PRESSURE VESSELS DESIGN AND FABRICATION

NOVEMBER 1993

PAGE 1 OF 34

EGE 12-B-1 1993

TABLE OF CONTENTS 1. 2. 3. 4. 5. Scope References Documentation General Design 5.1 General 5.2 External Loadings 5.3 Design Conditions and Allowable Stresses 5.4 Jacketed Vessels 5.5 Corrosion Allowance 5.6 Shell and Heads 5.7 Supports 5.8 Nozzles and Other Connections 5.9 Manways and Other Inspection Openings 5.10 Internals 5.11 Equipment Davits 5.12 Equipment Lifting and Tailing Lugs Materials 6.1 Pressure Parts 6.2 External Attachments and Supports 6.3 External Bolting 6.4 Alloy Linings Fabrication 7.1 Welding 7.2 Forming of Shells and Heads 7.3 Connections 7.4 Heat Treatment 7.5 Nonpressure Attachments 7.6 Dimensional Tolerances 8. Inspection and Testings 9. Repairs 10. Stamping and Records 10.1 Stamping 10.2 Records 11. Preparation for Shipment Appendix A Requirements for Contractor or Purchaser Appendix B Minimum Requirements for Pressure Vessels in Critical Service Appendix C Pressure Vessels with Special Design and Fabrication Requirements Appendix D Tolerances EGE 12-D-1A Pressure Vessel Data Sheet EGE 12-D-1B Documentation Requirements Sheet (DRS) EGE 12-D-1C Pressure Vessel Summary Sheet EGE 12-D-1D Witnessing Requirement for Inspection and Testing 7.

6.

1. SCOPE This Guide provides the requirements for the design, materials, fabrication, inspection, and testing of pressure vessels when any of the following conditions exists:

C C C

Designed for an internal pressure greater than 103 kPa gage (15 psig). Designed for vacuum conditions. When specified on data sheets or drawings.

MOBIL ENGINEERING GUIDE EGE 12-B-1 1993 2. REFERENCES The following publications form a part of this Guide. The references cited with dates in this Guide were used in its development. For all references which have been superseded, revised, and/or corrected, the user of this Guide is obligated to determine if the latest versions of the cited references have any impact on the content of this Guide or its use. MTC (Guide Sponsor) should be consulted if there are any concerns or questions.
Mobil Engineering Guides EGE 00-B-3 EGE 00-B-21 EGE 00-B-22 EGE 00-B-25 EGE 00-C-4 EGE 12-B-21 EGE 16-B-30 (1993) (1993) (1991) (1991) (1993) (1988) (1987) Structures and Equipment External Loading Design Basis Pressure-Containing Equipment Welding and Weld Inspection Pressure Equipment Impact Test Requirements Positive Materials Identification Equipment and Packaged Units General Purchasing Requirements Fractionating Tower Trays and Internals Piping Selection and Application of Piping Components and Materials (With Classification Sheets and Appendix)
PAGE 2 OF 34 NOVEMBER 1993

ASME (American Society of Mechanical Engineers) Standards Boiler and Pressure Vessel Code: (1992) Section I, Power Boilers (1992) Section II, Material Specifications, Parts A, B, and D (1992) Section VIII, Pressure Vessels, Divisions 1 and 2 B16.5 (1988) Pipe Flanges and Flanged Fittings, Steel Nickel Alloy and Other Special Alloys B31.3 (1993) Chemical Plant and Petroleum Refinery Piping B16.47 (1990) Large Diameter Steel Flanges ASTM (American Society for Testing & Materials) A-860 (1992) Standard Specification for High-Strength Butt-Welding Fittings of Wrought High-Strength Low-Alloy Steel

NACE (National Association of Corrosion Engineers) TM-02-84 TM-01-77 RP-01-78 (1987) (1990) (1991) Evaluation of Pipeline Steels for Resistance to Stepwise Cracking Laboratory Testing of Metals for Resistance to Sulfide Stress Cracking in H2S Environments Fabrication Details, Surface Finish Requirements, and Proper Design Considerations for Tanks and Vessels to Be Lined for Immersion Service

SSPC (Steel Structures Painting Council) SP6 (1991) Surface Preparation Specification No. 6 Commercial Blast Cleaning (Steel Structures Painting Manual, 5th Ed., 1989 - Ch 2 - Surface Preparation Specs.)

3. DOCUMENTATION 3.1 EGE 12-D-1A shall be completed for each vessel.

3.2 EGE 12-D-1B shall be completed for each vessel by the vendor and shall be submitted with the vendor proposals. Purchaser may specify critical dates for the receipt of the vendors data on the documentation requirements sheet (DRS).

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EGE 12-B-1 1993

3.3 The following information, in addition to that on the DRS, shall be submitted with the proposals. Quotations will be considered incomplete and may be rejected if they lack this itemized list. (a) Substitution of a pressure part material of a strength other than specified (see Paragraph 6.1.4).

(b) The location of, and reason for, any local postweld heat treatment (excluding repairs) and a description of the proposed procedure. (c) The proposed lining material, general lining procedures (clad or weld overlay), and proposed number of layers for both overlaying and backcladding seams. (d) Identification of subcontractors who will be forming and/or welding pressure parts, as well as suppliers of nonstandard or custom made forgings. 3.4 EGE 12-D-1C or equivalent shall be filled out and submitted by the engineering contractor after its data sheets/drawings are reviewed by Mobil. The engineering contractor shall be responsible for updating the pressure vessel summary sheet as necessary during the project duration. 3.5 EGE 12-D-1D or equivalent shall be filled out by the engineering contractor for each vessel (or group of similar vessels) and shall be sent to vendors in the inquiry package. 3.6 Prior to the start of fabrication, the fabricators general assembly, detail, applicable standard drawings, welding procedures, and design calculations, including lifting and tailing lugs, shall be submitted for Mobil review. When required, these drawings and calculations shall also be submitted to local governmental authorities. If calculations are computer printouts, input and output data shall be included along with necessary explanatory notes for interpretation. The fabricators welding procedure numbers shall be referenced in the drawings or on a weld map with indication as to where they apply. 3.7 The vendor shall register all ASME Code stamped vessels with the National Board of Boiler and Pressure Vessel Inspectors for US and Canadian locations. 4. GENERAL 4.1 Pressure vessels shall conform to the requirements of governmental regulations, any local statutory rules, project specifications, and this Guide, whichever are more restrictive. 4.2 The requirements of EGE 00-C-4 shall apply except as modified herein.

4.3 Requirements for the contractor or purchaser are included in Appendix A of this Guide. These are not intended for the direct use of the vendor. Design decisions based upon Appendix A must be clearly documented. 4.4 The minimum standards for pressure vessels in critical service (such as amine, caustic, HF acid, and wet H2S) are defined in Appendix B. 4.5 Pressure vessels with special design and fabrication requirements, as defined below, shall also conform to the requirements of Appendix C. (a) (b) Vessel shell is a ferritic alloy steel (chromium-molybdenum, manganese-molybdenum). Vessel shell thickness, including corrosion allowance/cladding, is greater than 50 mm (2 in.).

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Vessel is designed and fabricated in accordance with ASME Code, Section VIII, Division 2 rules.

(d) Vessel is in cyclic service as defined in Appendix A or as noted on the data sheet or the pressure vessel design drawing. 5. DESIGN 5.1 General

5.1.1 All unfired steam generators shall conform to the requirements of governmental regulations, any local statutory rules, ASME Code, Section VIII, Division 1, and this Guide except when part of steam generating equipment as defined by the ASME Code, Section I. 5.1.2 If economically justified, pressure vessels, including storage spheres, shall be considered for design according to the ASME Code, Section VIII, Division 2. 5.1.3 All vessels shall be stamped for their maximum allowable working pressure (MAWP) at the design temperature. MAWP shall be determined by calculation using actual thickness less the corrosion allowance in accordance with ASME Code, Section VIII, Division 1, Paragraph UG-98. The calculated MAWP shall not exc eed the flange pressure temperature rating selected for the design conditions. Nozzle reinforcement, cone-to-cylinder junction reinforcement, and saddle support designs shall not be a limiting factor in determining the MAWP. 5.1.4 Maximum allowable pressure (MAP) shall be calculated using the actual uncorroded thickness at ambient temperature and independent of any external loading such as wind and seismic. This pressure shall be used in determining the nozzle reinforcement and shop hydrostatic test pressure. 5.1.5 If required by the criteria of the ASME Code, Section VIII, Division 2, fatigue calculations shall be performed for Division 1 vessels in cyclic service. These calculations shall include stress concentration factors at welds and other discontinuities. 5.1.6 Stiffening and insulation rings on parts of vertical vessels with normal operating temperatures below 149C (300F) or in intermittent service shall have cutouts at their inner face for drainage. These drain slots shall be a minimum of 16 mm (5/8 in.) wide by 150 mm (6 in.) circumferentially long and spaced at no more than 1 m (3.3 ft) on center. 5.2 External Loadings

The project specifications and EGE 00-B-3 shall indicate the minimum external loadings to be used in the design. 5.3 Design Conditions and Allowable Stresses

5.3.1 Design conditions, allowable stresses, and the basis for calculating stresses shall be in accordance with Table 1 of this Guide. 5.3.2 The alloy lining thickness shall not be included in the calculations of the vessel wall thickness required for pressure.

