NIOEC-SP-41-04(0)

DOCUMENT CODE NO. OF PAGES: 18

PLAN/PRJ/SUB UNIT PHASE DISCIPLANE DOCUMENT TYPE SERIAL NO. REV. NO. DATE
NIOEC 000 EG PI SP 4104 A0 JULY, 2005

NATIONAL IRANIAN OIL REFINING & DISTRIBUTION COMPANY

NATIONAL IRANIAN OIL ENGINEERING
& CONSTRUCTION COMPANY

NIOEC SPECIFICATION
FOR

SUPPLEMENTREY REQUIREMENT FOR HEAVY

WALL PRESSURE VESSELS
FOR HYDROTREATING AND HYDROCRAKING
SERVICES

FIRST EDITION

JULY, 2005

THIS SPECIFICATION IS THE PROPERTY OF NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY. IT IS CONFIDENTIAL AND ALL
RIGHTS RESERVED TO THE OWNER. NEITHER WHOLE NOR ANY PART OF THIS DOCUMENT MAY BE DISCLOSED TO ANY THIRD PARTY,
REPRODUCTED, STORED IN ANY RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN
CONSENT OF THE NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY
JULY, 2005 NIOEC-SP-41-04(0)
 JULY, 2005 NIOEC-SP-41-04(0)
REVISION INDEX
REV. REV. REV. REV.
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
PAGE PAGE PAGE PAGE

1 26 51 76
2 27 52 77
3 28 53 78
4 29 54 79
5 30 55 80
6 31 56 81
7 32 57 82
8 33 58 83
9 34 59 84
10 35 60 85
11 36 61 86
12 37 62 87
13 38 63 88
14 39 64 89
15 40 65 90
16 41 66 91
17 42 67 92
18 43 68 93
19 44 69 94
20 45 70 95
21 46 71 96
22 47 72 97
23 48 73 98
24 49 74 99
25 50 75 100

NOTES:
1) THIS SHEET IS A RECORD OF ALL REVISIONS TO THIS SPECIFICATION.
2) REMARKS RELATED TO EACH REVISION SHOW A BRIEF DESCRIPTION. THESE REMARKS SHALL BE
INTERPRETED IN CONJUNCTION WITH THE REVISED TEXT MARKED BY REVISION NUMBERS.
3) WHEN APPROVED EACH REVISION SHALL BE CONSIDERED AS A PART OF THE ORIGINAL
DOCUMENT.
4) NUMBER OF PAGES EXCLUDES THIS SHEET AND THE COVER SHEET.

1
0 JULY, 2005 M.A.MIRAHADI M.H.ZAKER M.R.FARZAM M.A.A.SAJEDI
REV. DATE PREPARED CHECKED APPROVED AUTHORIZED
 JULY, 2005 NIOEC-SP-41-04(0)
CONTENTS: PAGE NO.

1. SCOPE 2

2. REFERENCES 2

3. UNITS 3

4. DEFINITIONS & TERMINOLOGY 3

5. GENERAL 4

6. DESIGN 4

7. MATERIALS 7

8. INTERNALS 8

9. NOZZLES 10

10. FABRICATION 11

11. WELDING 12

12. EXAMINATION 12

13. TESTS 15

14. INSPECTION 16

15. MARKING 17

APPENDIX I NIOEC STANDARD DRAWINGS 18

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1. SCOPE

This NIOEC Specification covers supplementary minimum requirements for design,

fabrication, installation and testing of heavy wall pressure vessels built for Hydro
treating and Hydro cracking services.

1.1 In addition to these requirements, General pertinent requirement, as outlined in

NIOEC-SP-41-03, in particular paragraph 11, shall also be considered.

1.2 The design, fabrication, test and inspection of unfired pressure vessels shall conform
to ASME Code Sect. VIII, Div. 2, “ASME Boiler and Pressure Vessel Code”.
All requirements of Division 2, shall be followed plus those noted in this
Specification.

1.3 These requirements constitute in part the design Specification as required and
defined in Paragraph A-301 of Division 2.
Other parts of this Project Specification define the operating and/or design
conditions, dimensions, materials to be used in fabrication, the method of vessel
support and other pertinent information.

1.4 The manufacturer who fabricates the vessel has the responsibility of complying to
the requirements of Paragraph A-302 of Division 2. It will be his responsibility, in
case of any conflicts between these Specifications, drawings and other pertinent
documents, to satisfy the discrepancy with the appropriate party, along with approval
by NIOEC.

