ENGINEERING SPECIFICATION

Project ;

PRESSURE VESSELS OF LOW ALLOY STEEL

SEP

ES No.

D-121

Revision

PAGE

1 OF 7

* REVISION HISTORY SHEET *

REV. NO.

DATE

DESCRIPTION

May. 21, 2008

Newly Issued For S-OILs Approval

Aug. 28, 2008

Reissued for S-Oils Approval

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844/Engg Spec D-121 Rev1.doc

TOYO ENGINEERING CORP.

ENGINEERING SPECIFICATION
Project ;

SEP

PRESSURE VESSELS OF LOW ALLOY STEEL

ES No.

D-121

Revision

PAGE

2 OF 7

CONTENTS

1.
1.1
1.2
2.
2.1
2.2
2.3
3.
3.1
3.2
3.3
3.4
4.

GENERAL
Scope
Code, Standards and Regulation
DESIGN
General
Material
Calculation
DETAIL DESIGN
Shell and Head
Nozzles and Manholes
Skirt
External Attachment
FABRICATION

PAGE
3
3
3
3
3
3
3
4
4
4
4
4
4

4.1
4.2
4.3

Material Identification
Plate Layout
Welding

4
4
4

5.

INSPECTION AND TEST

5.1 Base Material

5.2 Welding Qualification Plates

5.3 Production Test Plates

5.4 Pressure Holding Welds

5.5 Non Destructive Test

5.6 Hydrostatic Test

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844/Engg Spec D-121 Rev1.doc

TOYO ENGINEERING CORP.

ENGINEERING SPECIFICATION
Project ;

SEP

1.

GENERAL

1.1

Scope

1.1.1

1.2

PRESSURE VESSELS OF LOW ALLOY STEEL

ES No.

D-121

Revision

PAGE

3 OF 7

This specification, together with data sheets, Purchasers Requisition, Purchase Order/Inquiry, vessel
Engineering Drawings sets forth the requirements for the design, fabrication, inspection, testing and
supply of Cr-Mo steel pressure vessels and heat exchanger.
Codes, Standards and Regulation

1.2.1

Pressure vessels and heat exchangers shall be designed, fabricated, inspected and tested in
accordance with the requirements of ASME Sec. VIII Div.1, 2007 edition. Application of ASME Sec.
VIII Div.2 shall be subjected to Purchasers approval.

1.2.2

This specification supplements the following specifications.

D-101 Pressure Vessels
E-101 Heat exchangers
IN-42-1 Low Alloy Steels for Pressure Vessels Application to 1-1/4Cr-0.5Mo & 1-1/4Cr-0.5Mo with
clad or overlay
IN-42-2 Low Alloy Steels for Pressure Vessels Application to 2.25Cr-1Mo & 2.25Cr-1Mo with
clad or overlay

1.2.3

Priority for the Requirements

As a rule, priority order for the design, fabrication, inspection, testing and supply of Cr-Mo steel
pressure vessels and heat exchanger is as follows ;
(1)
(2)
(3)
(4)
(5)
(5)
(6)

2.

Applicable legal requirement, if any

Requisitions and minutes of meeting
Purchasers vessel Engineering Drawings and/or data sheets
IN-42-1 & IN42-2
D-121 (this specification)
D-101 & E-101
Code and standard, if any
However where there are conflicts between these drawings and documents, such conflicts shall
be promptly referred to Purchaser for solution.

DESIGN

2.1

General
Pressure vessels and heat exchangers shall be of mono-wall construction. Multi-wall construction shall
not be applied.

2.2

Material

2.2.1

For pressure retaining parts, materials shall be selected from those listed in ASME Sec. II, 2007
edition.

2.2.2

Material for skirt welded to the vessel shall be the same material as the vessel shell for the upper 800
mm as minimum. This length shall be verified, and extended if necessary, based on thermal
calculation. For vessels with design temperature above 400 , the thermal calculation shall be
submitted for Purchasers approval.

2.3

Calculation

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844/Engg Spec D-121 Rev1.doc

TOYO ENGINEERING CORP.

ENGINEERING SPECIFICATION
Project ;

SEP

PRESSURE VESSELS OF LOW ALLOY STEEL

ES No.

D-121

Revision

PAGE

4 OF 7

For skirt supported vessels with design temperature above 400 , a hot space shall be provided at the
shell to skirt junction in accordance with the Vessel Standard. Vendor shall determine a length of Z
shown in the Vessel Standard based on thermal stress analysis.
Stress evaluation shall be in accordance with ASME Sec. VIII Div. 2.