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EGE 12-B-1 1993

5.4

Jacketed Vessels

Both the vessel and jacket shall be designed in accordance with this Guide and the ASME Code, Section VIII, regardless of design pressure. Vessel and jacket shall be designed for the most severe condition of coincident pressure and temperature. 5.5 Corrosion Allowance

5.5.1 The minimum corrosion allowances shall be as given in Table 2, unless otherwise specified on the data sheet or the pressure vessel design drawing. Higher corrosion allowances are required for certain processes. Consult MTC Facilities Group for recommendations. 5.5.2 Corrosion allowance for nonremovable internals and removable major parts (such as support beams for trays and/or catalyst bed, support gratings, etc.) shall be applied as specified to all surfaces of such parts. 5.5.3 Corrosion allowance for removable minor internals (such as pipe guides, bolted clips, nonpressure distributor piping, bolted vortex breakers, etc.) shall have only one-half the specified corrosion allowance applied to the exposed surfaces when the specified corrosion allowance exceeds 2.5 mm (0.1 in.). 5.6 Shell and Heads 5.6.1 The minimum fabricated thickness of the pressure shell and heads shall be the greater of the following: (a) (b) 5.6.2 (a) (b) (c) (d) D 1000 + 2.5 mm (0.1 in.), where D is the nominal diameter of vessel in mm (in.). 5 mm (3/16 in.) plus corrosion allowance. Only 2:1 ellipsoidal or hemispherical heads shall be used for the following: Design pressures over 690 kPa gage (100 psig). Operating temperatures over 343C (650F). Bottom heads of vertical vessels having height-to-diameter ratios exceeding 5. Head diameters 3.7 m (12 ft) and larger.

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TABLE 1 DESIGN CONDITIONS AND ALLOWABLE STRESSES

Basic Allowable Stresses and Special Criteria

Design Condition

Calculation Basis

Normal Operation: 1. Allowable stresses for pressure parts shall be as Corroded thickness and design Includes ! Design pressure established by the applicable code. metal temperature of the part. ! Operating dead load ! Operating contents 2. For internally insulated vessels, the calculated ! Superimposed external loads tensile stress shall also be limited to the average ! Other effects (such as stress for rupture at the end of 100 hours at the pressure drop loads, thermally internal design temperature (in the event of a induced piping or internal failure of the insulating lining). strain loadings, and dynamic loads) All combined with 3. Allowable stresses for nonpressure parts shall be wind or earthquake whichever one-third of the ultimate tensile strength, two-thirds is greater. (90 percent for austenitic materials) of the yield Catalyst regeneration or reactivation strength, or that stress which produces a creep conditions shall be considered as rate of one percent in 10,000 hours, whichever is operating conditions. lowest. Exceptions are:
a. The following nonpressure parts shall be designed using the stresses for pressure parts: W elds attaching nonpressure parts to the pressure parts. Internals whose failure would have serious consequences, such as plenums, catalyst support grids, and cyclone supports. Internals whose performance would be affected by deformation, such as liquid distributors and their supports. b. Anchor bolting shall be designed for a stress of 103 MPa (15,000 psi). High-strength bolting may be used only with Mobil approval. 4. Allowable longitudinal compressive stresses in pressure shells and in supporting skirts shall not exceed the compressive stress permitted by the ASME Code. 5. Static or dynamic deflection shall not exceed 0.005 height of ves. A dynamic analysis shall be performed if required by EGE 00-B 3.

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EGE 12-B-1 1993

TABLE 1 - Contd DESIGN CONDITIONS AND ALLOWABLE STRESSES

Basic Allowable Stresses and Special Criteria

Design Condition

Calculation Basis and test

Test: Includes

of vessel, attached piping, and equipment. It shall also include the weight of contents in the vessel, attached piping and equipment. Vertical vessels shall also be designed for rehydrostatic testing of the corroded vessel in place at a minimum of 110 percent of the maximum allowable working pressure (measured at the top of the vessel). Mobil shall be advised if this requirement governs the cost of vessel and/or foundation.

! Test pressure ! Test dead load

The maximum allowable tensile stress shall not Test thickness exceed 90 percent of the specified minimum yield temperature. strength of the material. Special care shall be taken in design and in establishing test pressure for vertical vessels to ensure that local permanent distortion does not take place.

Upset Condition: Includes ! Operating condition plus the The stress basis shall be as specified or approved by Corroded thickness and effects of any short-time Mobil. applicable metal temperature. overload or upset condition that requires immediate remedial measures. This does not include planned conditions such as catalyst regeneration or reactivation.
Any planned condition shall be considered as an operating condition. Potential upset conditions shall be brought to Mobils attention and considered individually, and wind or earthquake effects shall not be included.

Empty Equipment: Includes ! Empty dead load of the In accordance with Items 1 through 4 under normal Corroded thickness vessel, attached piping, and operation, except that the allowable stress for anchor ambient temperature. equipment. The above loads bolting may be increased to 124 MPA (18,000 psi). to be combined with wind or earthquake load.

and

Erection: Includes ! Empty dead weight of the In accordance with Items 1 through 4 under normal New thickness at ambient vessel, trays, insulation, operation, except that the allowable stress for anchor temperature. internal attachments, ladder, bolting may be increased to 124 MPA (18,000 psi). platforms, and external piping.

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TABLE 2 MINIMUM CORROSION ALLOWANCE FOR VESSEL PART

Minimum Corrosion Allowance Vessel Part Pressure, structural nonremovable, and major structural removable Material of Part Carbon and low-alloy (Cr-Mo) steels Ferritic alloy steels (5 Cr-Mo to 9 Cr-Mo) Stainless steels and nonferrous materials
(1) (1)

mm 1.3

in. 0.05

0.5 0.0

0.02 0.00

Thickness of alloy (2) protection Alloy-lined steels (clad or weld overlaid) All materials
(1)

Minor structural

0.0

(3)

0.00

(3)

removable Fixed Supports (skirts, legs, and lugs) Anchor Bolts Carbon and low alloy steel 3.0 0.125

Carbon and low alloy steel

3.0

0.125

on the diameter
(1) For nonremovable structural parts and for major and minor removable structural parts, if the specified corrosion allowance is 5 mm (0.2 in.) or greater, stainless steel should be considered. All structural internals shall be of the same material as the lining, with a corrosion allowance only if specified. Parts need not have corrosion allowance added unless the specified minimum corrosion allowance exceeds 2.5 mm (0.1 in.); see Paragraph 5.5.2.

(2) (3)

5.6.3 Stresses in the knuckle region of torispherical heads with a thickness-to-diameter ratio less than 0.002 shall be calculated to ensure stability against buckling. 5.6.4 (a) (b) (c) Cylinder-to-cone transitions shall be toriconical sections when any of the following conditions apply: The vessel is in cyclic service. The section is subject to a major support reaction (for example, skirt-to-cone attachment). Shell thickness is over 32 mm (11/4 in.).

NOTE: The knuckle of toriconical sections shall satisfy the requirements for area and moment of inertia of Appendix 1 of the ASME Code Section VIII, Division 1.

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EGE 12-B-1 1993

5.7

Supports

5.7.1 Skirts on vessels 1.5 m (5 ft) or less in diameter shall have at least one access opening. Skirts on vessels larger than 1.5 m (5 ft) shall have two openings. The minimum access openings shall be 610 mm (24 in.) in diameter [or 430 mm x 915 mm (17 in. x 36 in.) obround] for vessels less than 3 m (10 ft) in diameter and 760 mm (30 in.) in diameter for larger-diameter vessels. All access openings shall be reinforced. Piping shall not pass through access openings. 5.7.2 A minimum of four NPS 2 (NPS = nominal pipe size, inches) nipples shall be located near the top of the skirt to vent the space at the bottom head intersection. 5.7.3 Skirts shall be attached to the underside of heads so that the skirt and shell plate centerlines coincide. In no case shall a skirt be positioned so that a vessel girth seam is covered. 5.7.4 Horizontal vessels shall be supported on saddles covering at least 120 degrees of the vessel circumference. If a pad is provided on the vessel, it shall be continuously welded to the shell and vented. Saddles and pads shall not cover circumferential or longitudinal welds. No more than two saddles shall be used per vessel unless approved by Mobil. Stiffening rings shall be used when required. Concrete saddles shall not be used. 5.8 5.8.1 Nozzles and Other Connections Requirements for opening reinforcement and reinforcing pads shall be as follows: (a) Reinforcement for openings larger than 50 mm (2 in.) shall be based on the MAP. Where the shell thickness is increased for the wind or seismic loadings, the nozzle reinforcement area shall be as follows: The total area of reinforcement A required shall not be less than: A=dt

Where:
d t = = the diameter of the finished opening the nominal uncorroded thickness of the shell at the nozzle location

(b) Integral or common reinforcement is required for multiple nozzles where the distance between reinforcing pad edges would be less than 2.5 Rt (R and t being the head or sphere radius and uncorroded thickness, respectively). (c) Each reinforcing pad or segment thereof shall be provided with a 6 mm (1/4 in.) diameter NPT threaded telltale hole, which must be filled with grease after pressure testing. (d) When integral reinforcement is provided on nozzles 150 mm (6 in.) and greater, the ratio of nozzle wall thickness-to-shell wall thickness shall not be greater than 2. 5.8.2 Flanges shall be designed for the pressure and temperature to be shown on the vessel nameplate in accordance with the ASME Code, Section VIII, and the following requirements. (a) Flanges in sizes NPS 24 and smaller shall conform to the requirements of ASME B16.5.

