
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The visual test shall be completed by the liquid penetrant or magnetic particle test, in the
following cases:
a. bevel thickness over 38 mm;
b. bevels of openings for nozzles having a nominal diameter equal to or greater than 76
mm (3”);
c. bevels recovered by welding;
d. all bevels except for carbon steel equipment without impact testing requirement.
Note: The same defects mentioned in item 7.1.18.1 are deemed to be unacceptable.
7.2 WELDING
Add to section
7.2.1
Welding shall be performed in compliance with the requirements stated in I-ET-3010.001200-955-P4X-001 – WELDING.
Qualification and certification for procedures and personnel shall be in accordance with IET-3010.00-0000-970-P4X-001 – REQUIREMENTS FOR PROCEDURES AND
PERSONNEL QUALIFICATION AND CERTIFICATION.
8 HEAT TREATMENT
Add new section
8.10
CONTRACTOR shall submit to OWNER´s approval a specific Heat Treatment procedure
containing at least the following information:
a. type of heat treatment performed;
b. identification of applicable performance standard;
c. parameters required for performance, such as:
- beginning and ending control temperatures;
- minimum and maximum heating rate;
- minimum and maximum treatment temperatures;
- minimum and maximum treatment times;
- minimum and maximum cooling rate;
- maximum difference of temperature between thermocouples;
d. details of support and deformation control devices of equipment;
e. indication of performance method, such as:
- treatment in furnace;
- localized treatment;
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f. indication of heating medium used;
g. furnace drawing (when applicable), indicating equipment the location inside it, burner
nozzles or electrical resistances, and the overlap region when the equipment item is not
fully inside the furnace;
h. when localized heat treatment is performed: welded joint drawing, indicating the location
and distribution of electrical resistances, width of soak band (SB), width of heated band
(HB), width of gradient control band (GCB) including SB, HB and insulation, distribution of
thermocouples, and insulation attachment details;
i. type, quantity and identification (number and color in chart) of thermocouples employed;
j. attachment method of thermocouples to equipment;
k. equipment sketch and/or test coupon indicating the location and relative distance
between thermocouples.
Add new section
8.11
Post weld heat treatment is required for all welded joints of pressure vessels subjected to
wet H2S or amine service.
Add new section
8.12
For vessels submitted to a post weld heat treatment, all materials, welding consumables
and procedures shall be qualified to include all predicted heat treatments during
fabrication, added of one PWHT in case any additional in-site welding repair is needed.
This additional heat treatment to be done by OWNER, if necessary, will have the same
specifications as the PWHT’s done during fabrication.
Add new section
8.13
CONTRACTOR shall inform how many PWHTs the vessel can withstand due carried out
repairs.
9 NON-DESTRUCTIVE EXAMINATION
9.1 GENERAL
9.1.1
Replace sentence with
Non-destructive examination shall be performed in accordance with the requirements
stated in I-ET-3010.00-1000-970-P4X-002 – REQUIREMENTS FOR NDT. All required
non-destructive examination for final acceptance of the vessel shall be performed at least
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48 hours after the completion of all welding, weld repairs and post weld heat treatment, if
required, and prior to pressure testing.
9.1.2
Add to section before first sentence
Qualification and certification for procedures and personnel shall be in accordance with IET-3010.00-0000-970-P4X-001 – REQUIREMENTS FOR PROCEDURES AND
PERSONNEL QUALIFICATION AND CERTIFICATION.
Add new section
9.1.4
Welds of any parts, regardless of the material, thickness or service, shall be fully (100%)
radiographed before any severe deformation (thickness to local radius ratio greater than
5%), by any process, such as spinning, pressing and rolling. After deformation, the welds
and the most deformed areas shall be examined by magnetic particles or liquid penetrant,
before any manufacturing operation is subsequently carried out.
Add new section
9.1.5
CONTRACTOR shall submit the Inspection and Test Plan (ITP) based on this technical
specification and S-619Q, with all witnessed inspections and tests identified. The
notification period for such inspections shall be informed in advance.
Add new section
9.1.6
CONTRACTOR shall ensure that all the witnessed inspection requirements by the
Classification Society are fully met and the due notice requirements are satisfied.
9.2 RADIOGRAPHIC AND ULTRASONIC EXAMINATION
9.2.1
Add to the end of section
For pressure vessels designed in accordance with ASME BPVC Sec. VIII Div 1, all welded
joints of the shell and heads shall be, as a minimum, examined by spot radiography.
Equipment classified as “service with H2S”, pressure vessels made of material P-number
10H and pressure vessels designed according to ASME BPVC Sec. VIII Div.2 shall be fully
radiographed.
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9.2.5
Add to the end of section
As the weld crossing points that shall be included in the extent of examination.
