No.: HURL-G-ED-C00-STA-SPC-000-D102 Engineering Specification For Pressure Vessels

Owner
Ammonia Urea Fertilizer

Project
Hindustan Urvarak & Rasayan Project
Limited (HURL)
PMC
PROJECTS & DEVELOPMENT Location Gorakhpur, India

INDIA LTD. (PDIL)
PLANT 2200 MTPD Ammonia &

Toyo Engineering Corp. 3850 MTPD Prilled Urea
Capacity Plant
Hindustan Urvarak & Rasayan Limited

HURL, Gorakhpur
Ammonia Urea Fertilizer Project
TOYO Work No.: BA-120511
HURL Work No.:
DOC No. : HURL-G-ED-C00-STA-SPC-000-

D102
Engineering Specification for

Pressure Vessels
0 30-05-2018 For Review R.K. S.I. H.H.
B 20-11-2017 For Review R.K. S.I. H.H. / T.S.

A 15-09-2017 For Review RK SI HH/NF
Rev DATE ISSUE PURPOSE PREPARE CHECKED APPROVED
“This document developed by Toyo Engineering and the information it contains are property of Toyo Engineering and Hindustan
Urvarak & Rasayan Limited. It shall not be used for any purpose other than for which it was supplied.”
CONFIDENTIAL - Not to disclose without Authorization
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REVISION HISTORY
Rev.A: First Issue.
Rev.B: Revised and re-issued.
Rev.0: Revised based on CRS BA1205-STA-CRS-002 review result with Owner
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CONTENTS
PAGE
1. GENERAL
1.1 Scope 5
1.2 Deleted 5
1.3 Codes, Standards and Regulations 5
1.4 Units 5
1.5 Purchaser’s Engineering Drawing and Documents 6
1.6 Supplier’s Drawings and Documents 6
2. DESIGN
2.1 Design Pressure 7
2.2 Design Temperature 7
2.3 Corrosion Allowances 8
2.4 Materials 8
2.5 Loading Conditions and Strength Calculations 10
2.6 Tolerances 13
3. DETAILED DESIGN
3.1 Shells and Heads 13
3.2 Internals 13
3.3 Nozzles and Manholes 14
3.4 Openings 14
3.5 Alloy Lining 16
3.6 Bolts, Nuts and Gaskets 16
3.7 Supports 17
3.8 Miscellaneous 17
4. FABRICATION
4.1 Plate Layout 18
4.2 Forming 18
4.3 Welding 19
4.4 Heat Treatment 20
4.5 Miscellaneous 21
5. INSPECTION AND TESTS 21
6. NAMEPLATES, PAINTING AND MARKING

6.1 Nameplates 21
6.2 Painting 22
6.3 Marking 22
6.4 Pickling and Passivation 22
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7. PACKING AND SHIPPING

7.1 General 23
7.2 Packing and Preparation for Shipping 23
7.3 Shipping 24
Appendix A Basic Design Requirements (P.1/4-4/4)

Appendix B Inspection Requirements (P.1/8-8/8)
Appendix C Calculation Method-Dynamic Wind Analysis (Guideline) (P.1/1)
for Vertical Equipment
Appendix D Special Design Code Requirements (P.1/1)
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1. GENERAL
1.1 Scope
1.1.1 This specification together with engineering drawings or mechanical data sheets covers the requirements for
materials, design, fabrication, inspection, testing and supply of pressure vessels.
1.1.2 This specification does not apply, in general, to auxiliary pressure vessels which are attached to turbines,
engines, pumps, compressors and other mechanical equipment which are normally designed to the
manufacturer’s standard.
1.1.3 When this specification is applied to such auxiliary pressure vessels, the vessels shall be designed in
accordance with the basic design requirements in Appendix A.
1.2 Deleted
1.3 Codes, Standards and Regulations
1.3.1 Pressure vessels shall be designed, fabricated, inspected and tested in accordance with the requirements of the
latest edition of codes, standards and national, regional and local regulations, in effect at the time of placement
of the order unless otherwise specified.
(1) National, regional and local regulations
(2) American Society of Mechanical Engineers (ASME)

- Boiler and Pressure Vessel Code, Section II
- Boiler and Pressure Vessel Code, Section V
- Boiler and Pressure Vessel Code, Section VIII Division 1 or Division 2
- Boiler and Pressure Vessel Code, Section IX
- B16.5 Pipe Flanges and Flanged Fittings
- B16.47 Large Diameter Steel Flanges
- B16.20 Metallic Gaskets for Pipe Flanges
- IS 875 / Site data: For wind load consideration
- IS 1893: Criteria for Earthquake Resistant Design of Structures
- API RP 941: Steels for Hydrogen Service at Elevated Temperatures and Pressures
- API 934-A: Materials and Fabrication of 2¼Cr-1Mo, 2¼Cr-1Mo-¼V, 3Cr-1Mo, 3Cr-1Mo-¼V Steel
Heavy Wall pressure Vessels for High-temperature, High-pressure Hydrogen Service
- API 934-C: Materials and Fabrication of 1¼Cr-½Mo Steel Heavy Wall pressure Vessels for High-
Pressure Hydrogen Service Operating at or Below 825 °F (441 °C)
- API 934-E: Recommended Practice for Materials and Fabrication of 1¼Cr-½Mo Steel Pressure
Vessels for Service above 825 °F (440 °C)
(3) American Society for Testing and Materials (ASTM)
1.3.2 Supplier shall be responsible for making all aspects of materials, design, fabrication, inspection and testing
conform to the requirements of the specified codes, standards and national, regional and local regulations.
1.4 Units
Unless otherwise specified, SI units shall be applied as the measurement system for the drawings and documents
to be submitted. However, nominal sizes of piping components shall be in accordance with inch system.
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1.5 Purchaser’s Engineering Drawing and Documents
1.5.1 Purchaser will provide engineering drawing for each pressure vessel which contains information such as the
shape, basic dimensions, estimated thickness and weight, design conditions, materials for primary parts, nozzle
specifications, and details of internals as required by Supplier to accomplish the mechanical design of the
pressure vessel.
When sketches, data sheets or duty specifications are provided; upon request of Purchaser, Supplier shall
prepare engineering drawings covering the same contents as specified above. Supplier may substitute its
assembly drawings for the engineering drawings if the information above is included.
1.5.2 Engineering drawings will be issued in the following stages, and at each stage additional information and/or
revisions will be incorporated. Supplier shall proceed with his work in accordance with purpose of each issue.
(1) Preliminary or For Approval : Preliminary information of design conditions, basic dimensions,
thickness for major parts and weight estimation are indicated.
(2) Approved for Design (AFD) : Almost all design information are settled and confirmed except
nozzle orientation. No further major revisions are expected.
(3) Approved for Construction (AFC) : All design information including nozzle orientation are fixed and
Supplier may start the fabrication based on this issue.
1.5.3 Purchaser will provide HURL-ED-C00-STA-SPC-000-D123 “Vessel Standard” which supplements

