GIS 46-010-New Pressure Vessels

Document No.
GIS 46-010
Applicability Group
Date 3 May 2005
Guidance on Industry Standards for

New Pressure Vessels
GIS 46-010
BP GROUP
ENGINEERING TECHNICAL PRACTICES
3 May 2005 GIS 46-010
Guidance on Industry Standard for New Pressure Vessels
Foreword
This is the first issue of Engineering Technical Practice (ETP) BP GIS 46-010. This Guidance on
Industry Standard (GIS) is based on parts of heritage documents from the merged BP companies as
follows:
British Petroleum
RP 46-1 Unfired Pressure Vessels.
GS 146-2 Pressure Vessels.
GS 136-1 Materials for Sour Service.
RP 7-1-1 Pressure Vessels.
RP 7-1-2 Heavy Wall and Special Service Pressure Vessels.
RP 7-1-3 Welding Requirements for Pressure Vessels.
RP 7-1-4 Metal Lining and Cladding.
RP 7-1-5 Supplemental Requirements for Pressure Vessels.
RP 7-2-1 Pressure Vessel Internals.
RP 7-2-4 Design Basis for High Temperature Equipment.
Amoco
A FE-VE-DV1-E Fabricated Equipment—Pressure Vessels—Division 1—Engineering
Specification.
A FE-VE-DV1-G Fabricated Equipment—Pressure Vessels—Division 1—Guide.
A FE-VE-DV1-P Fabricated Equipment—Pressure Vessels—Division 1—Procurement
Specification.
A FE-VE-DV2-E Fabricated Equipment—Pressure Vessels—Division 2—Engineering
Specification.
A FE-VE-DV2-P Fabricated Equipment—Pressure Vessels—Division 2—Procurement
Specification.
A FE-VE-LINE-P Fabricated Equipment—Pressure Vessels—Corrosion-Resistant Liners—
Installation Specification.
A FE-VE-TI-E Fabricated Equipment—Pressure Vessels—Titanium Clad—Engineering
Specification.
A FE-VE-TI-G Fabricated Equipment—Pressure Vessels—Titanium Clad—Guide.
A FE-VE-TI-P Fabricated Equipment—Pressure Vessels—Titanium Clad—Procurement
Specification.
A MM-GEN-00-E Metallic Materials—General—Selection Specification.
A MM-GEN-00-S Metallic Materials—General—Selection Specification.
A MM-SS-00-P Metallic Materials—Special Service—Procurement Specification.
A MM-TEST-PMI-S Metallic Materials—Test—Positive Material Identification—
Specification.
ARCO
Std 40-89 Pressure Vessels (Last revised 1992).
Std 42-95 General Welding: Fabrication and Inspection for General Refinery
Service, (last issued 6/95).
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3 May 2005 GIS 46-010
Copyright  2005, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organization. None of the information
contained in this document shall be disclosed outside the recipient’s own organization
without the prior written permission of Director of Engineering, BP Group, unless the
terms of such agreement or contract expressly allow.
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3 May 2005 GIS 46-010
Table of Contents
Page
Foreword ........................................................................................................................................ 2
1. Scope .................................................................................................................................. 10
2. Normative references........................................................................................................... 10
3. Definitions............................................................................................................................ 13
4. Symbols and abbreviations .................................................................................................. 15
5. Introduction, codes, legislation, and quality assurance......................................................... 17
5.1. Introduction ............................................................................................................... 17
5.2. Legislation................................................................................................................. 17
5.3. Quality assurance ..................................................................................................... 17
6. Materials selection ............................................................................................................... 17
6.1. General..................................................................................................................... 17
6.2. Process specific requirements .................................................................................. 18
6.3. Bolting....................................................................................................................... 21
7. Design ................................................................................................................................. 22
7.1. General..................................................................................................................... 22
7.2. Loadings ................................................................................................................... 22
7.3. Design against corrosion under insulation (CUI) ....................................................... 23
7.4. Design for non-intrusive inspection ........................................................................... 26
7.5. Plate layout and weld design .................................................................................... 27
7.6. Nozzles and manways .............................................................................................. 27
7.7. Flanges, gaskets, and bolts ...................................................................................... 29
7.8. Welds........................................................................................................................ 30
7.9. Internals.................................................................................................................... 31
7.10. Supports ................................................................................................................... 31
7.11. External attachments ................................................................................................ 34
7.12. Spheres .................................................................................................................... 35
7.13. Pig launchers and receivers...................................................................................... 35
8. Fabrication........................................................................................................................... 35
8.1. General..................................................................................................................... 35
8.2. Welding..................................................................................................................... 36
9. Inspection and testing .......................................................................................................... 38
9.1. Preparation ............................................................................................................... 38
9.2. Surface examination of welds ................................................................................... 38
9.3. Volumetric examination of welds............................................................................... 38
9.4. Fracture mechanics assessment of weld flaws ......................................................... 39
9.5. Hydrostatic test ......................................................................................................... 39
9.6. Positive materials identification and datum thickness readings ................................. 39
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3 May 2005 GIS 46-010
10. Internal non-metallic coating or refractory lining ................................................................... 39