1.5 Order of Precedence

In the event of a conflict among the various documents, the order of precedence shall
be as follows:
- The purchase order (including attachments) and variations thereon.
- The Data Sheets and drawings.
- This Specification.
- ASME Code Section VIII, Div. 2 “Alternative Rules”.
If conflict is discovered between the items listed, it shall be the responsibility of the
Vendor to call attention to the conflict.

2. REFERENCES

Throughout this Specification the following dated and undated standards/ codes are
referred to. These referenced documents shall, to the extent specified herein, form a part
of this Specification.
For undated references, the latest edition of the referenced document (including any
supplements and amendments) applies. For dated references, the edition cited applies.
The applicability of changes in dated references that occur after the cited date, shall
mutually be agreed upon by NIOEC and the Vendor/Contractor.

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ASME (AMERICAN SOCIETY OF MECHANICAL ENGINEERS)

ASME Code Sect. VIII, Div. 2 “Boiler & Pressure Vessel Code, Alternative Rules”
ASME Code Sect. II “Materials”
ASME Code Sect. V “Nondestructive Examination”
ASME Code Sect. IX “Welding & Brazing Qualifications”

ASTM (AMERICAN SOCIETY FOR TESTING AND MATERIALS)

UBC (UNIFORM BUILDING CODE)

Edition 1997

ASME (AMERICAN SOCIETY OF MECHANICAL ENGINEERS)

B1.1 “Unified Screw Thread” Edition 1989

B1.20.1 “Pipe Thread” Edition 1983
B16.5 “Steel Pipe Flanges and Flanges Fitting” Edition 1996
B18.2.1 “Square and Hex Bolts and Screw” Edition 1996
B18.2.2 “Square and Hex Nuts” Edition 1987
B36.10 “Welded and Seamless Wrought Steel Pipe” Edition 2000

NIOEC-SP (NIOEC SPECIFICATIONS)

NIOEC-SP-20-01 “NIOEC Specification for Structural Steel Specification”

NIOEC-SP-80-02 “NIOEC Specification for Painting”
NIOEC-SP-00-50 “NIOEC Specification for Design Criteria”
NIOEC-SP-00-01 “NIOEC Specification for Civil Design Criteria”
NIOEC-SP-50-04 “NIOEC Specification for Piping Material Specification”
NIOEC-SP-00-11 “NIOEC Specification for Site Conditions”
NIOEC-SP-00-10 “NIOEC Specification for Units”

NIOEC-SD (NIOEC STANDARD DRAWINGS)

Applicable standard drawings shall be those shown in Appendix I of this Specification.

3. UNITS

International system of units (SI) shall be used in accordance with NIOEC-SP-00-10,

unless otherwise specified.

4. DEFINITIONS & TERMINOLOGY

4.1 “Employer” means: “National Iranian Oil Engineering & Construction Company”.
(NIOEC)

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4.2 “Purchaser” means: “National Iranian Oil Engineering & Construction Company”.
When quoted in this Specification as part of a direct purchase order by NIOEC and
“Contractor” where this Specification is part of contract documents.

4.3 “Vendor” means: The manufacturer from which the equipment is to be purchased.

4.4 “Erector” means: The Company which is responsible for the erection of the vessel at site.

4.5 “Contractor” means: The person, firm, company or consortium whose tender has
been accepted by the Employer or legal successors in title to such person.

5. GENERAL

5.1 The Contractor, Purchaser or user shall supplement this document with the required
additional design information necessary for the fabrication of the vessel(s). The
complete package shall be supplied to the vessel fabricator as the User’s Design
Specification per Paragraph A-301 of Division 2.

5.2 Code Stamp

ASME U-Stamp is required, unless otherwise specified. In any case the manufacturer
shall be internationally reputable for manufacturing such equipment and shall hold valid
authorization to use ASME U-Stamp.

6. DESIGN

6.1 Design Pressure and Temperature

6.1.1 Design pressure and temperature shall be as per clause 5.1 of NIOEC-SP-00-50
“Design Criteria”.

6.2 Minimum Diameter

6.2.1 The normal minimum diameter shall be 914mm (36”) ID for vessels requiring
removal of internals, except where internals can be removed as one unit or
vessel is flanged in short sections.

6.2.2 Special approval by NIOEC is required for vessels with internals with an
absolute minimum diameter of 760 mm (30”) where provision for removal of
trays through man way below trays shall be provided.

6.3 Loading Conditions

6.3.1 All combinations of loads shall be considered to determine the maximum
design stress conditions for design as follows:
a) Hydrostatic test loads shall be considered simultaneous with 20% of wind
load, and not coincident with snow and earthquake loads.
b) Earthquake loads shall not be considered, simultaneous with wind loads.