engineering drawings and determines the detailed construction of pressure vessels. Applicable drawing
numbers shown in the Vessel Standard will be referenced in the engineering drawing.
When sketches or data sheets are provided, Supplier shall confirm to Purchaser the application of each drawing
in Vessel Standard.
1.6 Supplier’s Drawings and Documents
1.6.1 Supplier shall submit drawings and documents to Purchaser as called for in Purchaser’s requisition.
1.6.2 All drawings and documents shall show the name and logo of Client (HURL) and PMC (Projects and
Development India Limited), Purchaser’s Work No., Item No. and service of the commodity.
1.6.3 Drawings shall be prepared to scale and in third angle projection.
1.6.4 Drawings shall contain:
(1) Title block (Purchaser’s Work No., Requisition No., Item No. and service of the commodity)
(2) Design Data (conforming to Purchaser’s engineering drawings or mechanical data sheets)
(3) Material list (material specifications and quantities for all parts including spare parts)
(4) Nozzle list (conforming to Purchaser’s engineering drawings or mechanical data sheets)
(5) All weld seams, and weld and surface finish symbols
(6) Detailed dimensions and thickness
(7) Weight and capacity
1.6.5 Strength calculations shall cover:
(1) Code calculations for all pressure retaining parts including reinforcements for nozzle openings
(2) Structural calculations for internals
(3) Structural calculations for lifting lugs, tailing lugs and transportation fittings
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(4) Stability check of vessel and support for wind and/or seismic load
(5) Stability check of vessel and support at transportation, loading & unloading and erection
(6) Local stress analysis against external loading on nozzles and lugs
(7) Strength calculation under hydrostatic test condition at shop/site, if applicable.
(8) Local stress analysis at shell around attachments such as lifting lugs/saddles, platform clips, pipe clips etc.
for shop hydrostatic test and transportation etc.
(9) IBR calculation to be furnished for the equipment coming under IBR.
2. DESIGN
2.1 Design Pressure
2.1.1 Design pressure shall be as specified on Purchaser’s engineering drawing or mechanical data sheet.
2.1.2 Design pressure shall mean the gauge pressure at the top of a completed vessel in its operating position. Unless
otherwise agreed in advance, internal static head shall be added to the design pressure to determine the
thickness of any specific part of the vessel.
2.1.3 When design pressure of “F.V. (Full Vacuum)” is specified, vessels shall be designed to withstand for external
pressure of 101.3 kPa.
2.1.4 Unless otherwise specified, vessels normally subject to internal pressure only shall be designed to withstand a
minimum external pressure of 17.2 kPa at the ambient temperature (20 °C).
2.1.5 Vessel parts subject to different internal pressure on both sides shall be designed to withstand the most severe
combination of the pressures.
2.1.6 Maximum Allowable Working Pressure (MAWP) is the maximum gauge pressure at the top of a completed
vessel, which is obtained from the calculations for every element of the vessel based on the actual thickness in
the corroded condition. Supplier shall calculate the MAWP of each vessel, and the calculation shall be
included in design calculations. MAWP shall not be assumed to be the same as the design pressure except for
cases where MAWP cannot be determined by calculation to the applicable code.
2.1.7 MAWP shall be limited by shell / head and not by nozzle reinforcement, pipe schedule, etc.
2.1.8 Hydro testing of equipment shall be as per UG-99b. Design pressure of each nozzles shall be maximum
allowable working pressure.
2.2 Design Temperature
2.2.1 Design temperature shall be as specified on Purchaser’s engineering drawing or mechanical data sheet. Two
kinds of design temperature, one for maximum design temperature (called as “Design Temperature”) and the
other for minimum design temperature (called as “Minimum Design Metal Temperature” = MDMT) are
specified.
2.2.2 MDMT shall be 0 °C, unless otherwise specified on the engineering drawing or the mechanical data sheet.
2.2.3 When different temperatures are predicted for different zones of a vessel, these temperatures are indicated for
the respective zones of the vessel.
2.2.4 When design temperature or MDMT cannot coincide with the maximum pressure, the corresponding design
pressure shall be designated together with the design temperature and MDMT.
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2.2.5 Vessel parts in contact with two fluids having different temperatures shall be designed for both higher and
lower design temperatures.
2.2.6 When the vessel inside is insulated from high temperature fluid, the design temperature may be determined by
heat transfer calculations.
2.3 Corrosion Allowances
2.3.1 Corrosion allowance for the shell shall be as specified on Purchaser’s engineering drawing or mechanical data
sheet.
2.3.2 Unless otherwise specified in engineering drawings, mechanical data sheets or other applicable Engineering
Specifications, the corrosion allowance for internal parts of vessels shall be as follows:
(1) Parts directly welded to the shell or parts not removable from a manhole:
The full specified corrosion allowance shall be added on each side.
(2) Parts removable from a manhole:
The full specified corrosion allowance shall be added on one side only.
Notes: 1. In general, no corrosion allowance is added for high alloy and nonferrous internals.
2. For the internal parts specified in Vessel Standard such as lugs and support rings, corrosion
allowance shall conform to the stipulations stated.
3. The specified corrosion allowance shall mean the corrosion allowance for the shell.
4. Shell as used herein shall mean all pressure retaining parts of the vessel in contact with the
service fluid, including heads, nozzles, manholes and manhole covers.
5. The corrosion allowance on tray shall be in accordance with ES-DZ103 “Fractionating Tray”.
2.3.3 No corrosion allowance is required for parts not in contact with the inside fluid such as the outside surface of
shell, skirt, anchor bolt and so on.
2.3.4 When it is not practicable to provide corrosion allowance by increasing the thickness of base metal, a corrosion
resistant material shall be used in form of solid, cladding or weld overlay construction. Any change of these
construction materials shall be referred to Purchaser for approval.
2.4 Materials
2.4.1 Materials for primary parts shall be as specified on Purchaser’s engineering drawing or mechanical data sheet.
2.4.2 Materials of the parts not specified on Purchaser’s engineering drawings, mechanical data sheet or Vessel
Standard shall be decided by Supplier and shall be submitted by showing them on the Supplier’s drawings for
Purchaser’s approval.
2.4.3 Forging material to be used for pressure vessels shall have adequate impact property, especially for low
temperature service.
For the forging materials weighing over 1,000 kg and thicker than 100 mm in maximum thickness;
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(1) Supplier shall submit the name of steel maker, forging manufacturer, heat treatment supplier and
machining supplier to the Purchaser
(2) Carbon steel forging shall be produced from killed steel and the chemical composition requirements shall
be submitted prior to production to the Purchaser. As a minimum, carbon steel forging shall satisfy the
following chemical composition requirement:
- Mn: 0.9 wt% minimum
- Al : 0.015 wt% minimum
(3) Forging manufacturing plan including forging, heat treatment and quality control procedure shall be
submitted to the Purchaser.
2.4. 4 Materials for external attachments and vessel supports which are directly welded to the vessel shell shall be
made from similar materials as the vessel shell. For the skirt or leg type supports, the top 500 mm (minimum)
shall be selected in the same manner.
In case of low temperature service equipment (design temperature ≤ -45 °C), regardless of providing pad plates
on vessel parts, all external lugs/clips for platform, ladders, insulation supports, pipe supports, name plate
saddles, vessel davits and other non-pressure parts attached to the vessel shall be of the same material as the
vessel shell.
2.4.5 Supplier may propose the use of alternative materials. Such alternatives shall be clearly indicated on his
proposal giving official material designation or the chemical composition and physical properties for such
materials having only a trade or supplier designation, and shall be submitted for Purchaser’s approval.
2.4.6 When post weld heat treatment is required for pressure vessels, all material for pressure holding components
shall be simulation tested with additional two (2) heat treatment cycles. Additional two heat treatments are; one
for PWHT after shop repairing and the other for future PWHT at site.
2.4.7 For coarse grained & high tensile materials in carbon steels ( UTS>45 Kg/mm2) & low alloy steel, guaranteed
impact strength shall be ensured at a temperature 15 0C below envisaged hydraulic test temperature as a
precaution against brittle fracture during hydraulic test.
2.4.8 All carbon steel materials including forging used for pressure parts shall be procured in fully killed and
normalized condition. All low alloy steel materials including forging used for pressure parts shall be procured
as permitted in ASME sec. II part A.
However, carbon steel & low alloy steel materials above 50 mm thickness shall be vacuum degassed except for
plate ring flanges.
2.4.9 All Stainless steel plates shall be hot rolled & solution annealed and pickled as per SA 480.
2.4.10 Unless more restrictive prescription given by material specification, the max. content for carbon steel used for
fabrication as shown by ladle analysis shall be 0.23% for plates, pipes & tubes and 0.25% for forging.
2.4.11 In order to minimize the effect of temper embrittlement for material to 2¼ Cr 1 Mo specifications in the
temperature range of 375-575oC, the embrittlement factors 'X' & 'J' shall be limited to:
X = (10P + 5Sb + 4Sn + AS) / 100 ≤ 15

The elements above are expressed as ppm
J = (Si + Mn) (P + Sn) x 104 <160

The elements above are expressed as percentages
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A stimulated PWHT followed by step cooling shall be performed on a sample of material. Acceptable
toughness shall be demonstrated by means of a Charpy V Impact Test.
2.4.12 Unless otherwise specified Copper & Copper alloys shall not be used. Copper content up to 0.4% are
acceptable in carbon steel & 0.6% in stainless steel.
2.4.13 Steel for Hydrogen service at elevated temperature & pressure shall be selected as per API 941 & API 934 .The
following special requirements shall be met with for Hydrogen/Sour gas as per NACE standard.
a) All pressure parts shall be post weld heat treated.
b) All pressure retaining welds shall be 100% radiographed. (Root run & final weld radiography is must)
c) Hardness of base metals, weld and HAZ shall not exceed 22 HRC.
2.4.14 For high pressure equipment (design pressure 100 kg/cm2g and above), in shell & heads, the impurity limit
shall be Copper ≤ 0.20% & Nickel ≤ 0.30% for Mo & Cr- Mo low alloy steels while Copper shall be ≤ 0.20%
& Vanadium ≤ 0.15% for carbon steels.
2.4.15 Inter granular corrosion test shall be carried out on all SS 316 L materials, weld & HAZ as Per ASTM A 262
practice E (Strauss test) unless otherwise specified in specification
2.4.16 For equipment designed as per IBR, material shall strictly comply with the requirement of the IBR code.
2.4.17 For SS 316 & 316L, SS316L Mod (Urea Grade) materials and for other specialised urea grade materials, the
requirements of ferrite content and Intergranular corrosion test, shall have to be complied with in conformity
with Process Licensor’s standard. The inter granular corrosion test shall be carried on SS316 L mod (Urea
Grade) materials for other specialised urea grade materials, weld & HAZ as per ASTM A 262 practice C &
while for SS316L material ASTM A 262 practice E shall be applicable. The corrosion rate shall be as per the
recommendations of Process Licensor.
2.4.18 For SS 316 & 316L material Ferrite content for plate, pipe, tubes and forging shall be max. 2%. However, for
SS 316L Urea grade and for other specialised urea grade materials, ferrite content shall be max. 0.6%.
2.4.19 In case of equipment fabricated of materials of SS316L for urea service, low ferrite filler material shall be so
selected that ferrite content in two subsequent pass in contact with process fuel shall be max. 2% and for
equipment fabricated of material SS316L urea grade, the limitation of ferrite content shall be 1%. The welding
not in contact with process fluid may have ferrite content limited to 6%.
2.5 Loading Conditions and Strength Calculations
2.5.1 The thickness indicated on Purchaser’s engineering drawings are those proposed by Purchaser. Supplier shall
check and confirm under his guarantee that such thickness provide the proper strength under the specified
conditions. Any lesser thickness considered by Supplier shall immediately be referred to Purchaser, but in no
case, any proposed thickness will be decreased without Purchaser’s prior approval, even if it has an extra
margin beyond the required thickness.
2.5.2 Lining, cladding and weld overlay thickness shall not be considered to contribute to the strength of pressure
parts.
2.5.3 The following loading conditions shall be considered in designing of pressure vessels, vessel supports and
anchor and/or setting bolts.
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(1) Operating condition
The loading shall include those from:
(a) Internal or external design pressure

(b) Weight of vessels and contents at operating condition (including static head of liquids)
(c) Weight of insulation and fire proofing
(d) Weight of piping, platform and other attachments
(e) Weight of combined equipment, if specified
(f) Reactions from piping systems, if specified
(g) Cyclic or dynamic reactions from combined equipment, if specified
(h) Wind or seismic load (Not necessary to consider simultaneously)
(i) Deleted
(2) Erection condition
(a) Weight of vessels and contents at erection

(b) Weight of piping, platforms and other attachments, if any (See Note)
(c) Weight of combined equipment, if specified
(d) Wind or seismic load whichever is greater
Note: Erection of the tall tower is usually done under the fully dressed up condition. Supplier shall
confirm the extent of dress up to Purchaser.
(3) Testing condition (in the installed position and corroded condition)
(a) Test pressure

(b) Weight of vessels and contents at testing condition (including static head of liquids)
(c) Weight of insulation and fire proofing
(d) Weight of piping, platform and other attachment
(e) Weight of combined equipment, if specified
(f) 25% wind load.
Note: The hydrostatic test in the installed position shall be considered for all vessels unless otherwise
specified.
Weight of removable internals such as tray, packing, catalyst support, etc. can be excluded in the
hydrostatic test in the installed position, unless otherwise specified.
(4) Transportation condition
The equipment and its supports (fixed or temporary) and any shipping lashing points shall be designed in
order to withstand the following loads during transportation.
Longitudinal 0.6g
Transverse 0.7g
Vertical upwards 0.2g
Vertical downwards 1.5g
(Where, g = 9.81 m/s2)
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The following shock factor shall be applied to any ship’s deck lashing point that is added to the
equipment, unless otherwise specified;
1.50: for equipment lifting weight 100 ton and less

1.25: for equipment lifting weight exceeding 100 ton
Saddle skid for transportation shall be designed considering the following;
1) No interference between external attachments and ground