Add new section
9.2.6
Welds used for closing guide-holes at the center of formed heads shall be fully
radiographed.
9.3 MAGNETIC PARTICLE OR LIQUID PENETRANT EXAMINATION
9.3.1
Replace sentence with
9.3.1.1
A magnetic particle or liquid penetrant test shall be performed before the hydrostatic test in
the following regions:
a. internally and externally welded joints, covering a 200 mm wide area centered at the
joint;
b. plate repair welds;
c. regions of weld removed from auxiliary assembly device and temporary weld;
d. welds for attachment of accessories.
For equipment subject to heat treatment, the requirements above shall be met before and
after the heat treatment.
9.3.1.2
Liquid penetrant test or magnetic particle test shall be performed on all vessel lifting
devices (example: lifting lugs).
Add new section
9.4 VISUAL INSPECTION
9.4.1
A visual inspection shall be performed in all materials, sections and equipment used,
which shall be free of:
a. defects which cause a sudden transition on the surface of the part;
b. defects which reduce the thickness of the part to a value lower than the thickness
defined in fabrication drawing;
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c. any degree of corrosion for stainless steels and nonferrous metals.
d. corrosion above grade C of standard ISO 8501-1 for the following materials:
- Carbon Steels;
- Molybdenum Alloy Steels;
- Chromium Molybdenum Alloy Steels;
9.4.2
Flange faces shall be visually checked, for verification of the condition and type of
grooves, being unacceptable corrosion or dents at the sealing surface.
Add new section
9.5 DIMENSIONAL INSPECTION
It shall be performed in accordance with code ASME BPVC Section VIII and tolerances of
Annex E.
Add new section
9.6 TIGHTNESS TEST
Bubble formation test with positive pressure shall be performed in accordance with ASME
Section V Article 10. No leak is allowed.
Add new section
9.7 HARDNESS TEST
9.7.1
In welding procedure qualification and in production testing, the hardness measurement
shall be performed with bench instrument, according to ASTM E384.
9.7.2
Production test plates shall be treated together with the equipment. Their localization is
established at the option of the OWNER inspection.
9.7.3
When measuring hardness in equipment, the suitability of the portable instrument shall be
showed by comparison settlement in hardness measurements obtained by the portable
instrument and those obtained by the bench instrument. The comparison results shall be
previously submitted to OWNER for approval.
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9.7.4
The demonstration shall be performed in a welded joint of material of same applicable
specification (ASTM, ASME) of equipment material to be tested, using the outline of
hardness measurements for bevel similar to the equipment. Measurements performed with
bench instrument, Vickers method, as per ASTM E 384, hardness HV 5 or HV 10, shall be
similar to those obtained in adjacent positions with portable instrument, being considered
the maximum range of +10 % as acceptable. For equipment which may be subjected to
corrosion under stress condition, the maximum range shall be +5 %. Negative ranges are
not acceptable.
9.7.5
The comparison of measurements performed in standard blocks to decide for suitability of
portable instrument device for hardness measurement is not allowed.
9.7.6
To measure the hardness in Heat Affected Zone (HAZ), ultrasonic-type portable
instruments shall be used. For this measurement, it is required to perform the chemical
attack of the joint so that the HAZ region is revealed.
9.7.7
For pressure vessels subjected to heat treatment, hardness reading shall be taken after
heat treatment, being:
a. a hardness reading performed for each 6 m of weld;
b. at least two readings shall be taken per longitudinal bead and per circumferential bead.
The hardness measurement in circumferential joint shall be made in all crossings with
longitudinal welds;
c. at least one hardness reading shall be taken in the flange connection with neck and one
in the nozzle connection with vessel;
d. at least one reading shall be taken for each WPS used;
e. one reading in region of removal of temporary welds.
Note: Each reading shall contain three points in weld metal (cast zone), three points in
each HAZ, and one point in base metal of each side of bead.
9.7.8
Portable instruments based on Leeb (rebound) method and Poldi or elebrineller-type
portable instruments shall not be used.
10 PRESSURE TESTING
10.1
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Shop hydrostatic test shall be performed according to ASME BPVC Section VIII, based on
a calculated pressure, considering nominal thickness with corrosion allowance.
10.5
Add to the end of sentence
The design torque shall be applied in the tightening sequence, according to ASME PCC-1,
using a calibrated torque wrench. The record of applied torque shall be presented to
inspector during the test.
Add new section
10.7
Hydrostatic test shall be performed only after presentation of all inspection and testing
records provided in approved ITP.
Add new section
10.8
Vents shall be provided at the high points of the vessel to purge air from the tested
component while it is being filled.
Add new section
10.9
The test shall only be performed after 48 hours have elapsed from the last welding or after
PWHT in pressure parts and equipment supporting parts.