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(b) Carbon steel flanges larger than NPS 24 shall conform to ASME B16.47 for ratings not exceeding Class 300. (c) Slip-on flanges are limited to Class 150, maximum design temperatures of 343C (650F), and noncyclic service. They shall not be used in critical or hydrogen service. (d) Plate or forged flanges with no hub may be used only for internal nonpressure connections. Minimum flange thickness is 9.5 mm (3/8 in.) plus corrosion allowance. 5.8.3 Lap-joint flanges require Mobil approval.

5.8.4 Bolting on flanges shall clear vessel insulation by not less than the distance required to insert and operate a box wrench. 5.8.5 Threaded and socket connections used as pressure parts shall be Class 6000 forged steel full couplings. 5.8.6 Bottom head connections that are brought through a skirt shall be of buttwelded construction. They shall be fabricated of pipe and pipe components at least one schedule weight heavier than that required for the MAWP plus corrosion allowance. 5.8.7 Nozzles and their reinforcing pads may not be located in the knuckle region of a torispherical head, nor closer than 2.5 Rt (R and t being the shell radius and uncorroded thickness, respectively) from a cone-to-cylinder junction (sharp intersection), without Mobil approval. 5.9 5.9.1 Manways and Other Inspection Openings Manway covers shall be equipped with davits or hinges to facilitate handling.

5.9.2 Flange facing for manways and handholes shall be of the raised-face type, with a finish conforming to ANSI B16.5, unless otherwise specified. 5.10 Internals 5.10.1 Fractionating tower trays and internals shall be designed and fabricated in accordance with EGE 12-B-21. 5.10.2 Tower bottom baffles shall be of all-welded construction and seal welded to the vessel shell or head, except where differential thermal expansion between the vessel and internals is of such magnitude as to preclude this design. 5.10.3 The minimum thickness of tray support rings and downcomer bolting bars shall be 5 mm (3/16 in.) before the corrosion allowance is applied.

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5.11 Equipment Davits Davits shall be provided for handling equipment weighing more than 68 kg (150 lb), such as safety valves, trays, and grids, which are subject to removal for periodic repair or replacement. The davits shall be designed to swing equipment clear of the vessel for lowering to grade. 5.12 Equipment Lifting and Tailing Lugs Purchaser shall define lifting requirements for a vessel. Vessel fabricator shall provide lifting and tailing lugs as specified. These lugs shall be designed to include weights of vessel, intervals, insulation, platforms, ladders and external piping (if applicable). These lugs shall be designed for a minimum impact factor of 1.5. It is the responsibility of the contractor to assure the adequacy of lifting and tailing lugs. The contractor is also responsible for assuring the shell induced stresses are within the ASME Code, Section VIII, allowables during the lift. 6. MATERIALS 6.1 Pressure Parts

6.1.1 Materials of construction for pressure parts shall be in accordance with one of the appropriate specifications listed in the ASME Code, Section II, except as follows: (a) (b) SA-36 and other structural quality steel shall not be used. Castings shall not be used for pressure parts.

(c) Alternative materials equivalent to the ASME Code material specifications may be used, with Mobil approval, for vessels not requiring the ASME Code stamp. The nomenclature and complete chemical and physical properties of the proposed material shall be stated along with the ASME equivalent. Any added requirement (fully killed, fine-grain practice, inspection practices, etc.) necessary for equivalence shall also be stated. 6.1.2 For minimum design metal temperatures below 49C (120F), carbon steel and low-alloy steel pressure parts, major attachments, and major internals shall be in accordance with EGE 00-B-22. Major internals and major attachments include those which are essential to the structural integrity of the vessel (e.g., supports, stiffening rings) and those with greater than 41 MPa (6000 psi) tensile stress. Other attachments shall meet ASME Code, Section VIII, toughness requirements when minimum design metal temperature is lower than !29C (!20F). 6.1.3 Materials shall be represented by test specimens that have been subjected to the same heat treatment as the completed vessel. The term "heat treatment" shall also include any heating above the critical range for hot forming. 6.1.4 Any substitution of material used for pressure parts other than that specified in the pressure vessel data sheet or drawings shall not be made without prior Mobil approval. 6.1.5 High-alloy nozzles in ferritic vessels are restricted in accordance with Paragraph 6.4.2, Item (b).

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6.1.6 The "tramp element" content of ferritic (carbon, Cr-Mo, Ni-Steels, etc.) steels shall not exceed the criteria in ASME Code, Section II, Table 1 of SA-20. If the use of titanium, boron bearing steel, vanadium, and columbium bearing high strength low-alloy (HSLA) steels is proposed, Mobil shall review and approve the applicable material specifications prior to the start of any fabrication. Other limits and range of elements may be required in certain cases, as noted in the vessel data sheet or drawings. 6.2 External Attachments and Supports

External attachments and supports shall be in accordance with Table 3 (also see Paragraph 6.1.2). 6.3 External Bolting

Bolting shall be as shown in Table 4. For bolting not covered by Table 4 and bolting for special services, such as marine and stress corrosion cracking environments, consult MTC. 6.4 6.4.1 (a) Alloy Linings Alloy linings shall be one of the following types: Integrally clad: (1) (2) (b) Hot rolled (Lukens clad or Mobil approved equal). Explosion bonded (Detaclad or Mobil-approved equal).

Alloy weld overlay.

6.4.2 Connections, manways, and inspection openings in alloy-lined portions of vessels shall conform to one of the following methods of construction (loose-sleeve liners are not permitted): (a) Connections of all sizes may be fabricated from integrally clad plate or protected with deposited alloy weld metal. (b) Solid, stabilized austenitic nozzles, and other connections may be welded to ferritic base material in noncyclic service with Mobil approval. (c) Flanges of ferritic base material with alloy weld overlay may be welded to alloy nozzles with Mobil approval. 7. FABRICATION 7.1 Welding

7.1.1 Preparation, preheating, welding, heat treating, and nondestructive examination of welds to pressure-containing parts shall be in accordance with EGE 00-B-21 except as modified herein.

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TABLE 3 MATERIALS FOR EXTERNAL ATTACHMENTS AND SUPPORTS Attachments and Support Material Vessel Material Carbon steel Major Attachments(1) Carbon steel(3) Minor Attachments(2) C a r b o n s t e e l

Other materials

Same material as shell

Carbon steel or same material as shell(4)

NOTES: (1) Includes the top 610 mm (24 in.) of skirts; supports welded to pressure parts for platforms, piping, and equipment; and stiffening rings. Includes items that are lightly loaded during operation, such as insulation clips, studs, lifting lugs, davit clips. For design temperatures over 343 C (650F), structural quality steels such as SA-36 and SA-283 shall not be welded to pressure parts. For design temperatures over 232C (450 F), carbon steel shall not be welded to pressure parts.

(2) (3)

(4)

TABLE 4 EXTERNAL BOLTING Bolting Temperature Range C F -198 to -102 -101 to -46 to -29 to 401 to 455 to 541 to -47 -30 400 454 540 650 -325 to -151 -150 to -51 -50 to -21 -20 to 750 751 to 850 851 to 1100 1101 to 1200

Ferritic Flanges Bolts A320 Gr L7 (1) A193 Gr B7 (1) A193 Gr B7 (1,5) A193 Gr B16 (1,5) A193 Gr B8M CL1*(3,6)

Nuts 2H or 4 2H 2H 4 8MA

Austenitic Flanges Bolts Nuts A320 Gr B8M CL2 (2) or A320 Gr B8 CL 2 (2) A320 Gr L7 (1) A320 Gr L7 (1) A193 Gr B7 (1) A193 Gr B16 (1,4,5) A193 Gr B16 (1,4,6) A193 Gr B8M CL1*(3,6) 8MA 8A 4 2H or 4 2H 2H or 4 4 8MA

*Do not insulate these flanges. NOTES: (1) HIGH-strength bolt as classified by ASME B16.5, Table 1B. (2) INTERMEDIATE-strength bolt as classified by ASME B16.5, Table 1B. (3) LOW-strength bolt as classified by ASME B16.5, Table 1B. This grade bolt and other Class 1 grades of austenitic bolting made to A193 and A320 should be used only with sheet gaskets or self-energizing gaskets (For example, 0-rings or other types of gaskets considered as selfsealing). Low strength bolts are limited to pressure classes 150 and 300. (4) Consideration should be given to "controlled torquing" or "pre-loading" of bolts for specific design conditions. When low alloy bolts (B7 or B16) are used with austenitic flanges, the bolts shall be tightened to not more than 50 percent of the specified minimum yield strength, since the flanges will expand more than the bolts in the hot condition. Consideration should also be given to the use of Belleville spring washers to offset the differential thermal expansion. (5) Exercise caution when insulating flanged joints with a temperature of 400C (750F) or higher. Joints should be adequately torqued prior to installing the insulation. Additionally, use of B16 bolts should be considered, since they have a higher strength, compared to B7 or B8M bolts, at temperatures of 400C (750F) and higher. The insulation of flanges in hydrogen service with greater than 690 kPa (100 psi) hydrogen partial pressure and 260C (500F) shall be subject to Mobil approval. (6) ASTM A453 Gr 660B bolting may be used if higher strength bolting is needed for austenitic flanges with temperatures between 400C (750F) and 650C (1200F) and for ferritic flanges with temperatures between 540C (1000F) and 650C (1200F).