11. External coating ................................................................................................................... 39
12. Insulation ............................................................................................................................. 40
13. Packing and shipping........................................................................................................... 40
14. Documentation..................................................................................................................... 40
15. Spares ................................................................................................................................. 40
Annex A (Normative) Additional requirements for vessels in carbon steel or carbon-manganese
steel..................................................................................................................................... 41
A.6 Materials .............................................................................................................................. 41
A.6.1 Specification for Z-quality steel plate......................................................................... 41
A.6.2 Specification for Hydrogen-Induced Cracking (HIC) resistant steel plate................... 42
A.7 Design ................................................................................................................................. 43
A.8 Fabrication........................................................................................................................... 43
A.9 Inspection ............................................................................................................................ 43
A.9.1 Low temperature service........................................................................................... 43
A.9.2 Hydrogen service ...................................................................................................... 43
A.9.3 Amine, caustic, anhydrous ammonia, cyanides, hydrofluoric acid, sour water, or wet
H2S service ............................................................................................................... 43
A.9.4 Vessels in which plate thickness is equal to or more than 50 mm (2 in) .................... 44
Annex B (Normative) Additional requirements for vessels in Cr Mo material ................................. 45
B.1 General................................................................................................................................ 45
B.2 Materials .............................................................................................................................. 45
B.2.3 Materials for 2¼Cr 1Mo vessels (enhanced and normal) .......................................... 45
B.6 Materials .............................................................................................................................. 45
B.6.1 Materials general ...................................................................................................... 45
B.6.2 Materials for 1¼Cr ½Mo vessels............................................................................... 46
B.6.3 Materials for 2¼Cr 1Mo vessels (enhanced and normal) .......................................... 47
B.6.4 Materials for 2¼Cr 1Mo ¼V and 3Cr 1Mo ¼V vessels .............................................. 47
B.7 Design ................................................................................................................................. 47
B.8 Fabrication........................................................................................................................... 47
B.8.1 Fabrication general ................................................................................................... 47
B.8.2 Fabrication of 1¼Cr ½Mo vessels............................................................................. 48
B.8.3 Fabrication of 2¼Cr 1Mo vessels (normal and enhanced) ........................................ 48
B.8.4 Fabrication of 2¼Cr 1Mo ¼V and 3Cr 1Mo ¼V vessels ............................................ 49
B.9 Inspection and testing .......................................................................................................... 49
B.9.1 General..................................................................................................................... 49
Annex C (Normative) Additional requirements for clad vessels ..................................................... 50
C.1 General................................................................................................................................ 50
C.6 Materials .............................................................................................................................. 50
C.6.1 Clad plate ................................................................................................................. 50
C.6.2 Components made by weld overlay .......................................................................... 50
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C.7 Design ................................................................................................................................. 50

