VESSM001 (Specification for Small Pressure Vessel and Heat Ex Changer)

March 1999

Process Industry Practices Vessels

PIP VESSM001 Specification for Small Pressure Vessels and Heat Exchangers with Limited Design Conditions

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.

This Practice is subject to revision at any time by the responsible Function Team and will be reviewed every 5 years. This Practice will be revised, reaffirmed, or withdrawn. Information on whether this Practice has been revised may be found at http://www.pipdocs.org.

© 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 and subscribers may copy this Practice for their internal use.

PRINTING HISTORY March 1999 June 2000

Revision Reference Section Correction

Not printed with State funds

March 1999

Process Industry Practices Vessels

PIP VESSM001 Specification for Small Pressure Vessels and Heat Exchangers with Limited Design Conditions Table of Contents 1. Introduction................................. 2 1.1 Purpose ............................................. 2 1.2 Scope................................................. 2 1.3 Alternative Design Proposals............. 3

2. References .................................. 3 2.1 Process Industry Practices ................ 3 2.2 Industry Codes and Standards .......... 3 2.3 Government Regulations ................... 3

7. Fabrication.................................. 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7

Butt Welds ......................................... 7 Formed Head-to-Shell Welds ............ 7 Backing Strips.................................... 7 Liners ................................................. 7 Gasket Surfaces ................................ 7 Tolerances ......................................... 7 Postweld Heat Treatment .................. 7

8. Pressure Testing ........................ 7 3. Definitions ................................... 4 9. Purchaser Inspection................. 8 4. General ........................................ 4 4.1 4.2 4.3 4.4 4.5

Jurisdictional Compliance .................. 4 National Board Registration............... 4 Units of Measurement ....................... 5 Language........................................... 5 Documentation to be Provided to the Manufacturer................................ 5 4.6 Documentation to be Provided by the Manufacturer................................ 5

10. Manufacturer’s Nameplates ...... 8 11. Cleaning, Painting, and Shipping Protection ................... 8 11.1 Drying and Cleaning .......................... 8 11.2 Painting.............................................. 8 11.3 Protection of Machined Surfaces....... 9

5. Materials...................................... 6 5.1 Materials of Construction ................... 6 5.2 Swing Bolts ........................................ 6 5.3 Pressure-Resisting Bolting ................ 6

6. Construction Responsibility...... 6 Process Industry Practices

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1.

March 1999

Introduction 1.1

Purpose This Practice describes the general materials, design, fabrication, examination, inspection, testing, and documentation requirements for pressure vessels with limited design conditions.

1.2

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Scope 1.2.1

This Practice designates minimum general requirements for the construction of three classes of small pressure vessels (including heat exchangers) with the limited design conditions shown in Table 1. See Section 5.3 for material of construction limitations. This Practice is intended to apply to the Manufacturer’s standard, pre-designed pressure vessels and heat exchangers supplied as part of pre-engineered package units (e.g., refrigeration and aircompressor systems), “off-the-shelf” items and vessels (e.g., filters) built from the Manufacturer’s standard parts. Use of this Practice for customdesigned vessels is limited to applications that have been reviewed and approved in writing by the Purchaser. Special requirements are covered in the Vessel Specifications (see Section 3 for definition).

1.2.2

Vessels Not Included: •

Vessels intended for “Lethal Service” (as defined in the Code)

•

Vessels for which design wall thickness would be governed by loadings due to wind pressure or earthquake forces

•

Vessels that exceed the limitations of Table 1

1.2.3

Vessels for which shock (thermal or mechanical) and/or cyclical loading is a controlling design requirement and vessels in highly hazardous chemical (e.g., ammonia) service are not permitted to be constructed under Class A requirements (see Table 1).

1.2.4

Many recognized and generally accepted good engineering construction practices are included herein. However, in light of the many diverse service applications of vessels covered under this specification, these practices must be employed with engineering judgment and supplemented as appropriate with requirements related to specific materials of construction, service fluids, operating environments, and vessel geometries. Accordingly, provisions of this Practice may be overridden or supplemented by an Overlay Specification (see Section 3 for definition).