2) Ship load bearing capacity
3) Inland transportation requirements
4) Lay down and dress-up at site prior to erection
2.5.4 Wind load shall be calculated in accordance with Indian Standard IS 875-2015 (Part 3) with the following
factors. Wind forces will be increased by 20% to cater the effect of piping, platform and ladders etc.
- Vb (Basic wind speed): 47m/sec
- Terrain for the site: Category 2
- k1 (Probability factor (risk coefficient): As per Standard
(Mean probable design life: 50 years)
- k2 (Terrain, height and structure size factor): As per Standard
- k3 (Topography factor): 1.0
- k4 (Importance factor): 1.0
2.5.5 Wind forces shall be increased by 20% to cater for the effect of piping system, platforms and ladders etc.
Vertical vessels with height/diameter ratio equal to or greater than 10 shall be analyzed for vibration due to
vortex shedding when critical wind speed does not exceed 30m/s. For guidelines of Dynamic Wind Analysis
refer Appendix-C.
2.5.6 Seismic load shall be calculated in accordance with Indian Standard IS 1893-2016 (Sixth revision Part-1) and
IS1893-2015 Part 4 with the following factors.
- Soil profile type: Medium
- Equipment category: As per Table-6 of IS1893-2015 (Part-4)
- Z (Zone factor): 0.24 (Zone IV)
- R (Response reduction factor): As per Standard
- I (Importance factor): As per Table-3 of IS1893-2015 (Part-4)
2.5.6 Deleted.
2.5.7 Classification and evaluation of stresses at various loading conditions shall be done in accordance with the
applicable codes and standards. Higher allowable stresses may be used if allowed by applicable code
according to the category of the stresses for short time and local loads.
2.5.8 Allowable tensile stress of foundation bolts of SA307 Gr.B shall be 120 N/mm2 for long-term and 150 N/mm2
for short-term loading conditions (e.g. seismic and wind loading conditions).
2.5.9.1 Local stresses at shell around attachments such as vessel support, lifting lug and so on, shall be calculated and
evaluated.
The following generally accepted calculation procedure, or the equivalent, may be applied.
(a) Bulletin of Welding Research Council No. 107/537 or 297

(b) Deleted.
(c) Finite Element Analysis
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2.5.9.2 Local stresses at shell around attachments such as nozzle shall be calculated and evaluated as per followings:
(a) WRC Bulletin no.107 Local Stresses in Spherical & Cylindrical Shells due to External Loadings
(b) WRC Bulletin no.297 Local Stresses in Cylindrical Shells due to External Loadings on Nozzles
(c) WRC Bulletin no.537 and / or Finite Element Analysis with validation report
2.5.10 For tray towers or packed towers, the maximum shell deflection at the top of the shell shall be limited to 0.005
x Vessel total height from the base plate. For guidelines of Dynamic Wind Analysis refer Appendix-C.
2.6 Tolerances
2.6.1 Tolerances shall be in accordance with Appendix B “Inspection Requirement” unless otherwise specified on
Purchaser’s engineering drawings. However, tolerances mentioned in Appendix B shall not exceed the limits
mentioned in the applicable code.
2.6.2 The thickness after forming of any pressure retaining parts shall not be less than the calculated thickness.
Plates with an under tolerance of not more than the smaller value of 0.25 mm or 6 % of the nominal thickness
may be used, unless requested otherwise by the applicable code.
3. DETAILED DESIGN
3.1 Shells and Heads
3.1.1 The shape of the formed head shall be as specified on Purchaser’s engineering drawing or mechanical data
sheet. 2:1 ellipsoidal or hemispherical head shall be used, in general.
3.1.2 The nominal thickness of 2:1 ellipsoidal or dished head shall be selected to assure that the minimum thickness
after forming shall not be less than the minimum required thickness of head. Also, the nominal thickness shall
not be less than the minimum required thickness of connecting cylindrical shell.
3.1.3 Gasket contact surface of girth flange shall have a serrated concentric or serrated spiral finish equivalent to the
following in µm.
(1) For sheet gasket : Ra 3.2

(2) For spiral wound gasket : from Ra 3.2 to Ra 6.3
(3) For metal jacket, solid metal gasket : Ra 1.6 and finer
3.2 Internals
3.2.1 Unless otherwise specified in Purchaser’s requisition or indicated on Purchaser’s engineering drawings, all
internals are included in the scope of Supplier’s supply except packing and valve trays. Supplier shall design
internals in accordance with the information indicated on Purchaser’s engineering drawings.
3.2.2 Unless otherwise specified, removable internal parts shall be designed for installation / removal from the vessel
through the nearest upper manhole. Demister, however, may be installed / removed through the nearest lower
manhole or openings. The weight of one block to be withdrawn shall not generally exceed 400 N with the
exception on the internal support beams.
3.2.3 All removable internals shall be checked by suitable methods to ensure that they are able to pass through the
manhole. Extra care shall be given to the design of hold-down gratings which are inserted after the packing is
installed.
3.2.4 Supplier shall provide the detailed design of gratings and their supports, demisters, etc. according to
Purchaser’s information.
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3.2.5 Trays, distributors, baffles and support beams shall be so designed not to restrict deformation of the shell due to
operating pressure and thermal expansion.
3.2.6 Demisters shall be securely fastened to the support ring by bolting or clamping.
3.2.7 Plate-type internal flanges for feed pipe distributors / internal pipes may be used in accordance with Vessel
Standards.
3.2.8 Internal bolts subject to vibration, fluctuating load, impact load or dynamic load shall be protected against
loosening. Double nuts, anti-loose washers, tack welding, etc. shall be used.
3.2.9 Support bar on tray sloped downcomer shall not be manufactured by bending but welded with plate materials.
3.3 Nozzles and Manholes
3.3.1 Nozzle and manhole size shall not be changed by Supplier. However, if nozzles, reinforcement pads, and main
seams interfering with each other, Supplier shall immediately inform Purchaser of any deviation for approval.
3.3.2 The type, rating and facing of nozzle flanges shall conform to those specified in Purchaser’s engineering
drawing or mechanical data sheet.
3.3.3 Each manhole cover with weight over 200 N shall be supported by a davit or hinge as specified on Purchaser’s
engineering drawing. The details of davit or hinge shall be in accordance with Vessel Standard.
3.3.4 Nozzle flanges 24 inch and smaller shall be as per ASME B16.5. Nozzle flanges larger than 24 inch nominal
shall be as per ASME B16.47 Series B or designed per ASME Section VIII Division 1. In case a non standard
flange is designed by Supplier, the companion flange with bolt, nut and gasket shall be supplied by Supplier.
3.3.5 The nozzle neck thickness shall be selected in accordance with Vessel Standard duly supported by mechanical
calculation and complying minimum requirement of applicable code, based on material, nominal size, flange
rating and corrosion allowance. The pipe materials for nozzle neck shall be seamless, unless otherwise
approved by Purchaser.
3.3.6 Unless otherwise specified, the nozzle gasket surface shall be serrated concentric or serrated spiral finish
having a resultant surface finish 3.2 to 6.3μm average roughness except tongue and groove (T&G) or ring type
joint.
3.3.7 When male and female (M&F) or tongue and groove (T&G) type flanges are specified, the nozzle flange facing
of the vessel shall be of female or groove type.
3.3.8 All nozzles shall be flushed with the inside surface of the vessel unless otherwise specified on Purchaser’s
engineering drawing.
3.3.9 Nozzles to be welded directly to the connecting piping will be indicated on Purchaser’s engineering drawings.
Caps for pressure testing shall be attached to the nozzles by welding. After the pressure testing the caps shall
be cut off, and the nozzles shall be machined to form the specified welding bevel.
3.3.10 All nozzle connections up to DN 10” size shall be made of seamless pipes. For sizes above DN 10” nozzles
connection may be rolled from plates with full (100%) radiography of welds.
3.4 Openings
3.4.1 The opening reinforcement shall be so designed as not to limit MAWP of the vessel. Refer to Par.2.1.7.
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3.4.2 Nozzles made of pipe or plate and sized 2 inch nominal and larger shall generally be provided with
reinforcement plates. Each reinforcement plate shall be provided with at least one tell-tale hole of NPT 1/8
inch.
Long weld neck (LWN) type nozzle may be used without reinforcement pad up to 3 inch nominal.
3.4.3 The reinforcement for the nozzle opening shall be of integral type, when required by the applicable codes
and/or standards or where any of the following conditions are met:
(1) Design temperatures exceeds 450 °C

(2) Design pressure exceeds #600 class flange rating (*)
(3) Design temperature exceeds 350 °C and design pressure exceeds 3 MPaG
(4) Plate thickness exceeds 50 mm
(5) Size 1-1/2 inch and below
(*) Nozzle size 3” NPS and above, shell to Self-Reinforced nozzle welding shall be set-in type welding.
3.4.4 Supplier shall perform local stress analysis for vessel related to external force and moment onto nozzles
specified below or the calculated piping external force and moment, which is more stringent;
Table 1. Nozzle to Shell Loading
Flange Rating
Piping Loads Unit
150 lb 300 lb 600 lb 900 lb 1500 lb 2500lb
Axial Tension /
P kN 1.2 x D 1.4 x D 1.6 x D 3.6 x D 6.0 x D 6.6 x D
Compression Force
Circumferential
VC kN 0.9 x D 1.05 x D 1.2 x D 2.7 x D 4.5 x D 4.95 x D
Force
Longitudinal Force VL kN 1.2 x D 1.4 x D 1.6 x D 3.6 x D 6.0 x D 6.6 x D
Circumferential
MC kN-m 0.06 x D2 0.07 x D2 0.08 x D2 0.18 x D2 0.3 x D2 0.33 x D2
Bending Moment
Longitudinal
ML kN-m 0.078 x D2 0.091 x D2 0.104 x D2 0.234 x D2 0.39 x D2 0.429 x D2
Bending Moment
Torsional Moment MT kN-m 0.09 x D2 0.105 x D2 0.12 x D2 0.27 x D2 0.45 x D2 0.495 x D2
Table 2. Nozzle to Head Loading
Flange Rating
Piping Loads Unit
150 lb 300 lb 600 lb 900 lb 1500 lb 2500lb
Axial Tension /
P kN 1.2 x D 1.4 x D 1.6 x D 3.6 x D 6.0 x D 6.6 x D
Compression Force
Resultant
VR kN 1.5 x D 1.75 x D 2.0 x D 4.5 x D 7.5 x D 8.25 x D
Shear Force
Resultant
MR kN-m 0.098 x D2 0.114 x D2 0.130 x D2 0.294 x D2 0.49 x D2 0.54 x D2
Bending Moment
Torsional Moment MT kN-m 0.09 x D2 0.105 x D2 0.12 x D2 0.27 x D2 0.45 x D2 0.495 x D2
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Where D = Nominal Diameter of Nozzle in inch
See Par.2.5.9 for calculation procedures.
3.5 Alloy Lining
3.5.1 Alloy lining shall be either integrally clad plate or overlay weld metal. The minimum effective alloy thickness
shall be 3 mm unless otherwise specified on the engineering drawing or the mechanical data sheet. Lining is
acceptable only when specified by the process licensor in the process datasheet due to Process requirement.
3.5.2 Nozzles attached to alloy lined shell shall be alloy-lined by integrally cladding or overlay welding with
exception in Par. 3.5.3 and Par. 3.5.4.
3.5.3 Solid austenitic stainless steel nozzles may be welded to ferritic shells in case of the following. When postweld
heat treatment is required, such nozzles shall be made of stabilized stainless steel or low carbon grade and
welded by Inconel filler metal.
(1) Nozzle size is 2 inches and smaller with design temperature 400 °C and lower
(2) Nozzle size is 4 inches and smaller with design temperature 250 °C and lower
3.5.4 Loose metal lining may be used for the nozzles of the following.
(1) Nozzle size is 4 inches and smaller with design temperature 400 °C and lower.
(2) Nozzle size is 6 inch and larger with design temperature range of -10 °C to 250 °C
Expansion ring shall be provided when the design temperature exceeds 250 °C. Each segment divided by liner
welds shall be provided with tell-tale holes with threaded end for plugging.
When postweld heat treatment is required, such sleeve liner shall be made of stabilized stainless steel or low
carbon grade and welded by low carbon grade stainless filler metal. One end of loose sleeve liner shall be
welded after postweld heat treatment.
3.5.5 Tube sheets shall have a nominal clad or weld overlay thickness of 3/8 inch (10 mm) but not less than5/16
inches (8 mm) regardless of shell side or tube side face. The minimum thickness of clad or weld overlay at a
pass partition groove shall be 1/8 inch (3 mm) minimum.
3.5.6 Weld overlayed nozzle and girth flange gasket faces shall have a minimum thickness of 3/16 inch (4.8 mm)
after machining.
3.6 Bolts, Nuts and Gaskets
3.6.1 Unless otherwise specified, all bolting threads to be used for pressure vessels shall be ISO Metric System.
When bolt size are M30 and over, metric fine screw threads of 3 mm pitch series shall be used. When bolt size
is M27 and less, metric coarse screw threads shall be used. Girth flange bolting shall be of stud bolt type,
threaded full length, and at least M16 for flange of 600 mm and smaller inside diameter and at least M20 for
over 600 mm inside diameter flange.
3.6.2 Any gaskets which contain Asbestos shall not be used.
3.6.3 The hardness of metal gaskets shall not exceed the values in the following table. Supplier shall confirm this
hardness is lower than those of gasket contact surface.
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Gasket Materials Brinell Hardness