6.3.2 Specified loads due to earthquake, and climatic conditions shall be specified.
Should other loads such as listed below be of significance for the purposes of
vessel design those shall also be specified.
a) Erection loads: The loading to cover loads during construction.
b) Overhaul loads: The maximum maintenance loading conditions including

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hydrostatic testing of pipes and equipment and partial loading for
equipment loading.
c) Normal loads: Operating loads coincident with climatic or earthquake loads.

d) Conversion unit upsets: Conditions of normal operation plus the load

imposed by the weight of catalyst content that can build up inside towers,
vessels or piping covered by a sudden stoppage of flow at any point in the
system.

e) Internal equipment loads: If the actual tray weights are not known at vessel
design stage, loading estimates shall be made on the following basis:
Bubble trays: 1436.4 Pa (30 psf) (pressed carbon steel).
1197.0 Pa (25 psf) (pressed alloy steel).
Plus equivalent of 10 cm liquid on each tray to be added to
operating condition.

f) Earthquake load shall be in accordance with civil design criteria NIOEC-SP-

00-01. (clause 2.10)
g) Wind load shall be in accordance with U. B. C. as following:

1) Basic wind speed and exposure coefficient at site as per NIOEC-SP-00-11.

(Site Conditions)

2) Design wind pressure shall be in accordance with the chapter 16 of UBC

Vol. 2, division III.

h) Snow load shall be considered as per spec. No. NIOEC-SP-00-11 (Site

Conditions)

6.4 Design and Analysis

6.4.1 The design of the shell, heads, nozzles, skirt and other parts within code
jurisdiction shall be in accordance to Division 2. For Cr-Mo alloy steels,
plates and forgings, the allowable stress intensity values used shall be that of
quenched and tempered material. Reactors shells shall be of forged material.

6.4.2 When thermal gradients exceed 83°C in a distance equal to RT where R

and T are the radius and thickness of the vessel component in question, a
thermal stress analysis shall be performed. The procedures of the ASME
Code Section VIII Division 2 shall be used for this analysis. The thermal
stress shall not exceed the minimum guaranteed yield strength of the
material.

6.4.3 The effect on the shell of loads applied from both externals and internals
shall be analyzed, if necessary.

6.4.4 When approved by the company and when the vessel fabricator will
guarantee strength properties, the maximum allowable stress in tension shall
be the lowest of:
a) 30% of the design stress intensity values as per ASME Sec. VIII Div. 2.
b) 66.7% of the guaranteed yield strength at room or design temperature,

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whichever strength is lower.
c) The average stress to cause 1% creep in 100,000 hours.
d) Two-thirds of the average, or 80% of the minimum, stress required to cause
rupture in 100,000 hours, whichever is lower.
6.4.5 A fatigue analysis shall be performed when the allowed stress in tension
exceeds 33.3% of the guaranteed tensile strength. The procedure of ASME
Code Section VIII Division 2 shall be used for this analysis.

6.4.6 When weld overlay clad is specified, the thickness of cladding shall not be
included in design pressure calculations, but the minimum cladding thickness
shall be included in calculating the hydro test pressure, new and old.

6.4.7 The minimum inside corner radius for all openings shall be the lesser of the
following:
a) ¼ of the thickness of the vessel component penetrated.
b) ¼ of the finished inside diameter of the opening.
c) 19 mm (¾ in).

6.4.8 No exterior radius for attachments shall be less than 6 mm ( ¼ in.).

6.4.9 Pressure vessels made of carbon steel, carbon - molybdenum, chromium-

molybdenum low alloy steels (1 cr- ½Mo, 1¼ cr-½ Mo, 2¼ cr-1 Mo and 3 cr-
1 Mo) to be operated at temperatures of 350°C (660°F) and over, shall have a
skirt joint construction with full penetration weld from outside of the skirt by
integral forged ring as shown in Fig. 1.

SKIRT JOINT CONSTRUCTION

Fig. 1

6.4.10 The region of the bottom head-to skirt intersection shall be analyzed for
membrane and bending stress intensities. The temperature distribution in this
region, including the gradient down the skirt, shall be determined using
design temperature inside the vessel, plus the insulating information
furnished by the user or Contractor. The stress analysis shall include effects
of internal pressure, skirt loads, and temperature distribution.

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6.4.11 Attachment welds of all accessories such as plate lugs for platforms, ladders
and others including internal support lugs and rings shall be continuous welds
for heavy wall pressure vessels. Full penetration welds shall be employed as
attachment welds for the vessels in hydrogen services.