Process Industry Practices


March 1999

1.3

Alternative Design Proposals The Manufacturer shall provide a base bid in full compliance with the purchase 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 or shortening the anticipated life of the vessel. The Manufacturer shall comply with the following requirements when submitting an alternative bid: a. Alternative design quotations shall be accompanied by the base quotation and be clearly noted as an alternative design. b. Alternative designs shall be fully and clearly described and substantiated by sketches or drawings. Specific exceptions to the Vessel Specifications or this Practice shall be identified as such. c. An alternative design shall not be used unless approved in writing by the Purchaser.

2.

References Applicable requirements of the following industry standards and references shall be considered an integral part of this Practice, except as modified herein or in the Vessel Specifications. Short titles will be used herein when appropriate. 2.1

Process Industry Practices (PIP) The latest edition issued at the date of contract award shall be used. – PIP VEDV1003 - Vessel Drawing/Data Sheet and Instructions – PIP VEFV1100 - Vessel/S&T Heat Exchanger Standard Details PIP VEFV1101 - Vessel Nameplate Bracket

2.2

Industry Codes and Standards The latest edition or addenda issued at the date of the contract award, but which may not yet be mandatory, shall be used. • American Society of Mechanical Engineers (ASME) – ASME Boiler and Pressure Vessel Code Section VIII, Division 1 - Pressure Vessels

2.3

Government Regulations • US Department of Labor, Occupational Safety and Health Administration (OSHA) – OSHA 29 CFR 1910.119 - Process Safety Management of Highly Hazardous Chemicals


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3.

March 1999

Definitions For the purposes of this Practice, the following definitions apply: Code: Section VIII, Division 1 ASME Boiler and Pressure Vessel Code Construction: An all-inclusive term comprising materials, design, fabrication, examination, inspection, testing, certification, and pressure relief Designer: The party responsible for defining and specifying the mechanical design requirements (e.g., Vessel Drawing/Data Sheet) consistent with the Vessel Specifications or 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. Highly Hazardous Chemicals: See Appendix A of OSHA 29 CFR 1910.119 for list Manufacturer: The party entering into a contract with the Purchaser to construct a vessel in accordance with the purchase order. The Manufacturer shall possess an ASME Certificate of Authorization to construct “U”-stamped vessels. Overlay Specification: Technical requirements that supplement or override the provisions of this document, such as Vessel Specifications or a project specification 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 as described in the Purpose and Scope statements. This term refers to the owner and/or operator of the equipment. Vessel Specifications: This term shall be understood to include any drawings, specifications, or service-specific data designated by Purchaser for a particular vessel or group of vessels. The Manufacturer is responsible for notifying the Purchaser in writing of any apparent conflicts between the Vessel Specifications and this Practice.

4.

General 4.1

Jurisdictional Compliance All aspects of the work shall comply with applicable local, county, state, and federal rules and regulations. This includes, but is not limited to, the rules and standards established by EPA and OSHA, if applicable.

4.2

National Board Registration All Code “U”-stamped vessels shall be registered with the National Board of Boiler and Pressure Vessel Inspectors (NB).

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March 1999

4.3

Units of Measurement U.S. customary (English) units shall be regarded as standard; metric (SI) units may be included for reference only and shall not be interpreted as a precise conversion.

4.4

Language The language of all documents shall either be English or include the English translation.

4.5

Documentation to be Provided to the Manufacturer Purchaser shall provide the Design Data information per PIP VEDV1003.

4.6

Documentation to be Provided by the Manufacturer 4.6.1

Manufacturer’s Standard Vessels Manufacturer’s detailed fabrication drawings and certified design calculations are preferred and shall be furnished when practicable. For vessels supplied as part of pre-engineered package units (e.g., air compressor and refrigeration systems, ION exchange systems, etc.), “off-the-shelf” items and vessels fabricated from Manufacturer’s standard parts, Manufacturer shall provide certified outline drawings only if detailed drawings are not available. Outline drawings shall be legible and shall contain all dimensional and other data necessary for complete assembly, installation, proper operation and maintenance of the vessel. These data shall include pressure bolting and gasket information.