C.7.1 General..................................................................................................................... 50
C.7.2 Design of hydroprocessing reactors.......................................................................... 51
C.8 Fabrication........................................................................................................................... 51
C.8.1 Required weld quality................................................................................................ 51
C.8.2 Weld consumables.................................................................................................... 52
C.8.3 Welding processes.................................................................................................... 53
C.8.4 Cladding re-instatement only .................................................................................... 53
C.8.5 Weld procedures....................................................................................................... 54
C.9 Inspection and testing .......................................................................................................... 54
C.9.1 Inspection - specific to clad plate .............................................................................. 54
C.9.2 Inspection - applying to both weld overlay and cladding re-instatement .................... 55
C.9.3 Inspection - specific to weld overlay.......................................................................... 55
C.9.4 Inspection - specific to cladding re-instatement......................................................... 56
C.9.5 Hydraulic testing ....................................................................................................... 56
C.16 High temperature embrittlement in service........................................................................... 56
Annex D (Normative) Additional requirements for vessels in austenitic stainless steel (ASS)........ 57
D.1 General................................................................................................................................ 57
D.6 Design ................................................................................................................................. 57
D.8 Fabrication........................................................................................................................... 57
D.8.1 Forming .................................................................................................................... 57
D.8.2 Welding..................................................................................................................... 57
D.9 Inspection and testing .......................................................................................................... 57
Annex E (Normative) Additional requirements for vessels in duplex stainless steel (DSS) ............ 58
E.6 Material................................................................................................................................ 58
E.6.1 General..................................................................................................................... 58
E.6.2 Heat treatment by the material supplier and microstructure ...................................... 58
E.6.3 Mechanical properties............................................................................................... 58
E.6.4 Other issues.............................................................................................................. 59
E.8 Fabrication........................................................................................................................... 59
E.8.1 General..................................................................................................................... 59
E.8.2 Welding..................................................................................................................... 59
E.9 Inspection and testing .......................................................................................................... 61
E.10 Painting................................................................................................................................ 61
Annex F (Normative) Additional requirements for vessels in high nickel alloys.............................. 62
F.1 General................................................................................................................................ 62
F.6 Materials .............................................................................................................................. 62
F.7 Design ................................................................................................................................. 62
F.7.1 General..................................................................................................................... 62
F.7.2 Nozzles..................................................................................................................... 62
F.8 Fabrication........................................................................................................................... 63
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F.8.1 General..................................................................................................................... 63
F.8.2 Heat treatment .......................................................................................................... 63
F.8.3 Welding general........................................................................................................ 63
F.8.4 Welding specific........................................................................................................ 63
F.8.5 Welding procedures .................................................................................................. 63
F.9 Inspection and testing .......................................................................................................... 64
Annex G (Normative) Additional requirements for vessels in titanium ........................................... 65
G.1 General................................................................................................................................ 65
G.6 Materials .............................................................................................................................. 65
G.6.2 Titanium clad components ........................................................................................ 65
G.7 Design ................................................................................................................................. 66
G.7.1 General..................................................................................................................... 66
G.7.2 Solid titanium components ........................................................................................ 66
G.8 Fabrication........................................................................................................................... 74
G.8.1 General..................................................................................................................... 74
G.8.2 Solid titanium components ........................................................................................ 75
G.9 Inspection and testing .......................................................................................................... 77
G.16 Specific to chemical plant reactors....................................................................................... 77
Annex H (Informative) Additional requirements for vessels in zirconium ....................................... 79
H.6 Materials .............................................................................................................................. 79
H.7 Design ................................................................................................................................. 79
H.8 Fabrication........................................................................................................................... 79
H.8.1 General..................................................................................................................... 79
H.8.2 Welding..................................................................................................................... 79
H.9 Inspection and testing .......................................................................................................... 80
Annex AA (Normative) Requirements for vessels to the ASME Code ........................................... 81
AA.1 General................................................................................................................................ 81
AA.6 Materials .............................................................................................................................. 81
AA.7 Design ................................................................................................................................. 81
AA.7.1 General..................................................................................................................... 81
AA.7.2 Division 1 .................................................................................................................. 82
AA.7.3 Division 2 .................................................................................................................. 82
AA.8 Fabrication........................................................................................................................... 83
AA.8.2 Weld procedures....................................................................................................... 83
AA.8.3 Heat treatment .......................................................................................................... 83
AA.8.4 Dissimilar welds between austenitic stainless steels and ferritic steels ..................... 83
AA.9 Inspection and testing .......................................................................................................... 83
AA.9.1 Plates and forgings ................................................................................................... 83
AA.9.2 Component and weld inspections ............................................................................. 83
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AA.9.3 Hydrostatic testing .................................................................................................... 84

AA.16 Division 3 .................................................................................................................. 84
Annex BB (Normative) Requirements for vessels to PD 5500 ....................................................... 85
BB.7 Design ................................................................................................................................. 85
BB.8 Fabrication........................................................................................................................... 85
BB.8.2 Welding..................................................................................................................... 85
BB.9 Inspection ............................................................................................................................ 85
BB.9.1 Component inspection – ferritic materials ................................................................. 85
BB.9.2 Component inspection – austenitic and duplex materials .......................................... 85
BB.9.3 Weld and component inspection ............................................................................... 85
Annex CC (Normative) Requirements for vessels to BS EN 13445............................................... 86
CC.1 General................................................................................................................................ 86
CC.6 Materials .............................................................................................................................. 86
CC.7 Design ................................................................................................................................. 86
Bibliography .................................................................................................................................. 87
List of Tables
Table 1 – Permissible bolting materials at different temperatures ................................................. 21