7. MATERIALS

7.1 All materials used in the vessel(s) shall be new and of the type specified in this
Project Specification. The steel used for fabrication of heavy wall pressure vessels
shall be made by the basic electric and oxygen furnace and plate and forging materials
shall be made from vacuum degassed steel. Substitutions may not be made without
prior approval from NIOEC.

7.2 Defects requiring removal in plates and forgings shall be repaired by welding by the
vessel fabricator in accordance with ASME pressure vessel code section VIII Division
2 requirements. The repair weld shall be examined both by radiography and ultrasonic
means. A record of all such repairs shall be maintained.

7.3 When specified and for hydrocracking and hydro treating reactors, reactors shell shall
be made from forged cylindrical rings without having any longitudinal seam.

7.4 The forging material shall be in accordance with the ASME Section II Part A, SA-266
"Forgings Carbon Steel for Pressure Vessel Components" and SA-336 "Forgings
Alloy Steel for Pressure and High Temperature parts as applicable.

7.5 Temper embitterment of 1 Cr-½ Mo, 1¼ Cr-½ Mo, 2¼ Cr-1 Mo and 3 Cr-1 Mo class
low alloy steels to be operated at temperatures of 350°C and over shall be minimized
by controlling the temper embitterment factor (called J-factor) below 100. J-factor is
defined as:
J-factor = (Si+Mn) × (P+Sn) × 104 ≤ 100
Where Si, Mn, P and Sn are weight percentage of silicon, manganese, phosphorous and
tin respectively.

7.6 For weld metal of low alloy steels (1Cr- ½Mo, 1¼Cr-½Mo, 2¼Cr-1Mo and 3Cr-1Mo)
in the SAW (Submerged Arc Welding) and SMAW (Shielded Metal Arc Welding)
processes, the temper embitterment factor called X-factor shall be 15 ppm maximum.
X-factor is defined as:
X-factor = (10P+5Sb+ 4Sn +As) × 10-2 ≤ 15 ppm
Where P, Sb, Sn, and As are weight percentage of phosphorous, Antimony, tin and
Arsenic respectively.

7.7 Pressure vessels may have heads made from plates conforming to its relative ASME
standard.
Silicon content of head plates and shell forgings for vessels made of Cr-Mo alloy
steels shall be 0.07% maximum.

7.8 All wrought materials used in, or welded to pressure parts of the heavy wall pressure
vessels shall have an alloy composition in the same range as specified for the shell
and heads and shall be in the same heat treated condition. This includes non-pressure

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parts such as skirt, clips, lugs and all internals of non-cladded vessels. The tensile
strength of such parts shall be in the same range as specified for the shell and heads.

7.9 When the vessel drawings and Data Sheet specify stainless steel cladding, the metallic
internals and all materials welded to cladding or not welded (including bolting
material) shall be stainless steel of the compositions specified on the Data Sheet.

7.10 Mechanical properties of plate and forgings shall meet the requirements of the
specified material standard. Maximum tensile strength at room temperature shall be
690 MPa (100,000 psi). If design temperature of the vessel is greater than 343°C
(650°F), tensile test at design temperature shall be conducted with results reported
to NIOEC.

7.11 One set of 3 chirpy V-notch impact tests according to ASME standard SA-370 shall
be conducted on completely heat treated specimens from plates and forgings of each
heat treated lot. Toughness requirements for low alloy steel materials after temper
embitterment test shall meet the following criterion:
VTr 54 + 2.5 (VTr’54-VTr 54) ≤ 38°C (100°F)
Where:
54 is 54 Jouls (40 ft-lbs) transition temperature in the min. PWHT condition.
VTr’54 is 54 Jouls (40 ft-lbs) transition temperature in the min. PWHT plus step
cooled condition.
Step cooling procedures shall be approved by NIOEC.
Impact values for carbon steel material shall be as specified on the ASME code section
VIII Division 2.
Lateral expansion in mils and percent shear fracture shall be reported with the impact
test results.

7.12 Ferrite content of type 347 stainless steel weld overlay by schaefller’s diagram shall
be controlled between 3 to 10 percent.

8. INTERNALS

8.1 When materials are not specified, Vendor’s proposals shall be submitted to the
company for approval. Vendor’s proposals to use materials alternative to those
specified shall also be submitted to the company for review and approval.

8.2 Where Aluminized stainless steel screens are specified, aluminizing shall be applied
by a high temperature diffusion process, "Agonizing" or equivalent process. Other
aluminizing processes proposed shall be submitted for company’s approval.