Soft iron, Low Carbon Steel and Nickel 120
5 % Cr - 1/2 % Mo Steel 140
Austenitic Stainless 160
3.6.4 Threads of bolts and nuts shall be coated before installation with anti-galling agent.
3.6.5 Application of hydraulic bolt tensioning shall be considered in design of subject flanges/bolts for bolt M48 and
over. Stud bolts requiring tensioning shall be supplied with additional length of thread equal to at least one (1)
bolt diameter to accommodate bolt tension heads. End caps of steel material shall be provided to protect screw
threads from damage and corrosion. Flange hub details and nut space shall allow for the use of tensioning
equipment.
3.6.6 Gaskets for all medium with flange rating ≤ 600 # shall be SS spiral wound type with external & internal guide
rings shall be used unless otherwise specified. CAF (compressed asbestos fiber) gaskets are not acceptable.
3.6.7 Gaskets used for high pressure shall be of the following type:
- Ring Joint
- Double conical with graphite tape
- Diaphragm gasket
- Lip seal Gasket
3.6.8 Unless otherwise specified in engineering drawing or process data sheet, the gaskets used during testing shall
be same as specified for operating conditions. After hydro testing, gaskets used during testing shall be replaced
by new gaskets in Vendor’s shop.
3.7 Supports
3.7.1 Skirt shall be so designed that the both ends are continuously welded to the head and/or shell and the base ring
respectively.
3.7.2 The joint of the skirt to head and/or shell shall be designed and welded so as to prevent excessive stress
concentration.
3.7.3 Flanged connections shall not be provided inside the skirt unless otherwise specifically required.
3.7.4 Skirt shall be provided with vents and access holes as indicated in engineering drawings or in Vessel Standard.
3.7.5 Saddles, lugs or legs for pressure vessels shall be minimum as per the tables in Vessel Standard. Strength
calculation shall be submitted as per design condition considering design parameters such as wind, seismic,
combined loading etc.
3.7.6 Supports for low temperature horizontal vessels with the operating temperatures lower than -20 °C shall be
provided with wooden pillows according to Vessel Standard.
3.8 Miscellaneous
3.8.1 External shell attachments such as lifting lugs, clips for platforms and/or ladders and piping supports, insulation
support rings, etc. shall be provided as required.
3.8.2 Tailing lugs shall be provided for all vertical vessels supported by skirt. When erection weight of vertical
vessel is 1,000 kN and over, two tailing lugs shall be provided. The orientation of tailing lug shall be 90°apart
from trunnions / lifting lugs. Stiffener beam to base ring at tailing lug points shall be provided as per Vessel
Standard.
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3.8.3 Lifting lugs and tailing lugs shall be designed taking account of vessel weight and lifting method, etc. Supplier
shall decide location of lifting lug/tailing lugs in order to avoid interferences between lifting wires and external
attachments (such as platform, ladder, and nozzles) during erection. Materials, procedures of welding them to
the shell and inspection method shall also be carefully checked. The shock factor of 2 shall be considered in
the design of lugs and shell, unless otherwise specified.
3.8.4 For site assembling vessels, lifting lugs or jigs shall be provided for each block of vessel. After the assembling,
the lugs and jigs shall be cut off, in general. After cutting, MT or PT shall be performed for the cutting area.
3.8.5 Plate type lifting lugs shall be provided, in general. Trunnion type lifting device needs Purchaser’s approval.
3.8.6 According to Purchaser’s information, Supplier shall check the strength of the vessels during transportation and
field erection, and provide necessary reinforcements prior to shipment. The shock factor specified on 2.5.3 (4)
shall be considered in these designs. Supplier shall submit such strength calculations to Purchaser.
3.8.7 When specified in Purchaser’s requisition, Supplier shall design platforms & ladders and lugs for them in
accordance with Purchaser’s platform & ladder arrangement drawings and standard drawings. Supplier shall
submit fabrication drawings of platform & ladder and their support clips to Purchaser for approval prior to
welding of clips to shell. Support clips shall be welded to vessel by Supplier at shop.
3.8.8 Vessels shall be provided with two earth lugs, unless otherwise specified.
3.8.9 Lifting device shall not cut off after installation.
3.8.10 Design of supports and anchor bolts considering soil and importance factors shall be performed for
compressive and tensile loading. In no case shall diameter of anchor bolts be less than M24 for skirt support
and M16 for other type of support.
4. FABRICATION
4.1 Plate Layout
4.1.1 Shell plates shall be arranged in such a way that there are minimum numbers of welded seams.
4.1.2 Longitudinal and circumferential welded seams shall be arranged so as not to interfere with nozzle openings,
reinforcement plates and saddle pads, as far as possible. If, due to unavoidable reasons, welded seams are
covered with reinforcement plates or saddle pads, then after obtaining Purchaser’s approval, they shall be
ground flush with shell surface and radiographically examined for a length of “minimum three times the
diameter of the opening” or “pad width plus 50 mm beyond the filled weld of pad to shell” whichever is
greater, prior to welding of plates or pads.
4.1.3 Longitudinal welded seams on adjacent shell segments shall be separated by at least 4 times the wall thickness
of the thicker plate but not less than 100 mm.
4.1.4 Longitudinal and circumferential welded seams shall be kept away from the internal welds insofar as practical,
and shall be so located that they can be easily inspected with internals in place.
4.2 Forming
4.2.1 Selection of hot or cold forming of materials may be made by Supplier, but heat treatment after forming shall
conform to the requirements of applicable material specifications.
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4.2.2 Despite of Par. 4.2.1, low alloy steel of 50mm and over in thickness shall be subjected to hot forming. Cold
forming shall not be employed unless otherwise approved by Purchaser.
4.2.3 Despite of Par. 4.2.1, austenitic stainless steel including clad plate shall be subjected to cold forming, unless
otherwise approved by Purchaser.
4.2.4 (a) A formed head shall generally be made from a single plate. However, heads with one chordal weld seam are
acceptable. In such cases, the chordal seam shall preferably be in the middle one third of the blank plate.
Intermediate heat treatment, if considered necessary, shall be carried out by Vendor.
(b) Whenever a head is made of more than two plates, it must have a crown plate. Whenever a nozzle or a
manhole is positioned at the center of the dished end, the crown plate should be larger than the nozzle
/manhole reinforcing pad.
(c) In cases where multiple plates as mentioned in 4.2.4(a) & (b) are welded together to produce a large formed
head, the welding joints shall be examined by 100% Full RT before and after forming.
4.2.5 When type 304 stainless steel is used for formed head in low temperature service, following additional
requirement shall be satisfied;
(1) When cold forming is applied, material shall be changed from type 304 stainless steel to type 304L
stainless steel.
(2) When hot forming is applied, solution annealing heat treatment shall be done on formed head.
4.2.6 When temporary attachments are required during the forming work, they shall be welded to the shell plate or
head plate using the same welding procedures as for the main seams. After removing these attachments, the
surface shall be ground flush and examined by magnetic particle method. In case of high alloy steel or non-
ferrous materials, liquid penetrant method can be substituted.
4.3 Welding
4.3.1 Welding shall comply with HURL-ED-C00-STA-SPC-000-D106 “General Welding Requirements for Pressure
Containing Equipment”.
4.3.2 Supplier shall obtain Purchaser’s approval before welding starts.
4.3.3 “Approved welding processes” and “other welding procedures that require prior approval of Purchaser” shall
be in accordance with Par.3.1 on HURL-ED-C00-STA-SPC-000-D106. Restrictions on application of FCAW
shall be in accordance with Table 1 on HURL-ED-C00-STA-SPC-000-D106.
4.3.4 Welding procedure qualification shall be in accordance with specified code & standard and par.5 on HURL-
ED-C00-STA-SPC-000-D106. Welder and welding operator qualification shall be in accordance with specified
code & standard and Par.6 on HURL-ED-C00-STA-SPC-000-D106.
4.3.5 A proposed Welding Procedure Specification (WPS) shall be submitted to an approved inspection agency for
approval. On approval, a Procedure Qualification Test (PQT) shall be conducted which shall be witnessed by
approved inspection agency. On acceptance of all tests as per ASME Section IX, a final WPS along with
Procedure Qualification Record (PQR) shall be submitted. Production welding shall start only after approval of
final WPS/PQR and qualification of welders as per ASME Section IX, approved inspection agency may accept
previously qualified WPS/PQR at his sole discretion.
4.3.6 Weld seams for pressure retaining parts shall normally be full-penetration double-welded butt joints. Single-
welded butt joints which ensure full-penetration may be used, where double-welded butt joints are impractical.
Butt joint with backing strip requires Purchaser’s approval.
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4.3.7 Welding consumables shall be in accordance with par.4 on HURL-ED-C00-STA-SPC-000-D106. Welding