Table 2 – NDE required where welds lie within 40 mm (1 ½ in)..................................................... 31
Table 3 – Flatness tolerances of gasket contact surface ............................................................... 36
Table B.1 – Specifications for Cr Mo steels................................................................................... 45
Table B.2 – Specifications for Cr Mo V steels ............................................................................... 45
Table C.1 – Typical metal linings (by weld overlay or cladding)..................................................... 50
Table C.2 – Filler metal requirements for clad plate and weld overlaid plate ................................. 52
Table E.1 – Typical weld consumables for DSS............................................................................ 59
Table E.2 – Range of average heat input during welding .............................................................. 60
Table F.1 – Typical nickel alloys ................................................................................................... 62
Table G.1 – Grade and minimum thickness for titanium internals.................................................. 66
Radius table.................................................................................................................................. 70
Table G.2 – Maximum permitted hardness of weld metal and plate .............................................. 75
Table AA.1 – Minimum thickness of nozzles ................................................................................. 81
List of Figures
Figure 1 – Requirement for PWHT in caustic service Source: NACE Corrosion Data Survey, sixth
edition, 1985 ........................................................................................................................ 20
Figure 2 – Typical arrangement to prevent hold up of water at insulation rings ............................. 24
Figure 3 – Typical arrangements for sealing discs and plates on vertical vessels ......................... 25
Figure 4 – Sealing detail on horizontal nozzles ............................................................................. 26
Figure 5 – Skirts on vertical vessels of moderate pressure and temperature (for non-cyclic service)32
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Figure 6 – Skirts on high pressure, or high temperature, or cyclic service vessels ........................ 33
Figure C.1 – Cladding re-instatement at a vessel seam ................................................................ 53
Figure G.1 – Typical butt weld detail for titanium clad heat exchanger shell.................................. 67
Figure G.2 – Preferred details for titanium lined nozzles ............................................................... 68
Figure G.2a – Two alternative cladding arrangements for nozzles DN 80 (NPS 3) and larger....... 68
Figure G.2b – Nozzles DN 50 (NPS 2) and smaller....................................................................... 68
Figure G.2c – Nozzles DN 150 (NPS 6) and smaller..................................................................... 69
Figure G.2d – Two alternative cladding arrangements for studding pads DN 80 (NPS 3) and larger69
Figure G.2e – Studding pads DN 50 (NPS 2) and smaller............................................................. 70
Figure G.2f – Studding pads DN 100 (NPS 4) and larger .............................................................. 71
Figure G.2g – Detail 1 Butt weld of flange facing to bore liner ....................................................... 71
Figure G.2h – Detail 2 Fillet weld of flange facing to bore liner...................................................... 72
Figure G.2i – Type S Screw attachment in section........................................................................ 72
Figure G.2j – Type S Screw attachment – plan view ..................................................................... 73
Figure G.2k – Type C flange made from clad plate ....................................................................... 73
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1. Scope
This Engineering Technical Practice (ETP) provides guidance on industry standards for new pressure
vessels. Spheres built to pressure vessel codes and pig launchers/receivers are also included.
The codes, ASME Section VIII (Divisions 1, 2, or 3), PD 5500, and BS EN 13445, are specifically
addressed in this GIS, but the use of other internationally recognised codes is not precluded.
2. Normative references
The following normative documents contain requirements that, through reference in this text,
constitute requirements of this technical practice. For dated references, subsequent amendments to, or
revisions of, any of these publications do not apply. However, parties to agreements based on this
technical practice are encouraged to investigate the possibility of applying the most recent editions of
the normative documents indicated below. For undated references, the latest edition of the normative
document referred to applies.
American Petroleum Institute (API)

API RP 934 Materials and Fabrication Requirements for 2-1/4Cr-1Mo & 3Cr-1Mo
Steel Heavy Wall Pressure Vessels for High Temperature, High Pressure
Hydrogen Service.
API RP 941 Steels for Hydrogen Service at Elevated Temperatures and Pressures in
Petroleum Refineries and Petrochemical Plants.
American Society of Mechanical Engineers (ASME)

ASME Boiler and Pressure Vessel Code (ASME Code):
Section II, Part A Ferrous Material Specifications:
SA 20/20M Specification for General Requirements for Steel Plates for Pressure
Vessels.
SA 182/182M Specification for Forged or Rolled, Alloy-Steel Pipe Flanges, Forged
Fittings and Valves and Parts for High-Temperature Service.
SA 193/193M Specification for Alloy-Steel and Stainless Steel Bolting Materials for
High-Temperature Service.
SA 194/194M Specification for Carbon and Alloy Steel Nuts for Bolts for High-
Pressure or High-Temperature Service, or Both.
SA 240/240M Specification for Heat-Resisting Chromium and Chromium-Nickel
Stainless Steel Plate, Sheet, and Strip for Pressure Vessels.
SA 263/263M Specification for Corrosion-Resisting Chromium Steel-Clad Plate, Sheet,
and Strip.
SA 264/264M Specification for Stainless Chromium-Nickel Steel-Clad Plate, Sheet, and
Strip.
SA 265/265M Specification for Nickel and Nickel-Base Alloy-Clad Steel Plate.
SA 320/320M Specification for Alloy Steel Bolting Materials for Low-Temperature
Service.
SA 333/333M Specification for Seamless and Welded Steel Pipe for Low-Temperature
Service.
SA 336/336M Specification for Alloy Steel Forgings for Pressure and High-
Temperature Parts.
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SA 350/350M Carbon and Low-Alloy Steel Forgings Requiring Notch Toughness