4.6.2

Custom-Designed Vessels (see Section 1.2.1) Manufacturer shall provide detailed assembly and working drawings and certified design calculations for all vessels furnished as custom-designed items. Manufacturer’s drawings and calculations provided in accordance with this Section shall be reviewed by Purchaser prior to the start of fabrication unless a release to proceed is obtained from Purchaser in writing. Drawings shall be complete and shall include all relevant design, materials, fabrication, examination, and test requirements. Manufacturer’s drawings shall also include the following special notes as applicable: 1. All vessels - “Chlorides or substances that contain chlorine that will decompose to form chlorides (e.g., coatings to prevent adhesion of weld spatter) shall not be applied to any part of the vessel.” 2. Stainless steel vessels - “Zinc-coated (galvanized or painted) components shall not be in contact (welded, bolted, or loose) with any alloy parts of the vessel.”


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March 1999

3. All postweld heat-treated (PWHT) vessels shall have the following notice painted on two sides of the shell and insulation covering, if present, in 3-inch high letters visible in the shipping position from grade: POSTWELD HEAT TREATED - DO NOT BURN OR WELD 4. All vessels with nonmetallic linings shall have the following notice painted on two sides of the shell and insulation covering, if present, in 3-inch high letters visible in the shipping position from grade: LINED VESSEL - DO NOT BURN OR WELD 4.6.3

5.

A copy of the Manufacturer’s Data Report (Code Form U-1 or U-1A) shall be furnished to Purchaser for all Code “U”-stamped vessels. For all Code “UM”-stamped vessels, a copy of the Manufacturer’s Certificate of Compliance (Code Form U-3) shall be furnished.

Materials 5.1

Materials of Construction Materials of construction are limited to carbon steel and austenitic stainless steel, except for tubing for heat exchangers which may be copper or copper alloy. The use of other materials shall be approved by Purchaser and noted on the Data Sheet.

5.2

Swing Bolts Swing bolts (eye bolts) shall be of one-piece construction without welding. Hinge pins shall be solid (not rolled) and of the same material as the swing bolts.

5.3

Pressure-Resisting Bolting Pressure resisting bolting for Class A (except as otherwise permitted in this Section), B, and C vessels shall be either low- or high-alloy steel. Carbon steel SA-307, Grade B bolting is permitted on Class A vessels only and is limited to nameplate temperatures not hotter than 450° F (232° C) and not colder than -20° F (-29° C).

6.

Construction Responsibility Manufacturer shall be responsible for the construction of vessels in accordance with this Practice. Mechanical design provided in the Vessel Specifications by Purchaser shall not relieve Manufacturer of this responsibility.

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March 1999

7.

Fabrication 7.1

Butt Welds Except as permitted in Section 7.2, all longitudinal and circumferential welded joints in pressure-resisting components (Code Categories A, B, and when used, butt-types C and D) shall be full penetration butt welds.

7.2

Formed Head-to-Shell Welds For vessels in non-corrosive service not larger than NPS 12, welded joints attaching formed heads to shells may be any fillet-welded lap joint per Code Figure UW-13.1 and Code Table UW-12.

7.3

Backing Strips For vessels larger than NPS 12 or any vessel in corrosive or cyclic service, permanent weld-joint backing strips, including butt welds with one plate edge offset [Code Figure UW-13.1, Sketch (k)], are not permitted.

7.4

Liners Loose liners shall not be used.

7.5

Gasket Surfaces All gasket seating surfaces shall be plane and true. Gasket seating surfaces of fabricated flanges, fabricated lap rings, and bolted tubesheet joints (including passribs) shall be machined after welding and other fabrication steps that can result in warpage or distortion from a plane and true surface.

7.6

Tolerances Dimensional tolerances shall be in accordance with Manufacturer’s standard practice and the applicable requirements of the codes and standards designated in Table 1 and the notes thereto.

7.7

8.

Postweld Heat Treatment 7.7.1

Carbon steel vessels in ammonia service, permitted for Table 1 Class B and C vessels only, shall be postweld heat-treated.

7.7.2

Alternative PWHT requirements of Code Table UCS-56.1 shall not be employed.

Hydrostatic Testing All vessels constructed to this Practice shall be hydrostatically tested in accordance with the provisions of Paragraph UG-99(b) of the Code. See Section 11.2.


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9.

March 1999

Purchaser Access Purchaser shall have free entry to those parts of the Manufacturer’s plant concerned with fabrication, examination, and testing of the vessel.

10.