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7.1.2 All pressure containing welds and skirt welds shall be full penetration butt joints. Wherever practical, these welds should be made using double-side welding techniques. The skirt shell-to-baseplate joint shall be continuous fillet welds both inside and outside. 7.1.3 Nozzles inserted through a hole cut in the vessel shall be full-penetration welded. Nozzles inserted through cover plates shall be full-penetration or partial-penetration double welded. Nozzle attachment by solely fillet welds is not permissible. 7.1.4 Set-on connections with a nozzle inside diameter equal to the diameter of the opening in the vessel wall are limited to a maximum diameter of NPS 4. Before welding, the plate below the nozzle weld shall be ultrasonically examined. The weld attaching the nozzle to the vessel shall penetrate completely through the nozzle neck and may be either single or double welded. 7.1.5 In hydrogen service, all spaces fully enclosed by welds (for example, continuous fillet welded attachments) shall be vented. 7.2 Forming of Shells and Heads

7.2.1 When a difference in thickness exists between shell sections or shells and heads, the inside surfaces shall be aligned. 7.2.2 Cold-formed ferritic pressure parts with a ratio of thickness to local radius greater than five percent shall be stress relieved after forming and prior to welding. 7.3 Connections

7.3.1 All manways and nozzles that do not extend into the vessel for internal connections are to be finished flush with the inside of the shell. The inner edge shall be rounded. 7.3.2 Nozzles, manholes, and their reinforcing pads shall not be located less than 25 mm (1 in.) from the toe of the nozzle/reinforcing pad fillet weld to the edge of the main vessel seams without prior Mobil approval. If approval is given, any portion of the weld that is to be covered by a reinforcing pad shall be ground flush with the surface of the shell plates and radiographically examined prior to the installation of the pad. 7.4 7.4.1 Heat Treatment Local heat treating requires prior Mobil approval.

7.4.2 The complete postweld heat treating procedure for alloy-clad or alloy-lined vessels, including temperature and holding time, shall be submitted to Mobil for approval prior to heat treatment. 7.4.3 7.5 Machined surfaces shall be protected against scaling during heat treatment. Nonpressure Attachments

7.5.1 When corrosion allowance is greater than 2.5 mm (0.1 in.), welded attachments inside carbon and low-alloy steel vessels shall be completely welded to prevent corrosion behind the attachment. Intermittent welding may be used in noncorrosive services and in high-alloy and alloy-lined vessels where seal welding is not required. Seal welding is required on the top of support rings for trays, baffles, and pans in vertical vessels and on downcomer bolting bars. 7.5.2 Insulation support rings or clips for ring attachment shall be attached to vessels in the shop and prior to final postweld heat treatment.

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7.6

Dimensional Tolerances

See Appendix D of this Guide. 8. INSPECTION AND TESTING 8.1 All vessels shall be spot radiographed as a minimum.

8.2 All nondestructive examinations (NDE) may be performed on carbon steel vessels prior to final PWHT provided MT or PT of all accessible pressure retaining welds is performed after final PWHT. 8.3 All vessels shall be given a shop hydrostatic test prior to painting. The test pressure shall be 11/2 MAP for Division 1 vessels. (a) The test pressure shall be maintained for a period of at least one-half hour per inch of thickness, but not less than one hour. The thickness of the head or shell, whichever is greater, shall be used to determine the length of the test period. (b) The minimum metal temperature during initial pressure testing of ferritic vessels with shell or head thicknesses greater than 13 mm (1/2 in.) shall not be lower than the following: (1) Where base metal impact tests have been conducted, the impact test temperature plus 17C (30F). (2) Where base metal impact tests have not been conducted, the temperature from the appropriate curve of Figure A-2 of EGE 00-B-22 plus 17C (30F). (c) The chloride content of water shall not exceed 50 ppm for testing vessels fabricated from or lined with any austenitic stainless steel. 8.4 Mobil approval is required for a pneumatic or hydropneumatic test in lieu of a hydrostatic test.

8.5 All reinforcing pad welds shall be tested to 103 kPa gage (15 psig) minimum with dry air or light oil (before postweld heat treating). 9. REPAIRS Defects shall be removed and rewelded using qualified welding procedures. Repair welds shall be re-examined for defects by the original examination method. Mobil approval is required prior to making any major repairs when weld repair depth exceeds the lesser of 17.5 mm (1/2 in.) or one-half the weld thickness, or where defects in plates or forgings are observed.

MOBIL ENGINEERING GUIDE EGE 12-B-1 1993 10. STAMPING AND RECORDS 10.1 Stamping 10.1.1 Nameplates shall be corrosion-resistant and shall extend beyond the vessel by the required insulation thickness. In addition to that required by the ASME Code, nameplates shall bear the minimum design metal temperature at the MAWP. If the vessel is subject to a lower temperature at a lower pressure than the MAWP, this should also be listed. 10.1.2 Steel stamping of vessels with a minimum design metal temperature below 15C (59F) shall be done with low-stress stamps. 10.2 Records 10.2.1 Upon completion of fabrication, the fabricator shall supply purchaser with copies of final drawings and data, as specified. These shall include: (a) Assembly and detail drawings (showing as-built dimensions and details), design calculations, and weights. (b) ASME Code, Section VIII, Form U-1: Manufacturer's Data Report for Pressure Vessels.
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(c) Certified record showing location, heat numbers, and chemical and physical properties of all materials used. (d) (e) (f) (g) Copy of postweld heat treatment recording. Copy of hydrostatic test chart. Copy of nondestructive (RT, UT, MT, PT, WFMT, etc.) examination test results. Copy of positive material identification (PMI) log.

10.2.2 When weld production test plates are required, the test results shall be forwarded to Mobil no later than 10 working days after the test plates are welded. 11. PREPARATION FOR SHIPMENT 11.1 Vessels shall be cleaned internally, dried, and prepared for shipment in accordance with EGE 00-C-4. 11.2 Gaskets supplied by the fabricator shall be new and not those used for shop hydrostatic testing. Gaskets shall be separately boxed, shipped with each vessel, and clearly identified for field installation.

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APPENDIX A REQUIREMENTS FOR CONTRACTOR OR PURCHASER The data sheet or project specifications shall reflect the requirements of this Appendix. This Appendix shall not be submitted to the vessel fabricator but shall be submitted to the vendor of package units containing pressure vessels. A-1. DEFINITIONS

Cyclic Service Service that involves more than 150 cycles per year of either a full pressure cycle or a temperature cycle exceeding 260C (500 F). Cyclic service, if applicable, shall be indicated on the data sheet. Hydrogen Service When the partial pressure of hydrogen is greater than 100 psia.
A-2. A-2.1 DESIGN General

(a) The Engineering Contractor is to identify any vessel not conforming to the ASME Boiler and Pressure Vessel Code, Section VIII requirements. (b) The requirements of this Guide need not apply to any of the following pressure vessels: (1) Standardized vessels such as strainers and filters that conform to the ASME Code and are manufactured on a production line basis, provided prior Mobil approval is obtained. (2) Pressure vessels, 610 mm (24 in.) or less in diameter and 25 mm (1 in.) or less in thickness, which are excluded from the scope of the ASME Code, Section VIII, Division 1 by Paragraph U-1(c)5, provided they conform to the requirements of ASME B31.3. (c) Pressure vessels with design pressure over 20.7 MPa (3000 psi), when designed according to ASME Code, Section VIII, Division 1, shall be constructed to show conformance to the intent of Paragraph U-1 (d) of Division 1. A-2.2 Design Pressures Design pressure, measured at the top of vessel, shall be established on the basis of the following requirements. However, in no case shall this pressure be less than 34 kPa (5 psi) above the maximum operating pressure. (a) Pressure vessels protected by conventional safety relief valves shall be designed for an internal pressure not less than 10 percent above the maximum operating pressure. For operating pressures over 3450 kPa gage (500 psig), the economics of Paragraph A-2.2, Item (b) shall be considered.