consumables shall have chemical compositions and mechanical properties equal to or of higher grade than the
base material except for 9%Ni-steel welding electrodes.
4.3.8 Welding procedures shall be selected to minimize the residual stresses.
4.3.9 Preheating and interpass temperature shall be in accordance with Par.9.1 on HURL-ED-C00-STA-SPC-000-
D106.
4.3.10 Dissimilar metal welding shall be in accordance with Par.7.2 on HURL-ED-C00-STA-SPC-000-D106.
4.3.11 Dissimilar metal welding of stainless steel to carbon steel or low alloy steel in pressure retaining butt weld shall
be carried out in the following manner.
(1) Filler metal of Inconel 182 : For joints where PWHT is required or design temperature over 350 ºC.
(2) Filler metals of E309, E309L : For first layer of joints where no PWHT is required and design
E309Mo, E309MoL temperature is less than 350 ºC.
Note: The welding method and welding parameters of the dissimilar weld overlay shall be carefully selected to
control the dilution and micro-structure of the weld deposit to avoid any cracks. 20 000 J/cm is
allowable maximum heat input for the first layer of pressure retaining dissimilar butt weld.
4.3.12 The minimum bead length for low alloy and high alloy steel shall be 80 mm.
4.3.13 When joining alloy-clad plate, the alloy layer shall be stripped for a minimum distance of 8 mm from the bevel
to assure the sound weld joint of base materials. If Supplier would propose other procedure, the details of it to
assure the sound weld joint of the base material shall be referred to Purchaser for approval. The thinning of
base metal due to this clad stripping is not necessary to consider in the shell thickness calculations if the
thinning is within the smaller of 1.0 mm or 10 % of the base metal nominal thickness.
4.3.14 Production control coupons, when required as per code and/or specification, shall be subjected to all test like
impact, inter granular corrosion test etc. in addition to mechanical test as required. In case of heat treated
equipment, test coupons shall be given similar heat treatment as for the equipment.
4.4 Heat Treatment
4.4.1 Unless otherwise stated, postweld heat treatment shall be carried out in accordance with the applicable codes or
standards.
Carbon steel pressure vessel for minimum operating temperature of -29 °C or less shall be subjected to
postweld heat treatment.
4.4.2 No welding shall be performed on vessels after the final postweld heat treatment without Purchaser’s approval.
4.4.3 When clad steel or dissimilar metal welded parts are heat treated, the heat treatment procedure shall be
submitted for Purchaser’s approval.
4.4.4 The gasket faces of girth flanges, manhole flanges and nozzle flanges shall be inspected after final heat
treatment for free from defects such as warpage, distortion, oxidation, etc. If necessary, the flange faces shall
be machined to achieve the desired surface finish and/or tolerance.
4.4.5 Heat treatment of formed parts shall be carried out as per following:
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(a) For Carbon Steel:

(1) Cold formed dished ends or knuckles up to 16 mm nominal thickness shall be stress relieved.
(2) Cold formed dished ends or knuckles above 16 mm nominal thickness shall be normalized.
(b) For Low alloy Steel: Cold Formed Dish ends or Knuckles shall be stress relieved.
(c) Hot formed dished ends or similar parts, which have not been uniformly heated in the normalizing range in
the final stages of manufacture, shall be normalized.
(d) When the completed vessel involves post weld heat treatment, heat treatment recommended in (a)(1) above
shall not be applicable.
(e) Vessels in caustic service, Amine or Sour gas service shall be stress relieved.
(f) All internal and external attachments, clips, insulation studs, name plate bracket, and the like shall be
welded to the vessel before post weld heat treatment.
4.4.6 PWHT of complete vessel shall be carried out in one go in a furnace. Local stress relieving of weld joint in
multiple pieces shall be avoided as far as possible.
4.5 Miscellaneous
4.5.1 Materials to be used by the supplier of pressure vessels shall be suitably stored and protected against damage
and/or corrosion. Stainless steel material shall be stored under roof and protected from the contamination of any
harmful substances such as chloride and zinc.
4.5.2 Stainless steel materials shall be segregated from carbon steel materials to prevent carbon contamination.
5. INSPECTION AND TESTS
5.1 All pressure vessels shall be inspected and tested in accordance with the applicable local regulations, applied
code and Appendix B “Inspection Requirements” unless otherwise specified on Purchaser’s engineering
drawings and/or inspection and test requirements on the requisition.
5.2 Supplier shall submit inspection & test plan (ITP) and a detailed procedure of inspection and test for
Purchaser’s approval.
5.3 Purchaser and his designated representative shall have the right to witness inspection and test to be performed
by Supplier.
5.4 Positive Material Identification shall be applied to alloy materials for the pressure retaining parts according to
ES-RZ204 “Positive Materials Identification (PMI) at Vendor’s or Supplier’s Shop”.
5.5 All raw materials shall be inspected at source and test certificates to enable proper identification shall be
submitted.
6. NAMEPLATES, PAINTING AND MARKING
6.1 Nameplates
A nameplate as shown in Vessel Standard shall be mounted on each vessel. Mounting on the removable parts is
prohibited.
6.2 Painting
6.2.1 As a rule, all external surfaces of vessels shall be painted in accordance with Painting Requirements in spec.
HURL-PP-C00-CPL-SPC-000-0001, except the following, unless otherwise specified in the project painting
specification.
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A. Surface of Stainless Steel and high alloy steels; See Par. 6.2.2
B. Gasket contact surface; See Par. 6.2.3
6.2.2 Outside surface of high alloy steel vessels shall be coated by easy removable type (zinc free) protective coating
to avoid chloride stress corrosion cracking by sea water during transportation, in case of no permanent painting,
on deck transportation and any project specific requirement.
6.2.3 All flange faces and other machined surfaces shall be coated with a readily removable rust preventive paint.
6.2.4 Weld bevels on the end of carbon steel and low alloy steel which are to be welded at site shall be coated on the
inside and outside for a distance of 75 mm from the end of the steel with Deoxyaluminite, Taseto Silver or
equivalent.
6.2.5 Outside of gasket shall be painted by yellow color when temporary gaskets are used during transportation.
6.2.6 Temperature indicating paint shall be coated on outside surface of internal refractory lined pressure vessels to
monitor metal temperature of pressure parts during operation, in case design metal temperature lower than
internal fluid temperature is determined by temperature profile calculation for the composite steel pressure
parts and refractory lining. Color change temperature for temperature indicating paint shall be determined by
the Purchaser.
6.3 Marking
6.3.1 Each Pressure Vessels shall be marked in accordance with HURL-ED-C00-STA-SPC-000-D123 “Vessel
Standard”.
6.3.2 Vendor shall mark tangent lines, the position of the main axis and the center of gravity for orientation in a
clearly identifiable and permanent way on the vessel. Centre of gravity shall be clearly marked.
6.3.3 Orientation of longitudinal seams and position of circumferential seams shall be clearly marked in the
fabrication drawing. Nozzles, support and other attachments shall be located clear of welded joints.
6.4 Pickling and Passivation
All stainless steel material shall be Pickled & Passivated as per following procedures:
(a) Pickling: Aqueous pickling solution shall be as follows:

Nitric acid (Tech grade)-10 to 25% plus Hydrofluoric acid-1 to 8% (to be used only for stabilized SS
grades). Temperature 50 to 60° C for 10% Nitric acid and 20° C for 25% Nitric acid. When size and
shape of product permit, total immersion in the pickling solution is preferred. Where immersion is
impractical, pickling may be accomplished by wetting the surface by;
i) Swabbing or spraying
ii) Partial filling the item with pickling solution and rotating or rocking so that the entire surfaces receive
the required chemical treatment.
The maximum period for which the pickling solution shall be allowed to remain on the surface is 30
minute. During pickling, removal of oxides may be hastened by brushing with a hard fiber or stainless
steel wire brush. Over pickling shall be avoided.
The pickling agent shall be washed off with plenty of water so as to leave no trace behind.
(b) Passivation:
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After pickling and water rinsing, an aqueous caustic permanganate solution containing NaOH 10 weight %
and KMnO4 4 weight % shall be used for neutralizing pickling solution. This shall be followed by
thorough water rinsing.
Water used for pickling and washing shall not have chloride contents exceeding 30 ppm.
7. PACKING AND SHIPPING
7.1 General
Packing and shipping shall be in accordance with Engineering Specification HURL-PP-C00-TRS-PRC-000-0001

“Shipping Instructions”, HURL-PP-C00-TRS-PRC-000-0002 “Packing and Marking Instruction” and the
following additional requirements.
7.2 Packing and Preparation for Shipping
7.2.1 After hydrostatic test, it shall be duly inspected and recorded that all the vessels are dried up by draining and
air blowing, thoroughly cleaned inside and outside and free of all dirt and loose foreign materials. All process
equipment shall be supplied with nitrogen filled. In case of equipment assembled and welded at site, it shall be
filled with N2 after testing at site. Dry Nitrogen shall be filled at a pressure of 0.5 Kg/cm2g and equipment
shall be fitted with a pressure gauge and valve along with nitrogen cylinder.
7.2.2 All flanged openings shall be provided with bolted steel cover of minimum 4.5 mm thickness with rubber
gaskets. Number of bolting is one fourth of the service bolt but not less than 4 sets. Gap between flange and
steel cover shall be sealed by tapes for protection against water.
7.2.3 All beveled openings shall be covered or capped to protect the inside from rust and moisture. The welded
cover or cap shall be so designed to protect the weld bevel and to be removed easily at site.
7.2.4 Deleted.
7.2.5 Spare parts shall be packed separately from the vessels.
7.2.6 Tell-tale holes on the outside of vessels shall be plugged with hard grease.
7.2.7 Unless otherwise specified on Purchaser's document, gaskets for shipping for girth flange, manhole, hand hole
or nozzle with blind flange shall be as follows;
(1) For girth flange:
Service gasket shall be used for the hydrostatic test. Girth flange joint shall not be opened after hydrostatic test
and to be shipped as it is.
(2) For manhole, hand hole or nozzle with blind flange:
Test gasket which is same as service gasket shall be used for hydrostatic test and service gasket which is not
counted as the erection spare parts shall be delivered separately.
Test gasket used for hydrostatic test can be shipped as it is. Test gasket will be replaced with service gasket at
plant site by Purchaser, as a rule, after opening of these flanges for inside inspection or installation of the
internals or else. When flange is opened by Supplier after hydrostatic test, used test gasket can be re-used as
shipping gasket provided such gasket is clearly marked with yellow paint for replacement at site.
7.3 Shipping
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7.3.1 Templates and foundation bolting shall be shipped separately from the vessels according to Purchaser’s
instruction.
7.3.2 Internals within Supplier’s scope of supply shall be installed and assembled at Supplier’s shop before shipping,
unless otherwise instructed by Purchaser.
7.3.3 No vessels shall be released for shipment from Supplier’s shop until it has been approved by Purchaser’s
inspector.
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Appendix A: Basic Design Requirements
This appendix describes the basic design requirements for pressure vessels.
When purchaser provides the engineering drawing, the requirements of this appendix are reflected in Purchaser’s
engineering drawing.
When Purchaser provides the process specification on the data sheet in lieu of the engineering drawing, Supplier shall
provide design data including process design and pressure vessel sizing in addition to mechanical design. In such a case,
the requirements of this appendix shall be considered to be an integral part of the main body of this specification.
A.1 Design Pressure