Manufacturer’s Nameplates All vessels shall be furnished with the Manufacturer’s nameplate. The nameplate shall be made of austenitic stainless steel and attached by an austenitic stainless steel nameplate bracket in accordance with PIP VEFV1101. Nameplates for Class B and C vessels shall satisfy Code requirements. Nameplates for Class A vessels shall include:

11.

•

Maximum and minimum design temperatures and the coincident maximum allowable design pressures

•

Manufacturer’s serial number

•

Year built

•

Manufacturer’s name

Cleaning, Painting, and Shipping Protection 11.1

Drying and Cleaning 11.1.1 After completion of the hydrostatic test, the vessel interior shall be completely drained, thoroughly dried, and cleaned of foreign matter. 11.1.2 All PWHT vessels shall have the following notice painted on two sides of the shell and insulation covering, if present, in 3-inch high letters visible in the shipping position from grade: POSTWELD HEAT TREATED - DO NOT BURN OR WELD 11.1.3 All vessels with nonmetallic linings shall have the following notice painted on two sides of the shell and insulation covering, if present, in 3-inch high letters visible in the shipping position from grade: LINED VESSEL - DO NOT BURN OR WELD

11.2

Painting All required coatings shall be as indicated in the Design Data information. Only surfaces that are required by the Design Data information to be painted and that will be inaccessible after assembly (e.g., mating surfaces between lap-joint flanges and associated nozzle necks, shells, lap rings, or stub ends, bolt holes, and welded joints) shall be painted prior to assembly and hydrostatic testing. Otherwise, all painting shall be performed after hydrostatic tests.

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March 1999

11.3

Protection of Machined Surfaces 11.3.1 All gasket seating, threaded, or other machined surfaces shall be protected for shipment as follows: 11.3.1.1 Assembled Joints - Bolted flanged joints, plugged couplings, and other connections specified to be furnished with service covers shall be shipped assembled, if practicable. 11.3.1.2 Exposed Surfaces - For carbon and low-alloy steels, all exposed machined or threaded surfaces shall be cleaned with solvent and coated with temporary rust-preventative grease. The following products are acceptable: Ashland Oil-Tectyl 858C, Sanchem NoOx-Id-A, Exxon-Beacon 325, Houghton-Rust Veto Heavy. Other equivalent products are acceptable. Shipping covers shall be furnished per Section 11.3.2. 11.3.2 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. These covers shall be secured with a minimum 25% complement of carbon steel bolts, but no fewer than four. 11.3.3 Welding stub ends shall be provided with bevel protectors.


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March 1999

Table 1 Specification Requirements for Each Class of Vessels (1)

Vessel Class (2)(3)

Class A Maximum Size

6 inches ID

MAWP

300 psig

(4)

Class B

Class C

5 cu ft in volume and 250 psig 3 cu ft in volume and 350 psig 1.5 cu ft in volume and 600 psig Straight-line interpolation is permitted

24 inches OD 300 psig

Maximum External Pressure

15 psi (Full Vacuum)

Maximum Temperature

650° F (See Section 5.3 for additional limitations.)

Minimum Design Metal Temperature

Carbon Steel

Minus 20° F

Austenitic Stainless (5) Steel , Copper, and Copper Alloy

Minus 155° F

Construction Standard

Manufacturer’s (6) Standard

ASME Code Stamp

Not Required

ASME Code Section VIII, Division 1 “U” or “UM” Stamp Required

(6)(7)

“U” Stamp Required

NOTES: 1. When the Vessel Specifications do not designate the Vessel Class, the Manufacturer shall select the Class that covers all of the design parameters and minimum construction requirements included in the Vessel Specifications. 2. Plate coil type heat exchangers are included in this Class without size limitations. 3. See Section 1.2.2. 4. Filter presses and plate-and-frame, spiral-plate, and spiral-tube heat exchangers, without size limitations, are included in this Class. 5. Carbon content shall not exceed 0.10% and thermal treatments are not performed (see Code Paragraph UHA-51). 6. See Sections 7.1, 7.2, and 7.3 for weld joint requirements. 7. Applicable requirements of the Standards of the Tubular Exchanger Manufacturers Association (TEMA), Class B, shall also apply for custom-designed tubular heat exchangers. For Manufacturer's standard exchangers, requirements for compliance with TEMA Standards shall be as specified in the Vessel Specifications.

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VESSM001 (Specification for Small Pressure Vessel and Heat Ex Changer)

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