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(b) Pressure vessels protected by safety relief valves, with pilot operators or adapters providing bubbletight operation when pressures closely approach the set pressure, may be designed for an internal pressure not less than five percent above the maximum operating pressure. (c) Only those pressure vessels that will be subjected to vacuum conditions during operation (including startup and shutdown) shall be designed for such conditions. If the internal pressure is 34 kPa abs (5 psia) or less, the vessel shall be designed for a full vacuum. (d) Pressure vessels without safety relief devices, but with an outlet that cannot be completely blocked off, shall be designed for the maximum pressure that can be developed in the vessel. A-2.3 Design Temperatures A-2.3.1 Maximum design metal temperature shall not be less than the maximum operating temperature of the contained fluid after quenching or flashing, except as follows: (a) When the vessel is exposed to fluids before quenching or flashing occurs, the design metal temperature for vessel parts (such as inlets and the adjacent area) shall be the temperature of the fluid (before quenching or flashing) or the design metal temperature of the vessel, whichever is higher. (b) For internally insulated vessel parts, the design metal temperature shall be based on thermal calculations using the maximum operating fluid temperature, no wind, and the two percent summer dry-bulb temperature. A-2.3.2 Vessels subjected to a temperature gradient in fluid contents may be separated into zones for purposes of establishing design metal temperatures. A-2.3.3 The minimum design metal temperature shall be established in accordance with EGE 00-B-22. A-2.4 Design Calculations Prior to issuing for bids, the contractor shall submit design calculations to Mobil for towers with height-to-diameter ratios greater than 15 and for all reactors. A-2.5 Supports Vertical vessels shall be self-supporting units. Skirts shall be used when any of the following conditions apply: (a) (b) (c) Shell diameter is more than 1.5 m (5 ft). Vessel height-to-diameter ratio is greater than 5. Vibration may be expected.

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A-2.6 Nozzles and Other Connections A-2.6.1 Nozzles and other connections to vessels may be flanged, threaded, or welded types within the following limitations: (a) Connections shall not be smaller than NPS 1.

(b) Connections for pressure rating service of ANSI Class 900 and higher shall be flanged or buttwelded. Welding ends for buttwelding to piping may be used for high-temperature/high-pressure service involving low-molecularweight products, provided blinding is not required for maintenance. (c) Threaded and socket weld connections shall not exceed NPS 11/2. Threaded connections requiring seal welding and socket weld connections are not permitted on low-alloy steel vessels. (d) Flanged boots are not permitted without Mobil approval.

(e) Class 150 flanges shall not be used for design temperatures above 399C (750F). A-2.6.2 No flanges or threaded connections shall be located within a skirt.

A-2.7 Manways and Other Inspection Openings A-2.7.1 Vessels 0.9 m (3 ft) in diameter and larger shall have at least one manway of 450 mm (18 in.) minimum inside diameter. Smaller vessels with replaceable internals shall have a flanged head, and such vessels without replaceable internals shall have two inspection openings as required by the ASME Code, Section VIII. Flanged connections for instrumentation or piping of the same or larger size may be considered as inspection openings. Horizontal vessels shall have a manway in one head or on the top centerline of the vessel, preferably at the end opposite the vent. A-2.7.2 Manways on towers shall be located as follows:

(a) Above the top tray, at the normal feed tray, and below the bottom tray. In towers containing packed beds, manways shall be provided above and below each bed. (b) In towers where coke or other foreign material is expected or where frequent inspection and cleaning is necessary, manways shall be provided at every third tray level and shall be of 508 mm (20 in.) minimum inside diameter. (c) In tower sections containing trays, the maximum centerline distance between manways shall not exceed 6 m (20 ft), except with Mobil approval. A-2.8 Instrument Connections, Drains, Vents, and Steamouts A-2.8.1 Connections for internal-displacement liquid level devices shall be NPS 4 with ANSI Class 300 flanges minimum. A NPS 4 stilling well shall be provided for the float.

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A-2.8.2 Connections for external-displacement liquid level devices shall be NPS 2, with ANSI Class 300 flanges minimum. A-2.8.3 Vessels 610 mm (24 in.) in diameter and smaller may have an NPS 11/2 drain. All other vessels shall have a drain of NPS 3 minimum size. Drains shall be sized to empty the vessel filled with water within an eight hour maximum period. A-2.8.4 The minimum size nozzle for vents and steamouts shall be NPS 2. Vents shall be located at the highest point at one end of each compartment. Steamouts, when required, shall be located at the end opposite vents in horizontal vessels and near the bottom of vertical vessels. A-2.9 Gaskets Gaskets for nozzles, manways, and other inspection openings shall be in accordance with the applicable piping specifications.

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APPENDIX B MINIMUM REQUIREMENTS FOR PRESSURE VESSELS IN CRITICAL SERVICE SCOPE: This Appendix covers materials, fabrication, and inspection requirements for new and replacement carbon steel pressure vessels designed to ASME Code Section VIII and operating in critical services. Examples of critical services include those containing hydrofluoric acid, amine, caustic, and wet Hydrogen Sulfide above 50 PPM (by weight). The requirements contained herein do not apply to alloy clad or weld overlayed pressure vessels. The data sheet, drawings, or project specifications shall reflect the requirements for critical service. This Appendix shall not be submitted to the vessel fabricator but shall be submitted to the vendor of package units containing pressure vessels. B-1. INTRODUCTION

Carbon steel equipment may be susceptible to embrittlement and/or stress corrosion cracking (SCC) at welds in these environments. Additionally, nonwelded components such as plate materials are vulnerable to blistering and hydrogen induced cracking (HIC) due to the internal pressure generated by the recombination of atomic hydrogen within the plate at inclusions and other defects. This Appendix provides some standards which will minimize the occurrence of these problems. B-2. GENERAL

Table B-1 summarizes the paragraphs which are applicable for the service specified. Paragraphs B-3, B-4, and B-5 of this Appendix define the specific material, fabrication, and inspection requirements for the critical services. For vessels operating in dual critical service (i.e., amine and wet hydrogen sulfide), the more restricting environment (wet hydrogen sulfide) shall govern. B-3. MATERIAL REQUIREMENTS

B-3.1 Material shall be fully-killed carbon steel. The following list of material specifications are acceptable fully-killed carbon steels. This list of materials is provided for reference only and is not intended to be self-limiting.

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TABLE B-1 MINIMUM STANDARDS FOR CRITICAL SERVICE HF ACID B-3. MATERIAL REQUIREMENTS Killed Carbon Steel Chemical Composition Vacuum Degassed Inclusion Control Strength Level Normalized UT Per SA-578 HIC Testing B-4. FABRICATION REQUIREMENTS PWHT Nozzle Attachment Internal Lining Corrosion Allowance B-5. INSPECTION REQUIREMENTS WFMT Radiography Hardness B-5.1 B-5.2 B-5.4 B-5.1 B-5.3 B-5.4 B-5.1 B-5.3 B-5.4 B-4.1 B-4.2 B-4.4 B-4.5 B-4.1 B-4.3 B-4.4 B-4.5 B-4.1 B-4.3 B-4.4 B-4.5 B-3.1 B-3.3 B-3.5 B-3.6 B-3.7 B-3.8 B-3.10 B-3.11 B-3.1 B-3.3 B-3.5 B-3.6 B-3.7 B-3.8 B-3.9, B-3.10 B-3.11 B-3.1, B-3.2 B-3.4 B-3.7 WET H2S AMINE/CAUSTIC

NOTE: The above numbers reference the Paragraphs in the Standards which contain detail requirements for the applicable service.

SA-105-87a (or later) SA-106 Grade A or B SA-181 Class 60 SA-350 LF1 & LF2 SA-442 (>1 in. thick)

SA-515* SA-516 SA-524 SA-727 ASTM A-860

*Silicon-killed SA-515 is acceptable provided the material is capable of meeting toughness requirements at the minimum design metal temperature.

B-3.2 For equipment operating in lean amine (less than 50 ppm hydrogen sulfide) or caustic environments, SA-285 steel may also be used in addition to the above listed steels provided the material is produced to a killed or semi-killed steelmaking practice. The plate steels do not require HIC resistant properties; however, fabricated equipment must be given PWHT to prevent stress corrosion cracking.