A.2 Design Temperature (Maximum)
A.3 Design Temperature (Minimum)
A.4 Corrosion Allowance
A.5 Material Selection
A.6 Gasket Selection
A.7 Minimum Shell Thickness
A.8 Pipe Shell
A.9 Minimum Nozzle Size
A.10 Manholes and Hand Holes
A.11 Nozzle Flange Design
A.12 Nozzle Projection
A.13 Girth Flange Design
A.14 Support Design of Vertical Vessels
A.15 Fire Proofing
A.16 Extent of Radiographic Examination
A.1 Design Pressure
A.1.1 Design pressure, which is the basis of the pressure vessel design, shall normally be the maximum anticipated
operating pressure “Normal operating pressure plus 10%” or “normal operating pressure plus 98 kPa”,
whichever is greater, shall be set as the design pressure, in general.
A.1.2 Vessels operating under vacuum condition shall be designed for an external design pressure of 101.3 kPa and
designated as full vacuum. Only when a safety device is installed to the pressure vessel, the difference between
the absolute internal and the atmospheric pressure may be taken as the external design pressure.
A.2 Design Temperature (Maximum)
A.2.1 Design temperature shall be based on the process data sheet issued by the Licensor.
A.3 Design Temperature (Minimum)
A.3.1 The minimum design metal temperature (MDMT) shall be determined for each pressure vessel in accordance
with UG-20(b) of the ASME Boiler and Pressure Vessel Code Section VIII, Division 1.
A.4 Corrosion Allowance
A.4.1 The necessity and the values of corrosion allowances shall be determined depending on the material, inside
fluid characteristics, operating conditions and applicable codes and standards.
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A.4.2 Corrosion allowances for pressure retaining parts made of carbon steel and low alloy steel shall be 3 mm as
minimum. Unless otherwise specified, corrosion allowance is not required for high alloy and non-ferrous
metals.
A.5 Material Selection
A.5.1 Materials shall be selected from those listed in ASME Standards considering the inside fluid characteristics,
design conditions and applicable codes and standards. Application of other material standards shall be subject
to Purchaser’s approval.
A.5.2 Unless otherwise specified, girth flanges and flat covers shall be forged steel. Application of plate construction
for flanges and covers shall be subject to Purchaser’s approval.
A.5.3 Materials for the low temperature service shall be selected considering the impact properties of the material and
MDMT specified for the pressure vessel. The requirements of the impact test shall be in accordance with code.
A.5.4 SA283 Gr.C shall not be used for pressure retaining parts.
A.6 Gasket Selection
A.6.1 Gaskets for girth flanges shall be selected in consideration of their compatibility with the inside fluid
characteristics, design conditions and applicable codes and standards. As a rule, spiral wound gasket with
carbon steel rings shall be selected except instances where non-asbestos sheet gasket may be used when
satisfying all of the following conditions;
(1) Flange inside diameter does not exceed 1,200 mm

(2) Design pressure does not exceed 1 MPaG
(3) Design temperature, both maximum and minimum, is from 0 °C up to 180 °C
(4) Utility service such as cooling water, steam, steam condensate, air, nitrogen, etc.
A.6.2 Spiral wound gaskets, with inner rings shall be used for confined type flanges and with outer rings shall also be
used on raised face type flanges.
A.7 Minimum Shell Thickness
A.7.1 The minimum nominal shell and head thickness including corrosion allowance shall be as follows:
Shell Carbon Steel and High Alloy Steel and

Diameter (ID) Low Alloy Steel Non Ferrous Material
[mm] [mm] [mm]
ID < 500 5 4
501 < ID < 1200 5 4
1201 < ID < 2000 6 5
2001 < ID < 2600 8 6
ID > 2600 10 8
A.8 Pipe Shell
A.8.1 When shell diameter is 600 mm and under, pipe may be used.
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A.9 Minimum Nozzle Size
A.9.1 In general, nozzles shall be flanged and minimum 3/4 inch nominal size.
A.10 Manholes and Hand Holes
A.10.1 Manhole nominal diameters shall be as follows unless otherwise specified;
Shell
Tray & Packing Tower Drum
Diameter
[mm] [inch] [inch]
up to 800, incl. Girth Flange Hand Holes (Note 1)
over 800 to 1,500, incl. 20” 20”
over 1,500 24” 24”
Note 1: Girth flanges shall also be provided if removable internals are installed.
A.10.2 For tray towers, manholes shall be provided at top and bottom of tower and for each 20 trays or 15 m elevation
distance, whichever is less, as minimum.
A.10.3 Hand hole shall be minimum 6 inch nominal size.
A.11 Nozzle Flange Design
A.11.1 Nozzle flange shall be of welding neck or long welding neck type construction, however slip-on type may also
be adopted for nozzles when satisfying all of the following conditions;
(1) Material of nozzle is carbon steel, high alloy or non-ferrous

(2) Flange rating is class 150 and under for process and instrument nozzle
(3) Flange rating is class 300 and under for manhole, handhole and blind flange
(4) Design temperature, both maximum and minimum, is from -10 °C up to 350 °C
(5) Nozzle size is 2 inch and larger
A.11.2 Nozzle flanges equal and larger than 26 inch nominal shall be of welding neck type.
A.12 Nozzle Projection
A.12.1 Nozzle projection shall be decided according to Vessel Standard VS-49.
A.12.2 For the nozzles to be connected to piping, the distance of the flange face to the center of the vessel shall be
rounded up the next 10 mm by adjustment of the nozzle projection.
A.13 Girth Flange Design
A.13.1 All girth flanges shall be of welding neck construction.
A.13.2 For low alloy or clad shells, welding neck flanges shall be adopted.
A.13.3 Girth flanges must be made in one piece. Segmental butt-weld construction shall not be accepted.
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A.14 Support Design of Vertical Vessels
A.14.1 Vertical vessels shall generally be supported by skirts or lugs. Vessels may be supported by legs made of steel
angles or channels when satisfying all of the following conditions;
(1) Shell diameter is not more than 1,000 mm.

(2) Weight of vessel operating does not exceed 30 kN
(3) Vessel height-to-diameter ratio is not more than 3
(4) Support height is not more than 1,500 mm
(5) Vibration is not expected
A.15 Fire Proofing
A.15.1 Fire proofing of skirt and other support shall be provided for the vessels installed in the fire hazardous area in
the following manner. Application of fire proofing to vessels installed on elevated structure shall be decided for
each case.
For skirt type support, both inside and outside surface of the skirt shall be fire proofed when skirt inside
diameter is over 1,200 mm. Only outside surface of the skirt shall be fire proofed when skirt inside diameter is
1,200 mm and less.
For leg type support, fire proofing shall be provided for legs of longer than 500 mm.
For lug type support, fire proofing shall be provided with covering overall of lugs.
For saddle type support, fire proofing shall be provided for saddles whenever the non-insulated lowest height is
greater than 300 mm.
A.16 Extent of Radiographic Examination
A.16.1 The extent of radiographic examination of the shell and head seams shall be spot examination, as minimum.
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Appendix B: Inspection Requirements
B.1 Material
B.1.1 Ultrasonic Examination of materials shall be done in accordance with the following criteria.
(1) Plate material having thickness in excess of 50 mm ASTM A-435, A578 Level B
(to be checked for both at surface and edges)
(2) Forging material, plate-like one such as tubesheet, forging shell, ASTM A578 Level B
having thickness in excess of 100 mm.
(3) Forging material, not included in (2) above having thickness ASTM A508 Par. 8.3 or A388 (*)
In excess of 100 mm
(4) Cladding material in any thickness ASTM A263, 264 or 265
(*) Acceptance standard shall be as per para 3.3.4 of ASME Sec. VIII Div.2
B.1.2 Charpy impact test shall be made in accordance with the Code, based on MDMT specified on the Purchaser’s
engineering drawings or data sheet and shall be carried out on base metal, weld and HAZ.
For carbon steel and low alloy steel, when the nominal thickness of plate or forging exceeds 100 mm, charpy
impact test as specified in Table B-1 is mandatory.
Table B-1
Item CRITERIA
Sampling - Min. 1 set from each heat
- Min. 3 specimen in 1 set
- Sampling from 1/4T (Thickness) depth
Test Temperature 0 °C or MDMT whichever is lower
Absorbed Energy ASME Section VIII Division 1, Fig. UG-84.1
/ ASME Section VIII Division 2, Fig. 3.3 / 3.4
B.1.3 Integrally cladding material shall conform to ASTM A263, A264 or A265 whichever applicable, and shear test
is mandatory. All clad plate shall be UT examined at the steel works (mill) in accordance with ASTM A 578
level S8.
B.1.4 Thickness definitions for impact test and UT requirements on this specification are as follows;
(1) The specified thickness includes corrosion allowance.

(2) The specified thickness for forging shall be “t1” or “t2”, whichever is greater, in the following figure.
t1 t1
t2
t2
B.1.5 Knuckle surfaces of dished ends, expansion bellows and pipe bends shall be MT or PT examined.
B.1.6 All forgings except for flanges as per ASME/ANSI shall be procured in normalized / annealed condition.
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B.1.7 All forgings including nozzle flanges shall be examined for surface defects by MP/PT testing after machining
as per ASTM A 275.
B.2 Welds
B.2.1 Welding bevel shall be inspected by MT or “PT if material is nonmagnetic” when any of the following
conditions exist;
(1) Carbon steel material having the base metal thickness above 40 mm
(2) Low alloy steel (Cr-Mo) & Stainless steel material having the base metal thickness above 25 mm
(3) Low alloy steel (Ni) material having the base metal thickness above 25 mm.
(4) Dissimilar welding in any material and in any thickness
B.2.2 Welding backchip surface shall be inspected by MT or “PT if material is nonmagnetic” when any of the
following condition exist;
(1) Carbon steel material having the base metal thickness 50 mm and greater
(2) Carbon steel material having the base metal thickness 25 mm and greater and MDMT ≤ -10 °C
(3) Low alloy steel (Cr-Mo) material having the base metal thickness 25 mm and greater
(4) Low alloy steel (Ni) material in any thickness
(5) Austenitic stainless steel having the base metal thickness 25 mm and greater
Additionally, welding surface shall be inspected by MT or “PT for followings:

(1) Root and final layer of all butt welds
(2) Fillet welds of 3.5% Ni & Stainless steel
(3) Each layer of weld deposit in Stainless steel weld overlay
B.2.3 All butt weld joint shall be inspected by UT after PWHT in the following cases.
B.2.3.1 Spot UT (Min. 10% in length) is required for carbon steel material having the base metal thickness 38 mm and
greater, and below 50 mm. Purchaser’s inspector will specify location to be examined with UT.
B.2.3.2 Full UT (100% UT) in addition to RT is required when any of the following conditions exist;
(1) Carbon steel material having the base metal thickness 50 mm and greater
(2) Low alloy steel (Cr-Mo) material having the base metal thickness 50 mm and greater
(3) Low alloy steel (Ni) material having the base metal thickness 38 mm and greater
(4) Full penetration weld of nozzle attachments of base metal thk. above 50mm
(5) Clad Plates and formed heads from clad plates in all thicknesses
B.2.4 Welding surface shall be inspected by MT or “PT if material is nonmagnetic” after hydrostatic test, when any
of the following conditions exist. Inspection shall be done on all accessible interior and exterior surfaces.
(1) All material having the base metal thickness greater than 50 mm
(2) Low alloy steel (Cr-Mo) material having the base metal thickness 25 mm and greater including attachment
welds
(3) Low alloy steel (Ni) material having the base metal thickness 25 mm and greater including attachment
welds
(4) Welds in lining including attachment welds
(6) Fillet welds of intermediate heads
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B.2.5 MT or “PT if material is nonmagnetic” shall be performed for all area where temporary attachment was welded
and is removed, when any of the following conditions exit;
(1) After removal for all materials

(2) After hydrostatic test for low allow steel (Cr-Mo) material, in any thickness
B.2.6 The extent of radiography is specified on Purchaser’s drawings.