8.3 Free machining grades of steel are not permitted, except that type 416 nuts furnished
to ASTM A-194 Gr 6F with selenium are acceptable for use with ASTM A-193 Gr
B6 Bolts.

8.4 All bolting for internals shall be a minimum of 10 mm diameter.

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8.5 All bolting hardware shall be of the same type of material as the internal which they
are connecting or which are being connected to support members. However, 12% Cr
shall be used for carbon steel internals.

8.6 All stainless steel type 300 series bolts and nuts shall have micro-coating to prevent
ceasing and for ease of opening.

8.7 All removable internals shall be designed to permit installation and removal from the
top side.

8.8 Vessel internals which contribute to the total reactor height shall be designed for
minimum height. Similar parts shall be interchangeable where possible.

8.9 Screens shall be attached on top of grids and catalyst support members to prevent
inserts and catalyst from falling through holes or slot openings and blocking
clearances in support members that are required for thermal expansion.

8.10 A minimum of 25 mm overlap under the most adverse operating conditions shall be
provided between the support ring and the O.D of trays, decks and grids.

8.11 Clearance between thermo well and thermo well nozzle shall be minimum.

8.12 Bed support grids shall be covered with wire screen. All layers of screen shall extend
a minimum distance of 75 mm up the web section of the support beams and the
vessel shell.

8.13 All internals welded to the vessel shall be attached with full penetration welds.

8.14 Surfaces of fabricated parts shall be smooth and free of dents/hammer marks, kinks
and other defects, particularly in locations which might prevent close metal-to-metal
fit.

8.15 Tolerances for fabrication and assembly of internals for heavy wall pressure vessels
and reactors shall be in accordance with Table 1 below:

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TABLE 1 - FABRICATION AND ASSEMBLY TOLERANCES FOR INTERNALS OF HEAVY

WALL PRESSURE VESSELS AND REACTORS

DESCRIPTION TOLERANCES
mm
Location of parts bolted to clips or brackets welded to reactor ±3
Height of tubes chimneys, or weir notches above top of tray ±1.5
Distributor tray level:
Reactor ID- ≤ (1200 mm) 4 ft. ±3
Reactor ID- > (1200 TO 2100 mm) 4 TO 7 ft. ±5
Reactor ID- > (2100 mm) 7 ft. ±6
· Flatness for tray floor 6 Max.
· Leveling for support ring ±2
· Clearance between tray and support ring and between tray and
support beam 2 Max.
Deformation of support beam:
1) Vertical 3.2 Max.
2) Lateral 3.2 Max.
Diameter of hole (except bolt hole) ±0.1
Triangular pitch of hole ±2.0
Clearance between section tray deck:
1) For perforated tray 0, +3.0
2) For chimney tray ±1.0
Distance between tray support ring and grid support ring, and between tray support
ring and chimney tray ±2.0
Clearance between sectional grids, and between grid and support beam 0, +1.6
Location of hole for catalyst drain pipe:
1) Orientation ±0.5°
2) Distance from vessel center line ±3.2
Location of hole for quench pipe:
1) Orientation ±0.25°
2) Distance from vessel center line ±1.6

8.16 One tray, grid and deck of each diameter and type shall be assembled in the vessel at
fabricator’s shop to the extent necessary to check fit-up.

8.17 All welds on internal parts shall be examined using N.D.T. Scope of examinations
and tests shall be approved by the company.

8.18 Trays shall be leakage tested after installation in the erected reactor. Permissible
leakage shall be uniformly distributed across the area tested.

8.19 Quench nozzle spray pattern shall be tested with steam.

9. NOZZLES

9.1 All nozzles shall be the integrally reinforced type and conform to the details shown
in Fig, AD-613-1 of Division 2 except nozzles 4 inches and less not subject to
external loads may conform to details shown in Fig. AD-610-1. The large head
nozzle may be the studded type or through bolted linage type.

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9.2 Nozzles shall be flush and ground smooth with the inside of the vessel wall to form a
smooth rounded contour. Large head nozzles may project inside the vessel when
such projections are approved by NIOEC. External attachment welds shall be ground
to provide a smooth transition between head or shell and nozzle necks.

10. FABRICATION

10.1 All welding, including permanent or temporary attachment, and repair shall
conform to Division 2 requirements.

10.2 Procedure qualification tests shall be made on plates of the material specified for
the vessel using welding electrodes, wire, and flux of the same, type and brand to
be used on the work.