Add new section
10.10
At least two pressure gages shall be used, and a third one shall be used when the test
takes more than 6 hours, observing the following requirements:
- At least one of the pressure gages shall be located in an area allowing easy access,
visible to the inspector during the entire testing and pressurization time and one of the
pressure gages shall be located at the top of the equipment.
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- Pressure gages shall be calibrated before the beginning of the test. Calibration certificate
shall not be older than 3 months at test data. Calibration shall be done using a standard
deadweight gauge or a calibrated master pressure gauge or a column of mercury.
- The maximum scale value shall always be within 1.5 and 4 times the test pressure and
be preferably twice the test pressure.
- The smallest scale division shall not exceed 5% of the maximum scale indication.
- Valves shall be provided between the pressure gages and equipment to allow
substitution, if necessary.
Add new section
10.11
The hydrostatic test procedure shall consider the scheme presented below:
- Elevate the pressure until 50% of hydrostatic test pressure (PT) and proceed the
equipment inspection.
- Increase gradually, with a rise ratio of 20% of PT per minute or lower, till reach the
hydrostatic test pressure. Remain in this pressure during, at least, 30 minutes.
- Low down the pressure up to 77% of PT, being used a similar raise reduction the one
that was used for the pressurization, and to execute new inspection.
- Decrease gradually till the atmospheric pressure, remaining it same decompression
raise, and open the upper nozzles to avoid the emptying vacuum.
Add new section
10.12
After the hydrostatic test, the following items shall be completed:
- The equipment shall be fully drained, dried and cleaned.
- In nozzles left open, flange faces shall be protected against corrosion and mechanical
damage.
- In equipment with cladding a visual inspection shall be performed to check if blistering
occurred in the cladding; if any, it shall be repaired and re-examined.
- A dimensional examination of the perimeter of cylindrical shells and distances between
equipment tangent lines shall be performed to check if there is permanent deformation
after hydrostatic test.
11 COATING AND PAINTING
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11.1
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External painting shall be according to I-ET-3010.00-1200-956-P4X-002 - GENERAL
PAINTING.
11.2
Pressure vessels color shall be according the latest revision of DR-ENGP-I-1.15 – COLOR
CODING.
11.3
If TSA is required, it shall be in accordance with I-ET-3010.00-1200-956-P4X-003 THERMAL SPRAY COATING APPLICATION ALUMINUM.
11.4
If internal coating is required, it shall be in accordance with I-ET-3010.00-1200-956-P4X002 - GENERAL PAINTING.
*NOTE: For surfaces in which an organic internal coating is required, a weld overlay may
be required in the sealing areas, e.g.: RTJ flanges faces.
12 PREPARATION FOR SHIPMENT
Nothing to add or replace.
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ANNEX A – ADDITIONAL REQUIREMENTS FOR SOUR SERVICE
VESSELS
A.4
Replace sentence with
All welds subjected to pressure loads, in the shell and heads, shall be double-butt welded,
full penetration. and shall be subject to 100 % volumetric examination. Nozzle to vessel
wall joints shall be 100 % ultrasonically tested.
A.7
Add to sentence
Hardness testing shall also be performed on production welds. These tests shall be
performed in the deposited weld metal and on the Heat Affected Zone (HAZ).
Add new section
A.11
Post weld heat treatment is required for all welded joints.
Add new section
A.12
Production welds shall be checked for its chemical composition (100% PMI testing) and for
its phase balance (100% magnetic testing).
Add new section
A.13
Construction details that result in crevice in contact with the fluid is not allowed.
Confined space between welds is not allowed.
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ANNEX B – ADDITIONAL REQUIREMENTS FOR INTEGRALLY CLAD
AND WELD OVERLAY VESSELS
B.2.2
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The disbonding assessment shall meet at least level B of ASTM 578 standard. Final
thickness shall meet the minimum required according to the Calculation Report.
B.2.3
Add to sentence
The test shall include metal base´s thickness measurement and disbonding evaluation.
Add new section
B.2.7
For vessels with clad, any blistering detected in the visual inspection shall not be
permitted.
B.3.1
Replace sentence with
A minimum of two layers shall be applied for all overlay welding.
B.3.4
Add to sentence
The internals shall be of the same P-number as the overlay, in order to not have dissimilar
welds.
B.3.5
Replace section “a” with
a. detailed arrangement drawing showing:
‒ functionality of the nozzle or flange;
‒ constructive detail of nozzle (the use of set on is not allowed);
‒ preparation of the nozzle or flange;
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‒ tapering;
‒ line up and measurement prior to overlay welding.
B
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ANNEX C – ADDITIONAL REQUIREMENTS FOR CARBON STEEL
VESSELS
C.6
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When there is toughness requirement to the weld joint, the interpass temperature shall not
exceed 250 ºC.