(1) When “Full RT (100 %)” is specified on Purchaser’s drawings, all length of butt weld joint, including
Category B seam and Category C seam, shall be RT. When “Full RT” without a description of “(100%)”
is specified, RT shall be done in accordance with UW-11 of ASME Section VIII Division 1/ Table 7.2 of
ASME Section VIII Division 2.
(2) In addition to (1) above, all weld seams of formed head, if made in more than one segment, shall be fully
Radiographed after forming.
(3) In addition to (1) above, all the welded T- Joints shall be fully radiographed.
B.2.7 When Spot RT is specified, each intersection of longitudinal and circumferential welding seams in the shell and
heads (T-joints) & min. 10% of total weld length (excluding T-joints), or alternative location specified by
Purchaser’s inspector, shall be radiographed.
Acceptance standards for spot radiography are in accordance with UW-51 of ASME Section VIII Division 1 /
Par. 7.5.3.2 of ASME Section VIII Division 2.
B.2.8 RT shall be done before final PWHT. However, radiography of welds in C- 1/2 Mo & Cr- Mo - Steel
preferably shall be carried out after heat treatment
B.2.9 Supplier may apply ultrasonic examination in lieu of radiographic examination for welded joints of carbon steel
and lower alloy steel materials having the thickness of 38 mm and greater with prior approval of Purchaser
according to either of the following requirement;
- ASME Code Case 2235-10 “Use of Ultrasonic Examination in Lieu of Radiography”

- ASME Sec. VIII Division 2 Paragraph 7.5.5 “Ultrasonic Examination used in Lieu of Radiographic
Examination”
B.2.10 Acceptance criteria of MT, PT, UT and RT are as follows;
(1) MT: “ASME Sec. VIII, Div. 1 Appendix 6” / “ASME Sec. VIII, Div. 2 Para. 7.5.6”
(2) PT: “ASME Sec. VIII, Div. 1 Appendix 8” / “ASME Sec. VIII, Div. 2 Para. 7.5.7”
(3) UT: “ASME Sec. VIII, Div. 1 Appendix 12” / “ASME Sec. VIII, Div. 2 Para. 7.5.4”
(4) RT: “ASME Sec. VIII, Div. 1 UW-51 and Appendix 4” / “ASME Sec. VIII, Div. 2 Para. 7.5.3”
B.2.11 Visual Inspection
All welds and area adjacent to the welds shall be visually inspected after completion of the welding on
accessible interior and exterior surfaces. When access is not sufficient, remote visual inspection (refer to
ASME Section V, T-953) shall be conducted. Visual inspection shall satisfy all of the following conditions;
(1) Weld reinforcement in any weld joints shall be according to ASME Section VIII Div.1, UW-35 (d) /
ASME Section VIII Div.2, Par. 6.2.4.1, regardless of type of weld joint.
(2) Internal weld protrusion shall not exceed 1.5 mm in height for single side weld joints.
(3) Undercutting shall not exceed 0.3 mm in depth.
(4) Welds shall be free from overlap at the toe of the welds.
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(5) Spatter, slag and scale shall be removed.
(6) Crater and jig marks shall be finished smoothly.
(7) No cracks, incomplete penetration and lack of fusion shall present.
(8) The profile of fillet welds shall be uniform such that leg/throat length is regular and the surface of welds is
slightly convex.
B.3 Hardness Test
B.3.1 Hardness of base metal, weld metal and heat affected zone shall be checked as follows.
(1) For Non-PWHT pressure vessel : Minimum one point per one vessel
(2) For PWHT pressure vessel : Minimum two points per each circumferential weld, and
Minimum one point per each longitudinal weld, and
Minimum one point per each nozzle weld
B. 3.2 Hardness of base metal, weld metal and heat affected zone shall not exceed the limits shown below.
Material (P-Number) Brinell Hardness

Carbon Steel (P-1) 225
Low Alloy Steel (P-3, 4) 225 (see B.3.3 also)
Low Alloy Steel (P-5, 6, 7, 9) 235 (see B.3.3 also)
B.3.3 Hardness test on welds of Cr-Mo, materials after final heat treatment shall be performed. The value shall not
exceed to:
i) 215 HB for steel having Cr content less than 2%
ii) 240 HB for steel having Cr content more than 2%
B.4 Dimensional Inspection
B.4.1 Main dimension of pressure vessel shall be checked after PWHT. Unless otherwise specified, tolerances
for pressure vessel shall be in accordance with Fig. B.
B.4.2 Thickness of pressure retaining parts shall be checked after forming, at least one point of every 1 m2.
B.4.3 Pressure vessels to be field assembled shall be pre-assembled at shop, and miss-alignment, which shall be less
than those specified in UW-33, shall be reported.
B.5 Hydrostatic Test
B.5.1 Hydrostatic test shall be done prior to painting at weld and/or coating on weld.
B.5.2 Metal temperature during hydrostatic test shall be maintained at least 17°C above the MDMT to minimize the
risk of brittle fracture. With Purchaser’s written approval, the metal temperature during hydrostatic test may be
lowered down to 17°C above the Minimum Allowable Metal Temperature (MAMT) which is determined as
below.
(1) For Pressure retaining parts which are impact tested
MAMT = The highest value of impact test temperatures among all pressure retaining materials and their
welding joints
(2) For Pressure retaining parts which are NOT impact tested
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MAMT = The highest value of impact test exemption temperatures as per code among all pressure
retaining materials and their welding joints
B.5.3 The hydrostatic test pressure shall be held for at least 60 minutes.
B.5.4 When carbon and low alloy steel materials are exposed to test water, chloride content in the water shall be less
than 40 ppm.
B.5.5 When austenitic stainless steel materials are exposed to test water, chloride content of water shall be less than
30 ppm.
B.5.6 Jacketed pressure vessels shall be hydrostatically tested before mounting the jackets, as practical as possible.
B. 5.7 Gasket applied to hydrostatic test shall be same gaskets as service gaskets.
B. 5.8 After hydrostatic testing, the tightness of lining welds shall be tested by helium. The sensitivity of leak
detection shall be as per ASME SEC V.
B.6 Leak Test
B.6.1 Reinforcing pads shall be leak tested at least 10 kPaG with air before hydrostatic test.
B.6.2 Sleeve type nozzle shall be leak tested at least 10 kPaG with air after hydrostatic test.
B.7 Inspection and Test Records
B.7.1 Inspection and test records for each pressure vessel shall be supplied by Vender.
B.7.2 Inspection and test records shall include (where applicable);
(1) Manufacturer’s Data Report
(2) As-built sketch or tabulation for identification of the materials showing the location
(3) Certified Material Test Report, including data of impact tests and records/certificates of non-destructive
examination required for the materials
(4) Records of production weld tests
(5) Time-temperature charts of postweld heat treatment, and records of other heat treatments
(6) Records/certificates of non-destructive examination, such as radiographic, ultrasonic, magnetic-particle

and liquid-penetrant examination
(7) Data/results of dimensional inspection
(8) Certificates of hydrostatic test, pneumatic test or other pressure tests
(9) Records of painting work and total dry film thickness
(10) Positive material identification (PMI) records
(11) Rubbing of nameplates

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Fig. B TOLERANCES FOR PRESSURE VESSELS

NOZZLE [SHELLS AND HEADS]
Tolerances for shape of formed heads and out-of-roundness of shells
4b shall be as specified in the applicable codes.
1. Overall length between T.L.:
±13 or ±1.5 per 1 000, whichever is greater, but not exceed the
5b 8b
following value
MANHOLE CLIPS Length, (L) Tolerances
NOZZLE FLANGE
4e
L ≤ 30 000 ±25
4g L > 30 000 ±40
2a. Inside diameter as determined by circumferential measurements:
4f 4f
T.L. Nominal I.D., (D) Tolerances
W.L.
CLIPS T.L.
D ≤ 1 200 ±3
1 200 < D ≤ 2 100 ±5
6
8c
3 2 100 < D ≤ 4 000 ±6
TRAY SUPPORT RING 4 000 < D ≤ 6 000 ±7
8a
7d T.L.
6 000 < D ≤ 8 000 ±8
4d
NOZZLE 8 000 < D ≤ 10 000 ±10
10 000 < D ±15
1
7b
7a
7c 2b. Inside diameter of vessels with internal trays
4c (by direct measurements):
±0.5 % x Nominal I.D.
4a 3. Straightness (deviation of shell external surface from a straight
2a 2b
line)
4a 5d
MANHOLE (1) Max.6 in any 6 000 length
(2) As measured in the total length (from bottom to top T.L.):
SUPPORT LUG Length, (L) Tolerances
L ≤ 30 000 Max.19
5a 5c
11 L > 30 000 Max.25
W.L. 10
[NOZZLES, MANHOLES AND OTHER ATTACHMENTS]
T.L.
4a. Location of nozzle from T.L. : ±6
4a
4b. Orientation of nozzle from reference centerline : ±6
9a 4c. Nozzle flange face from shell external surface : ±5
SKIRT
LEG 4h 4d. Alignment of nozzle flange face : ±1/2°
4e. Rotation orientation of bolt hole at bolt circle : Max. 1.5
4f. Top (or bottom) flange face from adjacent T.L. : ±10
11
9b 4g. Location of nozzle on top head from center of : ±6
head
4h. Flange face of bottom draw-off nozzles from : ±10
T.L. T.L. reference centerline
4i. Out-of-level mount nozzle flange face for pump or agitator:
12a
±1/300 or pump/agitator supplier requirement, whichever is
12b 12c 12c severer
5a. Location of manhole from T.L. : ±10
5b. Orientation of manhole from reference centerline: ±10
5c. Manhole flange face from shell external surface : ±10
5d. Alignment of manhole flange face : ±1°
6. Location of nozzle and manhole (related to trays): ±3
from tray support ring
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7. Any pair of nozzles (i.e. nozzles for liquid level gauge and [TRAY SUPPORTS]
connected to reboiler) 13a. Location of tray support ring from bottom T.L. : ±10
7a. Difference in nozzle length : Max.1 13b. Tray support ring out-of-level (difference between max. and
7b. Distance between nozzles : ±2 min. distances from T.L. to tray support ring):
7c. Difference in orientation : Max.2 Nominal I.D., (D) Tolerances
7d. Alignment of flange face : ±1/4° D ≤ 1 500 Max. 2
8. Clips or other similar structural attachments for platform, 1 500 < D ≤ 2 500 Max. 3
ladder or pipe support
2 500 < D ≤ 4 000 Max. 4
8a. Location from T.L. : ±10
4 000 < D ≤ 6 000 Max. 6
8b. Orientation from reference centerline : ±10
6 000 < D ≤ 8 000 Max. 8
8c. Distance between any pair of clips : ±3
8 000 < D ≤10 000 Max. 10
10 000 < D Max. 13
[SUPPORTS (SKIRT, LUGS, LEGS AND SADDLES)]
9a. Distance from T.L. to bottom of baseplate 14. Distance between adjacent tray support rings:
(height of skirt or leg): Distance, (S) Tolerances
Nominal I.D., (D) Tolerances S ≤ 300 ±3
D ≤ 2 100 ±6 S > 300 ±4
D > 2 100 ±9 15. Height of downcomer support bar above tray : ±1.5
9b. Out-of-level of baseplate (difference between max. and support ring
min. distances from T.L. to bottom of baseplate): 16. Bottom of downcomer support bar above tray : ±3
support ring
Nominal I.D., (D) Tolerances
17. Distance between bolt holes of downcomer : ±7
D ≤ 2 100 Max. 3 support bar
2 100 < D ≤ 4 000 Max. 6 18. Distance from reference centerline to downcomer : ±3
4 000 < D ≤ 6 000 Max. 7 support bar
6 000 < D ≤ 8 000 Max. 8 TRAY SUPPORT RING
8 000 < D ≤10 000 Max. 10
13b
10 000 < D Max. 15
10. Distance from T.L. to support lug : ±6 13a 15 14
13b
11. Bolt circle diameter and pitch between bolt holes:
Nominal I.D., (D) Tolerances 13a 14
13b
D ≤ 2 100 ±3
D > 2 100 ±6 13a 16 16
12. Horizontal vessels
12a. Distance from reference centerline to : ±6 DOWNCOMER
SUPPORT BAR 13a
bottom of support saddle
12b. Distance from T.L. to bolt hole center of : ±6
support saddle
12c. Distance between bolt holes of support saddle: 18
17
Nominal I.D., (D) Tolerances
D ≤ 2 100 ±3
TRAY SUPPORT RING
D > 2 100 ±6
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[Packed Tower Internals Support]