3.

DETAIL DESIGN

3.1

Shell and Head

3.1.1 Heads shall be plate or forged steel, and be hemispherical without meridional joints.
3.2

Nozzles and Manholes

3.2.1

Flanges for nozzles and manholes shall be forged steel.

3.2.2

Pipe used for nozzle necks shall be seamless.

3.2.3

Reinforcement shall be of integral type.

3.2.4

All nozzles and manholes shall be attached to the shell or head in accordance with ASME Sec. VIII
Div.1 Fig. UW-16.1 (f-1), (f-2), (f-3) or (f-4). Fig UW-16.1 (g) may be adopted at design temperature
below 400 .

3.3

Skirt
Skirt to head or shell attachment shall be made by means of a forged ring with stub. A weld build-up
examined by ultrasonic testing may be applied only when specified by Purchaser.

3.4

External Attachment

3.4.1 External lugs such as platform/ladder and piping support clips shall be minimized.
3.4.2 In general, insulation support rings shall not be directly welded to vessel wall.
3.4.3 For vertical vessels, lifting cover shall generally be provided at a top manhole instead of lifting lug.
Also, adequate tailing lug shall generally be provided to facilitate handling.

4.
4.1

FABRICATION
Material Identification

4.1.1 Each plate or forging shall be legibly stamped or stenciled so that each of them will be positively
identified in its position in the finished vessel or exchangers.
4.1.2 Positive Material Identification (PMI) program shall be submitted for Purchasers approval.
4.2

Plate Layout
The minimum distance between the edge of girth or longitudinal weld seams and the toe of attachment
weld seams such as nozzle necks, stiffener rings, tray supports and packing/catalyst supports shall be
1.5 time the shell thickness.

4.3

Welding

4.3.1 Welding process shall be submerged arc welding (SAW) or shielded manual arc welding (SMAW).
Gas tungsten arc welding (GTAW) may be applied to nozzle weld.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844/Engg Spec D-121 Rev1.doc

TOYO ENGINEERING CORP.

ENGINEERING SPECIFICATION
Project ;

SEP

PRESSURE VESSELS OF LOW ALLOY STEEL

ES No.

D-121

Revision

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5 OF 7

Flux cored arc welding (FCAW) and gas metal arc welding (GMAW) shall not be applied to pressure
retaining welding and external/internal attachment welding to pressure retaining parts.
4.3.2 All pressure holding weld joints of category A, B or C shall be Type No.1 full penetration butt welds as
defined in ASME Sec. VIII Div.1 UW-12.
4.3.3 Weld seams in skirt including skirt to head or shell joint shall be made with full penetration butt welds.
4.3.4 All external and internal structural attachments, except such minor items as fire proof nuts and name
plate saddle, shall be attached to vessel or exchangers by full penetration welds.
4.3.5 Preheating shall be employed during welding. The minimum preheating temperature shall be as per
Appendix R of ASME Sec. VIII Div.1.
4.3.6 Welds that will not be immediately post-weld heat treated, shall be intermediate stress relived (ISR).
Vendor shall submit his ISR program with experience record for approval by Purchaser.
4.3.7 Dehydrogenation heat treatment (DHT) can be substituted for ISR, if Vendor has sufficient experience.
Vendor shall submit his DHT program with experience record for approval by Purchaser.
4.3.8 The minimum post-weld heat treatment temperature shall be as follows.
Material
1.25Cr-0.5Mo
2.25Cr-1Mo

P-No
4
5

Minimum PWHT Temperature ()

655 (Note 1)
677

Note 1: Minimum PWHT temperature shall be 680 , when design temperature exceeds 500 .

5.

INSPECTION AND TEST

5.1

Base Material

5.1.1 Tensile test specimens shall be subjected to maximum total heat treatment time anticipated during
fabrication plus one post-weld heat treatment cycle for future use.
Hot tensile test is not required.
5.1.2 For 2.25Cr-1Mo steel, step cooling test shall be conducted on a per heat basis on specimens
subjected to one post-weld heat treatment cycle. Step cooling cycle shall be as follows.
Heat to 593 at a rate of 55.6 per hour
593 hold for 1 hour, cool at 5.6 / hr maximum to
538 hold for 15 hours, cool at 5.6 / hr maximum to
524 hold for 24 hours, cool at 5.6 / hr maximum to
496 hold for 60 hours, cool at 2.8 / hr maximum to
468 hold for 100 hours, cool at 27.8 / hr maximum to
315 hold then air cool
5.1.3 Location and orientation of impact and step cooling test specimens shall be in accordance with the
requirements in ASME Sec. VIII Div.1 UG-84.
5.2
5.2.1

Welding Qualification Plates

Welding wire, flux and rod for procedure qualification tests shall be the same type and brand as
those to be used for the production welds.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844/Engg Spec D-121 Rev1.doc

TOYO ENGINEERING CORP.