testing for Piping Components.
SA 387/387M Pressure Vessel Plates, Alloy Steel, Chromium-Molybdenum.
SA 435/435M Specification for Straight-Beam Ultrasonic Examination of Steel Plates
for Pressure Vessels.
SA 516/516M Specification for Pressure Vessel Plates, Carbon Steel, for Moderate- and
Lower-Temperature Service.
SA 541/541M Specification for Quenched and Tempered Carbon and Alloy Steel
Forgings for Pressure Vessel Components
SA 542/542M Specification for Pressure Vessel Plates, Alloy Steel, Quenched-and-
Tempered, Chromium-Molybdenum and Chromium-Molybdenum-
Vanadium.
SA 578/578M Specification for Straight-Beam Ultrasonic Examination of Plain and
Clad Steel Plates for Special Applications.
SA 841/841M Specification for Steel Plates for Pressure Vessels, Produced by the
Thermo-Mechanical Control Process (TMCP).
SFA-5.11 Specification for Nickel and Nickel-Alloy Welding Electrodes for
Shielded Metal Arc Welding.
SFA-5.14 Specification for Nickel and Nickel-Alloy Bare Welding Electrodes and
Rods.
Section II, Part B Nonferrous Material Specifications:
SB 265 Specification for Titanium and Titanium Alloy Strip, Sheet, and Plate.
Section II, Part D Properties.
Section VIII, Division 1 Rules for Construction of Pressure Vessels.
Section VIII, Division 2 Alternative Rules.
Section VIII, Division 3 Alternative Rules for Construction of High Pressure Vessels.
Section IX Qualification Standard for Welding and Brazing Procedures, Welders,
Brazers and Welding and Brazing Operators.
ASME B16.5 Pipe Flanges and Flanged Fittings NPS ½ Through NPS 24 Metric/Inch
Standard.
ASME B16.47 Large Diameter Steel Flanges NPS 26 Through NPS 60.
ASME B36.10M Welded and Seamless Wrought Steel Pipe.
American Society for Testing and Materials (ASTM)

ASTM A923 Standard Test Methods for Detecting Detrimental Intermetallic Phase in
Duplex Austenitic/Ferritic Stainless Steels.
ASTM E94 Standard Guide for Radiographic Examination.
ASTM E112 Standard Test Methods for Determining Average Grain Size.
ASTM E140 Standard Hardness Conversion Tables for Metals Relationship Among
Brinell Hardness, Vickers Hardness, Rockwell Hardness, Superficial
Hardness, Knoop Hardness, and Scleroscope Hardness.
ASTM E165 Standard Test Methods for Liquid Penetrant Examination.
ASTM E562 Standard Test Methods for Determining Volume Fraction by Systematic
Manual Point Count.
ASTM G48 Standard Test Methods for Pitting and Crevice Corrosion Resistance of
Stainless Steels and Related Alloys by Use of Ferric Chloride Solution.
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American Welding Society (AWS)

AWS A4.2M/A4.2 Standard Procedures for Calibrating Magnetic Instruments to Measure the
Delta Ferrite Content of Austenitic and Duplex Ferritic-Austenitic
Stainless Steel Weld Metal.
AWS A5.4 Specification for Stainless Steel Electrodes for Shielded Metal Arc
Welding.
AWS A5.9 Specification for Bare Stainless Steel Welding Electrodes and Rods.
AWS A5.16/A5.16M Specification for Titanium and Titanium Alloy Welding Electrodes and
Rods.
British Standards Institute (BSI)

BS EN 1714 Non-destructive testing of welds — Ultrasonic testing of welded joints.
BS EN 10160 Ultrasonic testing of steel flat product of thickness equal or greater than
6 mm (reflection method).
BS EN 10164 Steel products with improved deformation properties perpendicular to the
surface of the product — Technical delivery conditions.
BS EN 287 Qualification test of welders – Fusion welding –
Part 1 – Steels.
BS EN 10228 Non-destructive testing of steel forgings –
Part 1: Magnetic particle testing.
Part 2: Penetrant testing.
Part 3: Ultrasonic testing of ferritic or martensitic steel forgings.
Part 4: Ultrasonic testing of austenitic and austenitic-ferritic stainless
steel forgings.
BS EN 10028 Flat products made of steel for pressure purposes
Part 2: Non-alloy and alloy steels with specified elevated temperature
properties.
Part 3: Weldable fine grain steels, normalized.
Part 6: Weldable fine grain steels, quenched and tempered.
BS EN 13445 Unfired pressure vessels
Part 1: General.
Part 2: Materials.
Part 3: Design.
Part 4: Fabrication.
Part 5: Inspection and testing.
Part 6: Requirements for the design and fabrication of pressure vessels
and pressure parts constructed from spheroidal graphite cast iron.
Part 7 (PD CR): Guidance on the use of the conformity procedures.
BS EN ISO 15156 Petroleum and natural gas industries. Materials for use in H2S-containing
environments in oil and gas production –
Part 2: Cracking-resistant carbon and low alloy steels, and the use of cast
irons.
Part 3: Cracking-resistant CRAs (corrosion-resistant alloys) and other
alloys.
BS EN ISO 9606 Approval testing of welders – Fusion welding –
Part 4: Nickel and nickel alloys.
Part 5: Titanium and titanium alloys, zirconium and zirconium alloys.
PD 5500 Specification for unfired fusion welded pressure vessels.
BP
GIS 46-040 Guidance on Industry Standard for Column Internals.
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GP 06-20 Guidance on Practice for Sour Service Design (GS 136-1).