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ANNEX D - ADDITIONAL REQUIREMENTS FOR
STAINLESS STEEL, 22CR AND 25CR DUPLEX VESSELS
AUSTENITIC
D.1.1
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When the sensitization of austenitic stainless steels is deleterious to their corrosion
resistance, materials that are not susceptible to sensitization shall be used (low carbon
steels, types L and ELC or stabilized steels). Attention is drawn to the fact that
sensitization may occur as a result of welding, heat treatments or operating temperature of
the vessel.
D.3
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D.3 FERRITE CONTROL FOR AUSTENITIC STAINLESS STEEL
D.3.1
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d. the material is operating in sour service.
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D.6.7
External coating shall be applied to austenitic stainless, 22Cr and 25Cr duplex in
accordance with I-ET-3010.00-1200-956-P4X-002 - GENERAL PAINTING.
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ANNEX E - VESSEL TOLERANCES
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ANNEX F - REQUIREMENTS FOR MAXIMUM ALLOWABLE CORROSION
ALLOWANCE (MACA)
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ANNEX G – REQUIREMENTS FOR NAMEPLATES
G.1
Pressure vessels shall have an identification nameplate containing at least the information
and dimensions shown in Figure G.1.
G.2
Nameplate shall be made of AISI 316 stainless steel plate with a minimum thickness of 1.5
mm.
Figure G.1– Nameplate (for translation of terms see Figure G.2).
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G.3
The plate shall be situated on the cover of the lower inspection cover of the vessel, or in
another visible and easily accessible location. The localization of the identification plate
shall be defined in the vessel manufacturing drawing.
G.4
The characters shall be engraved or stamped and shall have a minimum dimension of de
3 mm.
G.5
For fixation there shall be used Ø 5/16” x 5/8” screws made of stainless steel or tin, with a
six sided nut and a washer in a Ø 8.5 mm holes as shown in the drawing. In vessels with
thermal insulation or with any other external cladding, the identification plate shall be fixed
to a support welded to the body of the vessel, in a manner that it stands out well from the
external surface of the insulation or cladding.
Figure G.2 - Translation of Terms Used in Figure G.1.
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G.6
Notes of Figure G.2:
NOTE 1: Dimension in mm.
NOTE 2: The units shall be completed in the international system and in the technical
system.
NOTE 3: The language to be used for engraving all nameplate information shall be
Portuguese. For translation of the terms see Figure G.2.
NOTE 4: Equipment Identification (Tag Number). It shall be engraved as mentioned on
Process Data Sheet, P&ID and Equipment List.
NOTE 5: The year of the edition of the design code/standard adopted shall be shown.
NOTE 6: When applicable
NOTE 7: The minimum temperature of water for hydrostatic testing of the equipment shall
be determined according to ASME BPVC SECTION VIII.
NOTE 8: The hydrostatic pressure test for a new vessel shall be determined according
item 10.1.
NOTE 9: Show the equipment position and equipment point where the hydrostatic
pressure test is measured (e.g. vertical position/ at the top).
NOTE 10: The Maximum Allowable Working Pressure (MAWP) shall be determined using
the nominal vessel thicknesses, without the corrosion allowance, and the allowable stress
value in the working temperature.
NOTE 11: In this space shall be written “SERVIÇO COM HIDROGÊNIO” (service with
hydrogen) or “SERVIÇO COM H2S “(service with H2S) when applicable.
NOTE 12: In this space shall be inscribed the requirements for the hydrostatic test water.
G.7
In addition to the nameplate, the pressure vessel category, according to NR-13, shall be
shown at a visible location along with its TAG (identification code). The letters and
numbers of equipment TAG and category shall be arranged in the horizontal direction, with
“Helvetic”, “PETROBRAS Sans” or “Swiss 721 BT” fonts. The size shall be in accordance
with pressure vessels external diameter, as stated in Table G.1.
Table G.1 – Recommendation for height “H” of letters and numbers
External Pressure Vessel diameter
(mm)
Height “H”
(mm)
D ≤ 300
25
300 < D ≤ 1000
70
1000 < D ≤ 2500
125
2500 < D ≤ 5000
220
D > 5000
300
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SECTION II - IOGP S-619 SPECIFICATION FOR UNFIRED, FUSION
WELDED PRESSURE VESSEL
SECTION III – IOGP S-619D DATASHEET FOR UNFIRED, FUSION
WELDED PRESSURE VESSEL
SECTION IV – IOGP S-619L INFORMATION REQUIREMENTS FOR
UNFIRED, FUSION WELDED PRESSURE VESSEL
SECTION V – IOGP S-619Q QUALITY REQUIREMENTS FOR UNFIRED,
FUSION WELDED PRESSURE VESSEL