ENGINEERING SPECIFICATION
Project ;

SEP

PRESSURE VESSELS OF LOW ALLOY STEEL

ES No.

D-121

Revision

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6 OF 7

5.2.2

Weld tensile test specimens shall be subjected to the maximum total heat treatment time anticipated
during fabrication plus one post-weld heat treatment cycle for future use.

5.2.3

Impact test shall be conducted on specimens of weld metal and heat affected zone. Specimens shall
be subjected to minimum heat treatment.

5.2.4

For 2.25Cr-1Mo steel, step cooling test shall be conducted on specimens of weld metal and heat
affected zone. The requirements of heat treatment shall be as specified in paragraph 5.1.2.

5.2.5

Location and orientation of impact and step cooling test specimens shall be in accordance with the
requirements in ASME Sec. VIII Div.1 UG-84.

5.2.6

Hardness test of base metal, weld metal and heat affected zone shall be conducted after one postweld heat treatment cycle. It shall not exceed 225 BHN for 2.25Cr-1Mo steel and 220 BHN for 11/4Cr-0.5Mo. The results shall be shown in the Procedure Qualification Record.

5.3 Production Test Plates

Impact test shall be conducted on specification of weld metal and heat affected zone.

5.4 Pressure Holding Welds

5.4.1

PMI shall be conducted after welding and before PWHT. One location per each seam shall be
examined. Detailed procedure shall be submitted for Purchasers approval.

5.4.2

Hardness test of base metal, weld metal and heat affected zone shall be conducted after one postweld heat treatment cycle. It shall not exceed 225 BHN for 2.25Cr-1Mo steel and 220 BHN for 11/4Cr-0.5Mo. The number and location of hardness testing shall be as follows.
(1) Two per each circumferential and longitudinal seam
(2) One per each nozzle attachment weld

5.5 NON DESTRUCTIVE TEST

5.5.1

Radiographic examination
(1) All pressure holding welds, vessel to skirt weld and skirt welds in low alloy portion shall be 100%
radio graphed before PWHT. If a weld is not radiograph able, it shall be 100% examined with
ultrasonic test.
(2) Skirt welds in low alloy to carbon and carbon steel to carbon steel joints shall be 20% spot radio
graphed before PWHT.
(3) Radiographic examination shall be performed after ISR/DHT.

5.5.2

Ultrasonic examination
(1) All pressure holding welds shall be fully examined with ultrasonic testing after PWHT.
(2) All Cr-Mo weld deposits of internal lugs shall be examined with ultrasonic testing after ISR/DHT.

5.5.3

Magnetic particle examination

(1) Skirt welds in low alloy portion including vessel to skirt welds shall be examined with magnetic
testing after PWHT.
(2) Skirt welds in low alloy to carbon steel and carbon steel to carbon steel joints shall be examined
with magnetic particle testing after PWHT.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
BA-0844/Engg Spec D-121 Rev1.doc

TOYO ENGINEERING CORP.

ENGINEERING SPECIFICATION
Project ;

SEP

PRESSURE VESSELS OF LOW ALLOY STEEL

ES No.

D-121

Revision

PAGE

7 OF 7

(3) All Cr-Mo weld deposits of internal lugs shall be examined with magnetic particle testing.
(4) Attachment welds of non-pressure holding parts shall be examined with magnetic particle testing
after ISR/DHT, and also after PWHT.
(5) All area on pressure holding parts struck by arc shall be put on record and examined with
magnetic particle testing.
5.5.4

Liquid penetrant examination

(1) Welds in internals of stainless steel shall be examined with liquid penetrant testing.
(2) Chloride content of penetrant materials used on PT of stainless steel welds, i.e., penetrant,
remover of excess penetrant and developer shall be as low as possible.

5.6 HYDROSTATIC TEST

Metal temperature during hydrostatic testing shall be at least 17 above the minimum design metal
temperature.

This document embodies proprietary information of Toyo Engineering Corporation and described thereon may not be copied or disclosed in any form or medium to third parties,
or used for other than the purpose for which it has been provided, in whole or in part in any manner except as expressly permitted.
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TOYO ENGINEERING CORP.