10.3 Qualification test plates shall be in accordance with Section IX of ASME Code.

10.4 Test plates shall be subjected to 100 percent of the thermal treatments anticipated
for the finished vessel. Each test plate shall be subjected to Chirpy V-notch impact
tests in accordance with Article T2 of Division 2. Impact values shall conform to
paragraph 7.10 of this Specification. Tensile tests from these qualification test
plates shall have a tensile strength limited to 100,000 psi at room temperature after
final heat treatment. Tensile tests at design temperature shall be conducted per
paragraph 7.10 of this Specification.

10.5 All welding shall be completed prior to final heat treatment.

10.6 Where weld overlay is specified heads and nozzles shall also be overlay lined
except heads less than 4 inches thick may be integral clad with material similar to
the overlay. If clad heads are used, they shall be 100% ultrasonic examined for
lack of bond after forming. Unbounded areas shall be removed and repaired by
weld overlay of the same or similar analysis. Nozzles may also be clad by
explosion bending with the same examination as for clad heads above. If nozzles
are too small to be lined as above, alternates will be shown elsewhere in this
Project Specification.

10.7 The weld overlay procedure shall be qualified on base metal of the same
composition as the vessel and thickness of not less than one-half of the vessel
thickness. Overlay material unless otherwise specified, shall be 4.8mm minimum
thickness of uniform composition of TP 347 containing 5-12.5% as ferrite as
measured by the Severn gauge or 5-10% as calculated from the Schaefiler
Diagram. Flaws on the surface of the base metal that would interfere with bonding
of the overlay shall be removal by grinding.

10.8 The weld overlay shall be applied circumferentially to the vessel and shall be
relatively smooth with no notches and undercuts that would act as stress raisers.
The entire surface of the weld overlay shall be liquid dye penetrate examined.
When the overlay involves two passes (layers) and the procedure uses an
intermediate heat treatment with cooling to room temperature prior to applying the
second layer, each layer shall be examined.

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All cracks, fissures and circular defects greater than 1/16 inch diameter shall be
removed. Repaired areas shall be reinserted by dye penetrating.

10.9 Welds between austenitic stainless steel internals and the stainless weld overlay
shall be full penetration.

10.10 Where weld overlay is specified, heads and nozzles shall also be overlay lined
except heads less than 100 mm thick may be integral clad with material similar to
the overlay. If clad heads are used, they shall be 100% ultrasonic examined for
lack of bond after forming. Unbounded areas shall be removal and repaired by
weld overlay of the seam or similar analysis. Nozzles may also be clad by
explosion bonding with the seam examination as for clad heads above.

10.11 Stainless steel Type 347 weld overlay shall be applied after the vessel final post
weld heat treatment if practical. Otherwise, weld overlay cladding (Type 347) of
ring joint gasket grooves and other areas of high stress concentration shall be
applied after final post-weld heat treatment.

10.12 Nozzles shall be flush and ground smooth with the inside of the vessel wall to
form a smooth rounded contour.
External attachment welds of nozzles shall be ground to provide a smooth
transition between head or shell and nozzle neck.

11. WELDING

11.1 Welding procedure qualification test in strict accordance with the ASME Code
Section IX.

11.2 Production weld test plates are required when the vessel thickness exceeds 100 mm.
At least one plate shall be prepared for each type of shell welding in each vessel.
The plates shall be subjected to the total thermal treatment as the finished vessel.
The test plates shall be prepared from material actually used in construction of the
vessel having a thickness equal to the finished vessel thickness. Production weld test
plate shall be made in accordance with ASME Code Section VIII, Division 2 and
the company Specification.

11.3 Each test plate shall be subjected to chirpy V-notch impact test in accordance with
the ASME Code Section VIII Division 2 (At-203).

11.4 The weld overlay procedure shall be qualified on base metal of the same chemical
composition as the vessel and thickness of not less than one half of the vessel
thickness. Flaws on the surfaces of the base metal that would interfere with bonding
of the overlay shall be removed by grinding.

12. EXAMINATION

12.1 Magnetic Particle:

12.1.1 All magnetic particle examination shall be in accordance with Article 9-1
of Division 2. If prods are used, tips shall be carbon steel. Lead or copper
tips are not permitted.

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12.1.2 All plate edges after trimming, all root passes in she heads and nozzles,
weld build-ups on shell and heads, all back gouged surfaces, skirt to head
attachments weld and all attachment welds on the base metal shall be
magnetic particle examined.

12.1.3 Temporary shop attachments shall be cut off above the weld, ground
smooth to the plate and magnetic particle examined.

12.1.4 All external shell, head, and nozzle welds, permanent attachment welds
and skirt to head weld shall be magnetic particle examined after
hydrostatic test. The yoke method shall be used as much as possible for
this final examination.