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B-3.3 For plate materials, sulfur and phosphorus contents shall be limited to 0.005 percent and 0.015 percent, respectively. These restrictions are required to minimize the formation of manganese sulfides and phosphorus based inclusions. The chemical composition for the remaining plate elements and for all other materials of construction shall be in accordance with Paragraph B-3.4. B-3.4 For plate materials operating in critical service environments, the maximum chemical composition of unspecified elements shall be in accordance to ASME Code, Section II, Table 1 of SA-20. For plate material in HF service, the sum of Cr + Cu + Ni shall be limited to #0.20 percent maximum. The chemical composition for all forging material shall be per SA-105-87a (or later). These restrictions are imposed to limit the materials hardenability and ensure material weldability. The plate material shall have a 0.43 maximum carbon equivalent in accordance with the formula in the ASTM A-860. B-3.5 The plate steel shall be manufactured by a process which includes vacuum degassing while molten (ASME Code, Section II, SA-20 Supplementary Requirement S.1). This process is followed by the addition of deoxidizing agents and results in reduced oxygen and nitrogen in the melt. B-3.6 Plate material deoxidized with both silicon and aluminum shall be manufactured utilizing an inclusion shape control melting practice. Elongated inclusions supply the initiation sites for plate separation and blisters. Steelmaking processing practices that minimize elongated inclusions are required. B-3.7 For plate steels, the lower strength materials (Grade 55 or 60) are preferred. A dual rated material (Grade 60/Grade 70) essentially meets the requirements of the lower strength material and is also acceptable. The lower strength materials are less susceptible to sulfide stress corrosion cracking (SSC). In an emergency situation and with prior Mobil approval, Grade 70 steel would be acceptable. The use of Grade 60 material facilitates field weld repairs and lengthens the inspection interval. B-3.8 Plate material shall be normalized at 913C 13C (1675F 25F) for one-half hour per 25 mm (1 in.) of thickness and not less than one-half hour. The ease with which HIC propagates from nucleation sites at inclusions to the remainder of the steel is dependent on the matrix toughness. The microstructure that results from the normalizing treatment improves the matrix toughness resulting in substantially improved HIC resistance. Normalizing may also improve the material's HIC/blistering resistance by minimizing banding of the microstructure. B-3.9 Plate shall be straight-beam, ultrasonically examined per ASME Code, Section II, SA-578, Level I Acceptance Standards. For equipment operating in environments with a history of HIC, the parameters and acceptance criteria of Paragraph B-3.10 of this Appendix shall be specified. The recording of indications shall apply to all plate thicknesses (ASME Code, Section II, SA-578, Section 6.2). Recordable indications shall be reported in sketch form. The sketch shall mirror the flat geometry of the plate and dimension the location and depth (from the test surface) of the recordable indications.

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B-3.10 Plate shall be straight-beam, ultrasonically examined per ASME Code, Section II, SA-578, Level 1, with supplemental requirements S1 and S2.2 enforced. Any area with one or more discontinuities which produce a continuous total loss of back reflection and cannot be encompassed within a 25 mm (1 in.) diameter circle is unacceptable. The recording of indications shall apply to all plate thicknesses (ASME Code, Section II, SA-578, Section 6.2). Recordable indications shall be reported in sketch form. The sketch shall mirror the flat geometry of the plate and dimension the location and depth (from the test surface) of the recordable indications. In historically severe applications, consideration shall be given to conducting straight-beam, ultrasonic examinations on all forgings (ASME Code, Section II, SA388). All indications exceeding 10 percent of the back reflection shall be recorded. The acceptance standards for each forging shall be individually specified. B-3.11 Suppliers must perform HIC testing to demonstrate that their materials possess sufficient HIC resistance only when specified in the purchase order. When testing is specified, full thickness samples will be used. Testing shall be in accordance with NACE Standard TM0284 using the low pH solution defined in NACE Standard TM0177. Crack thickness ratio (CTR) and crack length ratio (CLR) shall not exceed 1.5 percent and 10.0 percent respectively. B-4. FABRICATION REQUIREMENTS

B-4.1 Post-weld heat treatment shall be required for all welded fabrication. Post-weld heat treatment of carbon steel reduces weld microhardness and residual stresses, minimizing the potential for weld/HAZ SCC and SSC. The PWHT temperature and holding times for carbon steel (P-1) equipment, as specified in EGE 00-B-21, are listed here for reference. The minimum PWHT temperature shall be 610C (1130F). The holding time at that temperature shall be one hour per 25 mm (1 in.) of thickness; one hour minimum. Lower PWHT temperatures for longer hold periods are not allowed. No welding after PWHT shall be permitted without prior Mobil approval. B-4.2 For HF service, integrally reinforced contoured-insert type fittings must be used for nozzle and manway construction, except where small nozzle diameter makes the use of these fittings unfeasible. Contoured-insert type fittings shall meet the requirements of ASME Code, Section VIII, Division 1, Figure UW 16.1 F1 through F4. Industry experience has shown that stub-in nozzle connections in these services produce high stress areas which are susceptible to cracking and are more prone to weld defects which can promote cracking. The contoured-insert type connections reduce the potential for cracking by reducing peak stresses and decreasing the probability of weld defect formation. The joint geometry also permits 100 percent radiography.

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B-4.3 The use of integrally reinforced nozzles Paragraph B-4.2 of this Appendix is not required.

as

discussed

in

B-4.4 In severe applications at lower operating temperatures < 93C (< 200F) or where a history of blistering or cracking exists, the use of nonmetallic, protective coatings, such as epoxies or phenolics, should be considered. Properly applied and maintained coatings can provide a barrier layer to separate the process environment from the steel surface. The coating specified must be compatible with the process stream. The coating installation and quality assurance requirements shall be individually specified for the respective application and shall be in accordance with NACE RP0178. The use of these nonmetallic coatings does not eliminate any of the requirements addressed in this specification. As an alternative to the above or for equipment operating above the immersion service temperature limit for nonmetallic coatings, corrosion resistant cladding and weld overlay should be considered. B-4.5 Unclad or unlined material shall include a minimum of 3 mm (0.125 in.) corrosion allowance. This allowance will permit the removal of surface indications during shop and future inspections and minimize the potential for weld repair. B-5. INSPECTION REQUIREMENTS

B-5.1 A wet fluorescent magnetic particle examination (WFMT) shall be performed on all internal weld surfaces after the shop hydrotest. The examination shall include tray support and internal attachment welds as well as all pressure containing welds. Due to the potential for arc strikes with the DC prod method, only the magnetic yoke method is to be used. Acceptance criteria shall be per ASME Code, Section VIII, Appendix 6. The test report shall map the location of all removed relevant indications and all remaining nonrelevant indications. This information will be used for the baseline data of future WFMT inspections. Prior to performing WFMT, the surface of the welds shall be prepared to a SSPCSP6 finish, as a minimum. The surface preparation shall include sufficient distance on each side of the weld to permit a magnetic particle yoke to make contact with the prepared surface area [a minimum 200 mm (8 in.)] wide band centered on the weld]. Where the equipment size or geometry does not permit access to the internal surface of the welds, an external ultrasonic examination shall be performed after the shop hydrotest. The test report shall be as Paragraph B-5.1. Since the same geometry constraints will apply in the field, this information will be used for the baseline data of future ultrasonic inspections.

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B-5.2 In HF acid service, all butt welds and stub-in nozzle welds shall be 100 percent radiographed after PWHT. Acceptance criteria shall be per ASME Code, Section VIII, UW-51. As an alternative to radiographic examination, welds may be ultrasonically examined after PWHT. Acceptance criteria shall be per ASME Code, Section VIII, Appendix 12. B-5.3 In wet H2S and amine/caustic service, it is recommended that all butt welds be 100 percent radiographed after PWHT. Twenty percent of the stub-in nozzles shall be radiographed to 100 percent acceptance criteria prior to repad installation (where applicable). The welds to be RT examined shall be determined by Mobil. If any of these nozzle welds are rejectable, the remaining nozzle welds shall also be RT examined. All welds shall be interpreted to ASME Code, Section VIII, UW-51 acceptance criteria. As an alternative to radiographic examination, welds may be ultrasonically examined after PWHT. Acceptance criteria shall be per ASME Code, Section VIII, Appendix 12. Additionally, all stubin nozzle welds shall receive in-progress examination. This examination shall consist of a magnetic particle inspection of the root, the backgouged bevel on a double-vee weld, and the final external weld surface, as a minimum. These examinations shall be conducted on surfaces prepared by grinding. B-5.4 Hardness testing shall be performed on deposited weld metal. The maximum hardness after PWHT, as measured with a macro hardness instrument such as a portable hardness tester, shall be equivalent to 200 HB. The type of hardness testing instrument shall be approved prior to the examination. Two hardness readings, 180 degrees apart, shall be taken on each circumferential weld and one hardness reading on each longitudinal and each nozzle weld. Where accessible, all hardness readings shall be performed on external (nonprocess side) weld surfaces.

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APPENDIX C PRESSURE VESSELS WITH SPECIAL DESIGN AND FABRICATION REQUIREMENTS Pressure vessels for special service shall also conform to the requirements of this Appendix. C-1. DOCUMENTATION

C-1.1 When design to the ASME Code, Section VIII, Division 2 is specified, the contractor shall submit the Users Design Specification to Mobil for approval no later than its issuance for vendors quotes. The Manufacturers Design Report shall be submitted for review as the various sections are completed. The completed and certified design report shall be submitted for record. C-1.2 The mill test reports for low-alloy or impact-tested pressure components shall be submitted to Mobil for review as soon as they are available but prior to start of fabrication. C-1.3 Vendor shall submit an inspection specification, including inspection extent, description, and timing relative to the fabrication sequence, to Mobil prior to start of fabrication. C-2. C-2.1 C-2.1.1 DESIGN Connections Reinforcement shall be integral. That is, no pads shall be used.