GP 43-50 Guidance on Practice for Guidance on Practice for Pigging, Pig
Launchers, and Receivers (GS 143-1).
International Organization for Standardization (ISO)

ISO 9001 Quality management systems.
NACE International (NACE)

NACE MR0103 Standard Material Requirements Materials Resistant to Sulfide Stress
Cracking in Corrosive Petroleum Refining Environments.
NACE MR0175 (Identical to BS EN ISO 15156. BS EN ISO 15156 is referenced herein.)
NACE RP0472 Standard Recommended Practice Methods and Controls to Prevent In-
Service Environmental Cracking of Carbon Steel Weldments in
Corrosive Petroleum Refining Environments.
NACE TM0177 Standard Test Method Laboratory Testing of Metals for Resistance to
Specific Forms of Environmental Cracking in H2S Environments.
NACE TM0284 Standard Test Method Evaluation of Pipeline and Pressure Vessel Steels
for Resistance to Hydrogen-Induced Cracking.
NACE Corrosion Data Survey, Sixth edition, 1985.
The Society for Protective Coatings (SSPC)

SSPC-SP 5/NACE No. 1 White Metal Blast Cleaning.
Welding Research Council (WRC)

WRC 107 Welding Research Council Bulletin 107 Local Stresses in Spherical and
Cylindrical Shells due to External Loadings, 1965.
WRC 297 Welding Research Council Bulletin 297 Supplement to WRC 107, 1984.
Other
Zick, L. P. Stresses in Large Horizontal Cylindrical Pressure Vessels on Two Saddle
Supports, Welding Journal Research Supplement, pp. 556-567,
September 1951.
3. Definitions
The following definitions apply to different duties:
amine service
process stream with 1% (by weight) or greater of MEA, DEA., MDEA., DGA or DIPA.
approval
acceptance by the purchaser.
ASME Code
ASME Boiler and Pressure Vessel Code
BP
the BP p.l.c., an associate or subsidiary, or other organization as defined in the Conditions of Contract
for the project.
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blast
either sand or grit blasting of steel surfaces.
clad plate
plate which has been purchased by the supplier already clad (by roll or explosion bonding).
cladding re-instatement
the process in which small areas at nozzles and attachments, where the cladding has been removed for
welding of the base material, are re-clad by welding.
contractor
a main contractor responsible to BP for the design and/or supply of goods or services, for a complete
project or installation.
cyclic service
duty where there are significant (relative to that permitted by the design code) cycles of pressure or
thermal loading on a component.
design by analysis
design of a component by selection of a failure mode, analysis and assessment of the results from the
analysis.
design by formula
input of the geometry, loading and material properties into a calculation method that gives the required
component thickness (also known as design by rules).
hydrogen service
process stream with operating conditions where the hydrogen partial pressure-temperature
combination is at or above the operating limit curve for carbon steel in API RP 941.
hydrofluoric acid service

process stream with trace amounts (ppm range) or more of hydrofluoric acid (HF).
integrally reinforced, butt welded nozzle

nozzle design as shown in details (F-1), (F-2), (F-3), and (F-4) of Figure UW-16.1 of ASME
Section VIII Division 1, (E-22) and (E-23) of PD 5500 annex E, or S1 and S2 of BS EN 13445-3
annex A.
may
indicates an action which is recommended, but not mandatory, and requires confirmation.
non-intrusive inspection
Inspection that can be made without entry and, preferably, whilst the vessel is operating.
positive material identification