19a. Location of support for packing support
plate from T.L. : ±10mm
19b. Distance between support for packing support plate and
nozzle below support for packing support plate : ±10mm
20. Distance between bed limiter support and support for packing
support plate
21b
: ±0.5% of packed bed height, max. 20mm
24a 24b 21a. Distance between distributor support
(RE) DISTRIBUTOR
and bed limiter support : ±3mm
21b. Distance between manhole and distributor support : ±3mm
21a
22. Distance between liquid collector support and support for
BED LIMITER
packing support plate : ±5mm
PACKED BED 23. Out-of-level of support for packing support plate
(difference between max. and min. distance from T.L. to
support for packing support plate)
Nominal I.D. (D) Tolerance
20
D ≤ 1,000 Max. 2mm
1,000 < D ≤ 2,000 Max. 4mm
2,000 < D ≤ 4,000 Max. 6mm
23 4,000 < D ≤ 6,000 Max. 10mm
PACKING SUPPORT PLATE 6,000 < D Max. 12mm
24. Out-of-level of distributor support (difference between max.
22 25 and min. distance from T.L. to distributor support)
LIQUID COLLECTOR Tolerances
19b Nominal I.D. (D)
19a a. Ring Type b. Lug Type
D ≤ 1,000 Max. 2mm Max. 2mm
FEED PIPE 1,000 < D ≤ 2,000 Max. 2mm Max. 4mm
2,000 < D ≤ 3,000 Max. 3mm Max. 6mm
3,000 < D ≤ 4,000 Max. 4mm Max. 8mm
4,000 < D ≤ 6,000 Max. 5mm Max. 8mm
6,000 < D Max. 6mm Max. 8mm
25. Out-of-level of liquid collector support (difference between
max. and min. distance from T.L. to liquid collector support)
Nominal I.D. (D) Tolerance
D ≤ 1,000 Max. 2mm
1,000 < D ≤ 2,000 Max. 3mm
2,000 < D ≤ 4,000 Max. 4mm
4,000 < D Max. 6mm
REMARKS:
1. Unless otherwise stated, all dimensions and tolerances are given in (mm).
2. T.L.: Tangent Line
3. Tolerances are not cumulative.
4. Tolerances indicated on Vessel Drawing shall govern.
5. Tolerances shown herein are intended to apply to both vertical and horizontal vessels.
6. For vessels fabricated from pipes, diameter tolerances shall be in accordance with the relevant pipe specification.
7. Tolerances as shown in 2a, 2b and 3 are not applied to distortion caused by welding for attaching parts, such as nozzles, support rings, lugs and
other fittings to shells and heads. Measurements shall be made to the surface of the parent plate and not to a weld, fitting or other raised parts.
8. Even if the distance to flange face of nozzles (or manholes) from centerline of vessel is specified on Vessel Drawing, measurements shall be
made as shown in 4c (or 5c).
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Appendix C: Calculation Method-Dynamic Wind Analysis (Guideline) for Vertical Equipment
Check of the towers for dynamic wind moments due to vortex shedding shall be performed based on following
assumptions:
Vcr = f x D/St
Vcr = Critical wind velocity

D = Outside diameter of tower
f = First natural frequency of tower considering foundation complete rigid (s-1)
St = Strouhol number, may be taken as 0.15 for Re > 106 and 0.2 for Re < 106
Re = Reynolds number at critical wind velocity
For Vcr < 30 m/s following shall be considered:
The tower shall be checked for additional moments due to vortex shedding in 2 cases.
1. Operating condition
2. Shut down condition
Dynamic wind moment shall be calculated as follows:
Md = Pd x Ck x S x Pi/d x H
Pd = Wind pressure at critical velocity = 0.5 x den x (Vcr)2

Ck = Crosswind oscillatory force coefficient may be taken as 0.5 + ( 4 - Log10 Re)/5.7 for Re <106 and
0.17 for Re > 106
d = The logarithmic decrement of damping. For towers with trays or packing it is estimated 0.035
S = Surface on which dynamic wind forces are acting (height * diameter)
H = Height from base ring of point of application for dynamic wind force
Pi = 3.14
den = Density
For tapered construction only the tip diameter shall be considered in calculation.
Moments to be considered for dynamic wind:
Mres = √ (Md 2 + Mst 2)
Mst = Static wind moment at critical wind velocity
Only if Mres exceeds moments due to static wind or earthquake moments, it shall be considered for equipment design.
Page 1/1
TITLE Rev 0
Pressure Vessels
DOC NO. Date 30-05-2018
D102
Appendix D: Special Design Code Requirements
D.1 Application of ASME Boiler and Pressure Vessel Code Section VIII, Division 2 shall be considered for
construction of pressure vessel when specified by the process licensor in process data sheet. Unless otherwise
specified, the design, materials, fabrication and inspection of welded pressure vessels shall comply with ASME
Code Section VIII, Division 1 latest edition.
D.2 When a vessel unit consists of more than one independent pressure chamber, different code may be applied to
each chamber. In such a case, only the combination of ASME Boiler and Pressure Vessel Code Section VIII,
Division 1 and Division 2 is acceptable.
D.3 When the equipment is fabricated by ASME Boiler and Pressure Vessel Code Section VIII, Division 2,
Supplier shall hold the valid U2 certificates of authorization, even though certification mark with the UD
designator is not required for the equipment.
D.4 When finite element method (FEM) analysis is applied for stress analysis or fatigue analysis, Supplier shall
submit analysis report including following information.
- Name of software and its version
- Analysis model
- Finite element model
- Loading and boundary condition
- Stress contour drawing
- Evaluation
D.5 When the equipment is fabricated by ASME Boiler and Pressure Vessel Code Section VIII, Division 2,
basically Class 2 construction shall be used. Class 1 construction shall be subjected to Purchaser’s approval.
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Owner

Ammonia Urea Fertilizer

PROJECTS & DEVELOPMENT Location Gorakhpur, India

PLANT 2200 MTPD Ammonia &

Hindustan Urvarak & Rasayan Limited

DOC No. : HURL-G-ED-C00-STA-SPC-000-

Engineering Specification for

0 30-05-2018 For Review R.K. S.I. H.H.

B 20-11-2017 For Review R.K. S.I. H.H. / T.S.

Rev.A: First Issue.

Rev.B: Revised and re-issued.

Rev.0: Revised based on CRS BA1205-STA-CRS-002 review result with Owner

5. INSPECTION AND TESTS 21

6. NAMEPLATES, PAINTING AND MARKING

7. PACKING AND SHIPPING

Appendix A Basic Design Requirements (P.1/4-4/4)

1.3 Codes, Standards and Regulations

(1) National, regional and local regulations

(2) American Society of Mechanical Engineers (ASME)

(3) American Society for Testing and Materials (ASTM)

1.5 Purchaser’s Engineering Drawing and Documents

1.5.3 Purchaser will provide HURL-ED-C00-STA-SPC-000-D123 “Vessel Standard” which supplements

1.6 Supplier’s Drawings and Documents

1.6.3 Drawings shall be prepared to scale and in third angle projection.

1.6.4 Drawings shall contain:

1.6.5 Strength calculations shall cover:

2.1 Design Pressure

2.2 Design Temperature

2.3 Corrosion Allowances

The full specified corrosion allowance shall be added on each side.

(2) Parts removable from a manhole:

X = (10P + 5Sb + 4Sn + AS) / 100 ≤ 15

J = (Si + Mn) (P + Sn) x 104 <160

2.5 Loading Conditions and Strength Calculations

(1) Operating condition

The loading shall include those from:

(a) Internal or external design pressure

(2) Erection condition

The loading shall include those from:

(a) Weight of vessels and contents at erection

The loading shall include those from:

(a) Test pressure

(4) Transportation condition

1.50: for equipment lifting weight 100 ton and less

Saddle skid for transportation shall be designed considering the following;

1) No interference between external attachments and ground

(a) Bulletin of Welding Research Council No. 107/537 or 297

3.1 Shells and Heads

(1) For sheet gasket : Ra 3.2

3.3 Nozzles and Manholes

(1) Design temperatures exceeds 450 °C

Table 1. Nozzle to Shell Loading

Table 2. Nozzle to Head Loading

Where D = Nominal Diameter of Nozzle in inch

See Par.2.5.9 for calculation procedures.

3.5 Alloy Lining

3.6 Bolts, Nuts and Gaskets