C-2.1.2 Nozzles in cyclic service shall be the contoured-insert type (buttwelded and radiographable type). C-2.1.3 Thermowell connections shall be flanged and shall be NPS 11/2 minimum. C-2.2 Attachments and Supports

C-2.2.1 Attachment welds attaching nonpressure parts to pressure parts shall be the full-penetration type or continuous double fillet welds. Fillet welds shall be limited to the following: (a) Lightly loaded attachments such as clips for insulation, ladders, and davits. (b) A maximum size of 9.5 mm (3/8 in.).

(c) A minimum distance of Rt from gross structural discontinuities (heador flange-to-shell junctions, nozzles, and junctions between shells of different diameters or thicknesses), where R and t are shell radius and thickness, respectively.

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C-2.2.2 Skirt attachment in low-alloy or quenched and tempered steel vessels with skirts that exceed 19 mm (3/4 in.) in thickness at their point of attachment shall be attached in accordance with Figure C-1. C-2.3 Corner Joints

Pressure-retaining corner joints (where a head, shell, or connection is welded directly to a flat pressure-retaining plate) are not permitted. C-3. MATERIALS

C-3.1 Plate that is more than 63 mm (21/2 in.) in thickness and has not been vacuum degassed, as well as all plate and forgings over 100 mm (4 in.) thick, shall be ultrasonically examined. C-3.2 Plate ultrasonic examination shall be in accordance with ASME SA-578 (Boiler and Pressure Vessel Code, Section II). C-3.3 Forging ultrasonic examination shall be in accordance with ASME SA-388 (Boiler and Pressure Vessel Code) and the following: (a) The calibration block shall have the same nominal thickness, composition, and P-number group as the item to be examined. (b) Angle-beam examination shall be calibrated with a notch of a depth equal to 9.5 mm (3/8 in.) or 3 percent of the nominal section thickness, whichever is less. The notch length shall be approximately 25 mm (1 in.), and its width shall not be greater than twice its depth. (c) A forging shall be unacceptable if: (1) Straight-beam examination results show one or more discontinuities that produce indications accompanied by a complete loss of back reflection not associated with, nor attributable to, the geometric configuration. (2) Angle-beam examination results show one or more discontinuities that produce indications exceeding in amplitude the indication from the calibration notch. C-3.4 Ferritic alloy material shall be heat treated to produce grain refinement in all thicknesses. Grain sizes shall be ASTM 6 or finer.

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Forging Detail

Weld Buildup Detail

FIGURE C-1 SKIRT ATTACHMENT DETAILS

C-3.5 The following requirements apply to test coupons and mechanical testing of ferritic alloy plates and forgings thicker than 50 mm (2 in.) when produced in the normalized and tempered (N&T) or quenched and tempered (Q&T) heat treatment condition. C-3.5.1 Plates and forgings shall be qualified at the mill prior to shipment. Test specimens shall be taken, prepared, and tested in accordance with ASME Code, Section VIII, Division 2, Articles M2, T-1, and T-2, applicable ASME specifications, and the requirements of this Guide. Plate and forgings tensile tests shall be performed on representative samples of material in the final heat treatment condition [i.e., N&T or Q&T and including any postweld heat treatment (PWHT)]. Tensile properties shall be in accordance with the applicable ASME material specification. For Cr-Mo material, the tensile strength shall not exceed 690 MPa (100 ksi). The forged and plate material test specimens shall be processed in accordance with ASME Code, Section VIII, Division 2, Paragraph AM-202, so as to simulate the actual heat treatment of the materials. For plate material, tensile tests shall be taken from both ends of each plate. The sample shall be taken from the 1/4 t location in the transverse direction in accordance with ASME Code, Section II, SA-20 and Code requirements. For forgings, samples for tensile testing shall be taken at the the axis of the specimen oriented in the tangential direction.
1/2

t location with

C-3.5.2 When required by the applicable ASME material specification or EGE 00-B-22, Charpy V-notch impact test specimens shall be taken from one end of each plate in the transverse 1/2 t location. For forgings, impact test specimens

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shall be obtained from material adjacent to each tensile test location. The test specimens shall be oriented normal to the direction of greatest forging elongation and shall be taken from the 1/2 t location. One set of tests, consisting of three Charpy V-Notch impact test specimens per set, shall be made on completely heat treated specimens (i.e., N&T or Q&T including any PWHT). The tests shall be in accordance with ASME Code, Section VIII, Division 2, Paragraph AM-204. Acceptance criteria shall be in accordance with EGE 00-B-22. C-4. FABRICATION

C-4.1 The welded joint between the shell and skirt shall merge smoothly with the shell. C-4.2 For vessels in cyclic service operation, all welds, both inside and outside, on pressure-retaining parts shall be ground smooth (but need not be flush). C-4.3 (a) Forming and stress relieving shall be in accordance with the following: Forming temperatures for ferritic materials shall be as follows:
Hot bending or roll forming 900C to 1094C (1650F to 2000F) Closed die or press forming 900C to 1094C (1650F to 2000F) Cold sizing, rounding out, or roll forming plate: Up to: 50 mm (2 in.) thick 100 mm (4 in.) thick 93C (200F) min. 149C (300F) min.

(b) All ferritic alloy plates shall be stress relieved after hot forming and prior to welding. This requirement does not apply to 21/2 to 31/2 percent nickel steels. C-5. INSPECTION AND TESTING

C-5.1 After final edge preparation, cut edges of base materials shall be examined by the magnetic particle method or liquid penetrant method (see footnotes to Table C-1). C-5.2 Weld inspection shall conform to Table C-1.

C-5.3 Positive Material Identification (PMI) shall be performed on welds of CrMo material in accordance with EGE 00-B-25. C-5.4 All shop-fabricated vessels designed in accordance with the ASME Code, Section VIII, Division 2 shall be given a shop hydrostatic test in accordance with Paragraph AT-301 of that Division.

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NOVEMBER 1993 PAGE 31 OF 34

EGE 12-B-1 1993

TABLE C-1 WELD INSPECTION TYPE OF JOINT Before Final PWHT Longitudinal and circumferential, in shells, heads, and connections. Longitudinal and circumferential in skirt including skirt-to-head weld. Connections to shell or head. Attachments. Weld repairs: 1. Minor 2. Major-depth of repair $ 9.5 mm ( in.) or weld thickness. RT RT RT* or UT Original inspection methods EXAMINATION (100%) After Final PWHT UT UT UT MT or PT MT or PT UT After Hydro Test MT or PT MT** or PT** MT or PT MT or PT

LEGEND:
RT MT PT UT Radiography Magnetic particle Liquid penetrant (Use only for austenitic stainless steel, nonferrous metals, and 5% through 9% Ni steels.) Ultrasonic

*Use radiography for radiographable buttwelds. **Skirt-to-head weld only.

MOBIL ENGINEERING GUIDE EGE 12-B-1 1993

PAGE 32 OF 34 NOVEMBER 1993

APPENDIX D TOLERANCES

MOBIL ENGINEERING GUIDE

NOVEMBER 1993 PAGE 33 OF 34

EGE 12-B-1 1993

NOTES TO FIGURES D-1 AND D-2:

Tray Support Ring and Tray Tolerances: The maximum out-of-level dimension permitted for tray support rings shall be 3 mm (1/8 in.) for vessels up to 2440 m (8 ft) in diameter and 5 mm (3/16 in.) for larger-diameter vessels. Rings shall be perpendicular to the vessel wall and shall not deviate from the perpendicular by more than 1.5 mm (1/16 in.) at the inner edge of the ring. The maximum tolerance permitted for the dimension between adjacent tray rings is 3 mm (1/8 in.). Maximum out-of-level tolerance for trays shall be 2.5 mm/m (1/32 in./ft) of diameter, with a maximum of 6 m (1/4 in.) over the full diameter of the vessel. Outlet weirs shall be within 1.5 mm (1/16 in.) of level. Tolerance on tray diameters shall be plus zero, minus 6 mm (1/4 in.) for vessels up to 2130 mm (7 ft) in diameter and plus zero, minus 13 mm (1/2 in.) for larger vessels. Clearance between the lower edge of downcomers and seal pan floors shall not vary from that specified by more than 3 mm (1/8 in.). 1 Tolerance on longitudinal dimensions from the reference plant shall be the smaller of 1 percent or 30 mm (1-1/4 in.) unless noted otherwise. REFERENCE PLANE 2 3 4 Punch mark inside and out 75 mm (3 in.) from root of bottom course. Flange face of nozzle from centerline of vessel 5 mm (3/16 in.). Flange face of nozzle shall be parallel with the indicated plan in any direction 1/2 (1/4 for agitator mount nozzles) but not to exceed 5 mm (3/16 in.) across the diameter. Location of nozzle from reference plane 6 mm (1/4 in.): exception liquid level controller nozzle 1.5 mm (1/16 in.); nozzle related to trays, draw-off pans, etc., so dimensioned on drawings, distance from support ring 3 mm (1/8 in.). Flange face of manhead from outside of tower 6 mm (1/4 in.). Flange face of manhead shall be parallel with the indicated plane in any direction 1. Location of manhead from reference plant 13 mm (1/2 in.). Flange face of top or bottom nozzle to reference plane 6 mm (1/4 in.). Orientation of nozzles and other attachments shall be within 3 mm (1/8 in.). 3 mm (1/8 in.) maximum lateral translation. 1.5 mm (1/16 in.) maximum rotation of flanges from the indicated position, measured as shown. 15 16 17 13 In addition to ASME tolerances, tolerance from nominal inside shell diameter as measured by external strapping shall be as given in the table below. Maximum deviation from straight applied to the shell shall be: 3 mm (1/8 in.) in any 3 m (10 ft) or 13 mm (1/2 in.) in any 15 m (50 ft) of length. In addition, distortion caused by welding of longitudinal or circumferential joints shall not exceed 6 mm (1/4 in.) maximum depth in a 900 mm (36 in.) length of shell centered on the weld. Distance from reference plane to base +0,-6 mm (1/4 in.) or to lug + 6 mm (1/4 in.), -0. Base or support lug out of level over any diameter shall be as given in the table below. Bolt hole circle tolerance shall be 3 mm (1/8 in.) up to 2.4 m (8 in.-0 in.) diameter and 6 mm (1/4 in.) for larger diameters. Distance from reference plane to the centerline of the saddle 3 mm (1/8 in.). Distance between the centerlines of the saddle 3 mm (1/8 in.). Distance between the centerlines of the support bolt holes across width 3 mm (1/8 in.). Saddle base plate out of level over any diameter shall be as given in table below. Saddle base plate out of level slope 1.5 mm (1/16 in.), across the width of the saddle. Location of nozzle from vessel center line 6 mm (1/4 in.).