chemical analysis for verification of alloy content in metallic materials.
purchaser
a contractor acting on behalf of BP or BP itself in the case of a direct purchase.
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quality assurance
planned and systematic actions necessary to provide adequate confidence that a product or service
satisfies given requirements for quality.
quality plan
a document setting out the specific quality practices, resources and sequence of activities relevant to a
particular product, service, contract or order.
quality system
the organisation, structure, responsibilities, resources and actions that together provide procedures and
methods of implementation to ensure the capability of the organisation to meet quality requirements.
reinforcing plate
reinforcing element as used in ASME Code,
compensation plate as used in BSI PD 5500,
reinforcing plate as used in BS EN 13445.
shall
states a mandatory requirement, deviation from which requires approval from purchaser.
sour water, wet H2S, or wet sour service

as determined by the purchaser and indicated on the data sheet.
supplier
the organisation, purchaser or agency which is contracted to provide the vessel to BP.
will
indicates an action generally by the purchaser.
weld overlay
the process in which cladding is applied by weld deposit.
weldment
weld, HAZ and adjacent parent metal.
4. Symbols and abbreviations
ASS austenitic stainless steel
ASNT American Society for Non-Destructive Testing
CUI corrosion under insulation
DHT dehydrogenation heat treatment
DN nominal pipe diameter
DSS duplex stainless steel
FCAW flux cored arc welding
FEA finite element analysis
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FN Ferrite number (per Welding Research Council Bulletin Number 342)
GMAW gas metal arc welding
GTAW Tungsten inert gas welding
HAZ heat affected zone
HIC Hydrogen-induced cracking
HRB Rockwell hardness number, B scale, tested with a steel ball
HBW Brinell hardness measured by tungsten carbide ball (also referred to as HB)
Hv10 Vickers hardness measured with a 10 kgf indenter (also referred to as HV)
IPWHT intermediate post-weld heat treatment (also known as ISR Intermediate stress relief)
LFWN long forged weld neck flange
MDMT minimum design metal temperature
MT magnetic particle testing
NDE non-destructive examination
NPS nominal pipe size
PCN Personnel Certification in Non-Destructive Testing
PD Published Document
PMI positive material identification
PQR procedure qualification record
PT liquid or dye penetrant testing
Q+T Quenched and tempered
RT radiographic testing
PWHT post-weld heat treatment
PWHTmin shortest time for which the vessel may be heat treated to meet code requirements
PWHTmax longest time for which the vessel may be heat treated
SMAW shielded metal arc welding
SAW submerged arc welding
TMCP Thermo-Mechanical Control Process
UT ultrasonic testing
WFMT wet fluorescent magnetic particle testing
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WPQ Welder/Welding Operator Performance Qualification
WPS Welding Procedure Specification
5. Introduction, codes, legislation, and quality assurance
5.1. Introduction
a. The main part of this GIS, comprising sections numbered 1-15, applies to all pressure
vessels. Annexes A–H apply to specific materials and Annexes AA, BB, and CC to the
ASME Code, PD 5500, and BS EN 13445 respectively. The paragraph numbering system
used in the annexes is consistent with that in the main part.
b. Supplier may propose alternatives, e.g. for materials, for approval.
5.2. Legislation
Vessels shall conform to national requirements and local, state, or insurance regulations that
apply at the point of usage.
a. Requirements of the Occupational Safety and Health Administration shall be met in U.S.
b. If specified by the purchaser, a National Board Registration Number shall be assigned and
stamped to the vessel.
c. In European Economic Area (i.e. European Union and countries such as Norway), vessels
shall be purchased under the Pressure Equipment Directive.
5.3. Quality assurance

a. The supplier shall operate a quality system that shall be in accordance with the relevant
part of ISO 9001 or equivalent.
b. Before start of fabrication, the supplier shall produce a quality plan for approval. It shall
state all quality related activities, reference standards, acceptance criteria, and the names of
the responsible persons in the supplier. Spaces for signatures and dates relating to
inspections shall be provided.
6. Materials selection
6.1. General
a. Carbon or carbon manganese steels shall not be used if the design temperature exceeds
425°C (800°F). Above 400°C (750°F) such steels shall be fully killed. For vessels having a
design temperature exceeding 425°C (800°F), materials shall be 1 Cr ½ Mo or higher alloy
steel.
b. Unless otherwise specified, a life of 100 000 h shall be used for vessels if the design stress
is creep-related.
c. C ½ Mo steel shall not be used.
d. Castings shall not be used without specific approval.
e. Unless otherwise approved, attachments shall be fabricated from the same grade of
material as the shell to which they are attached.
f. Material substitutions shall not be made without approval.
g. The use of reclaimed materials is prohibited.
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6.2. Process specific requirements
6.2.1. General
In the services described in this section, it is assumed that hydrocarbon is present.
6.2.2. Sour water, wet H2S/wet sour service