- The following areas shall be magnetic particle inspected. Magnetic particle

inspection shall be in accordance with ASME Code. Section V and Section
VIII Division 2 article 9-2.

12.1.5 Welding edges (Bevels) for category A,B and D joints.

12.1.6 Back gouged surfaces of category A,B and D joints and skirt to bottom
head joint.

12.1.7 All inside surfaces of category A,B and D joints prior to weld overlay
cladding.

12.1.8 All outside surfaces of category A,B and D joints and attachment weld of
skirt to bottom head after PWHT and hydrostatic testing.

12.1.9 All weld joints (circumferential and longitudinal seams) in the skirt both
inside and outside after PWHT.

12.1.10 The areas where temporary attachment welds have been removed. The
areas shall also be examined after final PWHT.

12.1.11 Repaired areas (if any) shall be examined after final PWHT.

12.1.12 External attachment welds shall be examined after final PWHT.

12.2 Radiographic:

12.2.1 All radiographic examinations shall be in accordance with Article 1-5 of

Division 2.

12.2.2 All shell and head seams shall be 100% radio graphed. Radiographs for
acceptance of the vessel(s) may be done after an intermediate PWHT at a
temperature less than the final PWHT temperature.

12.2.3 Welds between nozzles conforming to Fig.AD-613.1 and shell or heads

shall be 100% radio graphed. See paragraph 12.2.2 for time of acceptance
radiographs.

12.2.4 100% of category A,B and D joints in shell and heads.

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12.2.5 Repaired weld in base metal having a depth over 10 mm.

12.2.6 100% of Cr-Mo to Cr-Mo butt joint within the skirt (longitudinal and
girth seams).

12.2.7 One spot per each seam of Cr-Mo to carbon steel and carbon steel to
carbon steel within the skirt.

12.3 Ultrasonic:

12.3.1 Plate and forgings 4 inches thick and over shall be ultrasonically examined
as required in paragraph AM 203.1 and 2 of Division 2, with the exception
that a 100% search be made.

12.3.2 All ultrasonic examinations of welds shall be in accordance with Article 9-

3 of Division 2.

12.3.3 All butt welded joints in the shell and heads, all nozzle to shell and head
welds shall be 100% ultrasonically examined after final PWHT.

12.3.4 Repair welds described in paragraph 7.2 shall be examined.

12.3.5 Steel plates or plate like forgings such as shell rings after final machining.

12.3.6 All forged materials except plate-like forgings such as forged nozzles after
machining.

12.3.7 Head plates before hot forming (100% scanning).

12.3.8 100% scanning of head plates after hot forming and heat treatment.

12.3.9 Cr-Mo skirt plate after heat treatment (100% scanning)

12.3.10 Carbon steel skirt plate, base plate and compression ring after heat
treatment (230 mm grid scanning).

12.3.11 100% of category A,B and D joint in shell and heads after final post weld
heat treatment (PWHT) and after hydrostatic testing.

12.3.12 100% of attachments weld of skirt to bottom head and longitudinal seams
of Cr-Mo steel skirt after PWHT.

12.3.13 Repair welds in base metal after PWHT. For repaired welds in base metal
having a depth 10 mm and less, the repaired weld shall also be
ultrasonically inspected before PWHT.
12.3.14 Overlay cladding of shells and heads including weld joint overlay after
cladding and after PWHT.

12.3.15 Weld overlay cladding of nozzles with inside diameter 200 mm and larger
after cladding and after PWHT.

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12.3.16 Weld build-up deposit of low alloy steel material after final machining.

12.4 Liquid Penetrate:

12.4.1 All liquid penetrate examinations shall be done in accordance to Article 9-2
of Division 2.

12.4.2 Weld overlay as described in paragraph 10.8 shall be examined.

12.4.3 Welds joining austenitic stainless steel internal attachments to austenitic

weld overlay shall be 100% dye penetrate examined. Defect removal shall
be as defined in paragraph 10.8.

12.4.4 Full area of final weld overlay cladding of shell and heads after cladding
and after PWHT.

12.4.5 Gasket seating surfaces of nozzles after final machining and also after
PWHT.

12.4.6 Inside surface of attachment welds of skirt to bottom head after PWHT.

12.4.7 All internal attachment welds shall be examined after PWHT.

12.4.8 Repaired areas (if any) shall be examined after PWHT.

13. TESTS

13.1Chemical Analysis:

13.1.1 Certified chemical analysis of all automatic weld wire is required. A

check analysis of every 15th reel of wire or heat for alloy content is
required.