14

6 7 8 9 10 11 12

18 19 20 21 22 23

Inside Diameter Specified Item Number 13, 16 <1.2 m (4 ft) 3 mm (1/8 in.) 1.2 m to 2.1 m (4 ft to 7 ft) 5 mm (3/16 in.) 2.1 m to 4.9 m (7 ft to 16 ft) 6 mm (1/4 in.) 4.9 m to 7.6 m (16 ft to 25 ft) 8 mm (5/16 in.) >7.6 m (25 ft) 10 mm (3/8 in.)

MOBIL ENGINEERING GUIDE EGE 12-B-1 1993

PAGE 34 OF 34 NOVEMBER 1993

PLAN VIEW VERTICAL VESSEL OR END VIEW HORIZONTAL VESSEL

FIGURE D-3 TYPICAL NOZZLE BOLT HOLE ORIENTATION

MOBIL ENGINEERING GUIDE PRESSURE VESSEL DATA SHEET

ISSUE 1 2 3 APPROVED 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Radiographed Joint Efficiency: Shell Corrosion Allow., mm (in.) Postweld Heat Treatment Cyclic Service Yes/No Press., kPa gage (psig): Max. Oper Temp., C (F): Max. Oper Code Mobil Guide ISSUE APPROVED JOB NAME ITEM NAME LOCATION/UNIT JOB NO. ITEM NO.

EGE 12-D-1A 1993

Page 1 of 1

NO. REQD

Stamped: Yes/No

Design Max. Design Min. Design Heads Sp. Gr.

Critical Service

Yes/No Exposure

Hydrogen Service Earthquake Zone

Yes/No

Design Wind Vel. @ 9 m (30 ft) elev, m/s (mph) Catalyst Grid Design Load, kPa (psi) Test Press., kPa Gage (psig)

Test Min. Temp., C (F)

MAWP (Max. Allow. Working Press.)., kPa gage Max. Allow. External Press., kPa gage (psig) Relief Valve Set Press., kPa gage (psig) Type of Heads Material: 22 23 24 25 26 27 28 29 30 31 Shell Top Head Bottom Head Internal Head Lining Supports Internals (Excl Trays) Nozzle Necks Flanges Manway Bolting Thick., mm (in.) Thick., mm (in.) Thick., mm (in.) Thick., mm (in.)

32 33 34 35 36 37 38 39

Weight Empty, kg (lb) Operating Weight, kg (lb) Weight Full of Water, kg (lb) Insulation Yes/No Yes/No Yes/No Thick., mm (in.) Shop Painting

Skirt Fire Proofing

NOZZLE SCHEDULE SIZE mm CLASS/ FACING SERVICE NO. REQ.D

MARK

MOBIL ENGINEERING GUIDE DOCUMENTATION REQUIREMENTS SHEET (DRS) PRESSURE VESSELS

ISSUE 1 2 3 Instructions: 1. 2. 3. 4. Name: Title: Phone: 1. Outline Drawing 2. Design Calculations including all internals 3. General Assembly Drawing 4. Detail Fabrication Drawings including all internals 5. Tray Arrangement Details 6. Ladder and Platform Details 7. Certified Mill Reports (see Note 1) 8. Heat Treatment Reports & Temperature Charts 9. Hydrotest Chart or Certification of Hydrotest 10. 11. 12. 13. 14. 15. 16. 17. Notes: 1. The certified mill reports shall include the following: Chemical analysis including all trace elements Heat (melt) numbers Tensile and yield strength Heat treatment report Percent Elongation Ultrasonic test report (if applicable) Charpy V-notch impact values, size of specimens, specimen orientation, and test temperature Nameplate Rubbing ASME Form U-1 Division 1 Vessels ASME Form A-1 Division 2 Vessels Welding Procedures, Specifications and Qualifications Manufacturers Data Book List of Sub-suppliers APPROVED 4 5 6 ISSUE APPROVED FACILITY NAME LOCATION ITEM NAME ITEM NO. P.O. NO.

EGE 12-D-1B 1993

Page 1 of 1

REQ. NO. PROJ. NO. CON. PROJ. NO.

Vendor to complete and return this form and the data required with quotation. Indicate time required, in weeks after receipt of Purchase Order, to furnish vendor data and drawings for approval and record. Purchaser to indicate quantities required. All vendor data must be identified with project, Purchase Order, and item numbers. Cost of data shall be included in quotation. In the spaces provided below, enter the name, title, and telephone number of the person responsible for complying with the documentation requirements. All vendor drawings, literature, installation, operation, and maintenance instructions shall be originals or first generation copies which shall be of original quality. With Quotation Quantity Required Time Required for Vendor to Supply Data For Approval Quantity Required Time Required For Record Quantity Required Time Required

MOBIL ENGINEERING GUIDE WITNESSING REQUIREMENT FOR INSPECTION AND TESTING (WRIT) PRESSURE VESSELS
ISSUE 1 2 3 APPROVED 4 5 6 Inspection or Testing ISSUE APPROVED FACILITY NAME LOCATION ITEM NAME ITEM NO. Vendor Supplied Inspection & Testing Mobil Witnessed P.O. NO.

EGE 12-D-1D 1993

Page 1 of 2

REQ. NO. PROJ. NO. CON. PROJ. NO. Additional Comments

Welding/Inspection Qualifications 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 drostatic Test 28 Brinell Hardness Test After Final PWHT Visual & Dimensional Check of Shell and Support 29 During Fabrication 30 Final Welders Performance Qualification Test Review of Welders Performance Qualification Records Welding Procedure Qualification Test Review of Welding Procedure Qualification Test Records NDE Personnel Performance Qualification Test Review of NDE Personnel Performance Qualification Records Heat Number Chemical Analysis Mechanical Properties Heat Treatment Condition Material Identification Heat Numbers Nondestructive Examination Review of Nondestructive Examination Records Visual and Dimensional Check Positive Material Identification (PMI) of Alloy Materials Ultrasonic Examination Liquid Penetrant Examination Visual and Dimensional Check PWHT of Cold Formed Heads Prior to Welding Magnetic Particle/Liquid Penetrant (MT/PT) Test Weld Bevels Weld Joint Fit Up Preheat Temperature per EGE 00-B-21 Radiography Ultrasonic Testing MT/PT Backgouged Root Pass MT/PT Accessible Weld Surfaces After Final PWHT

Certified Material Test Reports

Material Inspection

Formed Heads

Welding Inspection

MOBIL ENGINEERING GUIDE WITNESSING REQUIREMENT FOR INSPECTION AND TESTING (WRIT) PRESSURE VESSELS
Inspection or Testing Vendor Supplied Inspection & Testing Mobil Witnessed

EGE 12-D-1D 1993

Page 2 of 2
Additional Comments

Visual & Dimensional Check of Internals, Including Tolerances 31 During Fabrication 32 Final Heat Treatment 33 Intermediate PWHT or Hydrogen Outgasing per EGE 00-B-21 34 Final PWHT Tests, Painting, Preparation for Shipment 35 36 37 38 39 40 41 42 43 44 45 Pneumatic Test for Reinforcing Pads Hydrostatic Test Final Witness Name Plate & Code Stamping Painting Surface Preparation Primer Preparation for Shipment Internal Cleanliness Nozzle Protection Packaging, Cribbing, etc. All Special Testing Required by Mobil Job Specifications

Notes: 1. Mobil denotes Mobil or its designated representative. 2. Mobil, at its option and with prior notification, shall be permitted free access to the vendors facilities during all phases of the work for performing visual inspections and for routine checking of documentation and work progress.