13.1.2 Samples of each completed shell, head and nozzles weld shall be
analyzed to confirm required alloy content. Samples to be taken from the
inside weld surface prior to weld overlay.

13.1.3 Two samples of the stainless weld overlay shall be taken from each
overplayed shell section and each head to confirm required analysis. Each
manual weld overlay such as on girth seams and nozzles shall also be
sampled. Analysis to the required depth of 4.8mm, or as otherwise
specified, shall conform to: 0.08%C max, 18 to 22.5% Cr, 8 to 12.5% Ni,
1.75 to 2.75% Mn and 8x carbon % Cb. Any deviation from this analysis
is unacceptable unless approved in writing by NIOEC.

13.1.4 Chemical analysis of base metal welds and chemical analysis and ferrite
check of weld overlay cladding shall be made before PWHT as per the
following. Acceptance shall be per ASME Code Section II Part C and this
Specification.

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13.2 Hardness Tests:

13.2.1 One hardness reading shall be taken on each shell section, head,
longitudinal weld, girth weld and nozzle after final post weld heat
treatment. The Brielle hardness readings shall not exceed 200 for carbon
steel and 225 for alloy steels.

13.2.2 Hardness test on weld metal, base metal and heat affected zones shall be
performed after PWHT as per the followings:

13.2.3 One per each weld seam between shell and shell and shell and head.

13.2.4 One per each size and each WPS for nozzle attachment weld of heads and
shell.

13.3 Hydrostatic Test:

13.3.1 The vessel(s) shall be hydrostatic tested in accordance to the requirements

of Article T-3 of Division 2.

13.3.2 The vessel metal temperature shall be a minimum of +50ºF during test. If
a maximum temperature is deemed necessary, it will so be indicated in
the general notes (not for reactors).

13.3.3 Water used for testing should contain no greater than 30ppm chloride for
reactors.

13.3.4 When testing vessels containing austenitic stainless steel lining and water
used contains greater than 30ppm chloride, the testing solution should
contain a ½% solution of sodium nitrate. Vessel(s) shall be dried
thoroughly, immediately after draining to prevent the possibility of
evaporation and concentration of chlorides.

13.3.5 Heavy wall pressure vessels shall be hydrostatic tested in accordance with
the ASME Code Section VIII Division 2 Paragraph AT-301.

13.3.6 The vessel metal temperature during hydrostatic test shall be 21°C
minimum.

13.3.7 Water used for testing heavy wall cladode pressure vessels shall contain
not more than 30 ppm chloride

14. INSPECTION

14.1Visual and Dimensional Inspection

The following areas shall be visually and dimensionally inspected. Acceptance of

results shall be according to the relative drawings and Specifications.

14.1.1 Fit-up of category A (shell to head), B(Shell to shell) and D(nozzles to

shell and heads) joints and skirt to bottom head joint.

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14.1.2 As built dimensions of pressure bearing parts.

14.1.3 As built dimensions of attachments.

14.1.4 Visual inspection of internal surface of vessel.

14.1.5 Visual inspection of full area of first layer weld overlay cladding.

14.2 In addition to the Division 2 qualified inspector on duty, the Purchaser’s inspector
or his agent shall have free entry at all times while work on this order or contract is
being performed, to all parts of the manufacturer’s work connected with this order
or contract, for periodic as well as final verification that the work is done in
accordance with the required Specifications and codes.

15. MARKING

15.1 In addition to the required Code Marking, the fabricator shall legibly and
permanently mark the vessel(s) at a location visible and legible at all times that
welding or arc-striking anywhere on this vessel is not permissible.

15.2 If welding for any reason is required anywhere on this vessel in the future, the
fabricator must be consulted prior to any welding for appropriate welding
procedures. NIOEC shall be notified in writing the reason for, location of, extent of,
and procedure used for any such welding.

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APPENDIX I
NIOEC STANDARD DRAWINGS

NIOEC-SD-4022-1/1-A3 Support Ring for Hot Insulation

NIOEC-SD-4025-1/1-A3 Earth Lug

NIOEC-SD-4026-1/1-A3 Fireproofing Tie Wire Nut

NIOEC-SD-4027-1/1-A3 Name Plate for Vessel

NIOEC-SD-4028-1/1-A3 Skirt and Base Plate for Vertical Vessels

NIOEC-SD-4105-1/1-A3 Hinge and Davit Details for Manholes

NIOEC-SD-4114-1/1-A3 Alloy Clad & Overlay Welding Details for

Nozzles shell & Head Joints

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