a. This service will be determined by the purchaser and indicated on the data sheet.
b. For unclad carbon steel vessels, material shall be in the normalised condition unless
approval is given for the steel to be supplied quenched and tempered (Q+T) or made by
thermomechanical controlled process (TMCP). In addition:
1. The specified minimum tensile strength of carbon and C Mn steels shall not exceed
585 MPa (85 000 psi).
2. Vessels shall be stress relieved.
3. As a minimum, Z quality plate, see A.6.1, shall be used for carbon steel. Under
conditions of severe hydrogen charging (e.g. sour water containing cyanides), as
specified by the purchaser, the plate shall be to A.6.2 to include testing to confirm
resistance to HIC.
If a SOHIC (stress orientated hydrogen induced cracking) or soft zone cracking
(SZC) test is specified in addition to the HIC test, unless otherwise agreed with the
purchaser, a NACE Standard Tensile Test shall be carried out to TM0177 using
Method A and Test Solution A. The material shall pass this test and un-failed test
samples, shall be evaluated for acceptance by one of two methods:
a) At least two metallographic sections shall be taken parallel to the sample axis.
There shall be no ladder-like cracks > 0,5 mm in length in the through-thickness
direction, or
b) The remaining tensile strength (after hydrogen degassing at 150°C (302°F)) shall
be 80% of the original actual tensile strength of the material.
4. For refinery applications, hardness of carbon steal HAZ, as measured in the weld
procedure test, shall not exceed 248 Hv10 (Brinell 237 HBW) as per NACE RP0472.
Acceptable hardness values for other materials shall be as given in NACE MR0103.
Note: Hardness conversions are based on ASTM E140.
Hardness checks on the weld deposit of the completed vessel shall comply with
NACE RP0472, which specifies a maximum hardness of Brinell 200 HBW in the
weld metal.
5. For upstream applications, hardness in the weldment on cracking resistant carbon and
low alloy steels, measured in the weld procedure test, shall be in accordance with
BS EN ISO 15156-2, which specifies a maximum hardness of 250 Hv10 for the weld
root area and a minimum temperature for PWHT of 620°C (1 150°F).
6. Weldments shall be subject to blasting of the surface (to an SSPC-SP 5/NACE No. 1
(white metal)) and WFMT. This shall be made after PWHT.
c. Vessels clad with a corrosion resistant lining or fabricated from solid corrosion resistant
alloys for Upstream environments shall be in accordance with BS EN ISO 15156-3. The
conditions of acceptability for each of the material classes given in Annex A in
BS EN ISO 15156-3 shall be met. For Downstream environments, the material
requirements given in NACE MR0103 shall be met.
Explosively clad, roll bonded, and fusion bonded corrosion resistant overlays utilizing
austenitic stainless steel and nickel base alloys are considered to be effective barriers in
Page 18 of 87
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wet H2S environments, provided the material is suitable for the specific process conditions.
If such overlays are used, the backing material need not be designed for sour service.
d. With non-ferrous materials:
1. If the service temperature is less than 150°C (300°F), alloy 400 (UNS N04400,
N044405, and K-500 (UNS N05500) alloy may be used.
2. If neither amine nor ammonia is present, aluminium bronze (UNS C61300) and
inhibited admiralty brass (UNS C44300) may be used.
6.2.3. Amine service

a. In certain aqueous environments containing amines, carbon steel shall be subject to PWHT
per GP 06-20.
b. In amine service, welds and HAZ shall be blasted and examined by WFMT. If the vessel is
subject to PWHT, this examination shall be performed after PWHT.
c. Copper, brasses, bronzes and copper-nickel alloys shall not be used.
6.2.4. Hydrogen service

a. Materials selection shall be to API RP 941 Figure 1.
b. Enhanced 2¼ Cr 1 Mo shall be limited to design temperatures not exceeding 425°C
(800°F).
c. For design temperatures above 425°C (800°F) up to and including 454°C (850°F) either
standard 2¼ Cr 1 Mo, 3 Cr 1 Mo V or 2¼ Cr 1 Mo V shall be used.
d. For design temperatures above 454°C (850°F) up to and including 482°C (900°F), 2¼ Cr
1 Mo V shall be used.
e. Materials shall be subject to UT to ASME SA 578, including Supplementary Requirements
S1, S2, S3, and S4. Acceptance standard shall be Level 1.
6.2.5. Hydrogen service with hydrogen sulphide

If the concentration of H2S is greater than 0,02 mol % and the design temperature is above
260°C (500°F), stabilised ASS (austenitic stainless steel) (Type 321 or 347) shall be used.
6.2.6. High temperature hydrogen sulphide

a. If H2S is present at high temperature without hydrogen, the following shall be used: solid
5 Cr ½ Mo; solid 9 Cr 1 Mo; 12 Cr clad steel (Type 405 or 410S); or an ASS clad steel.
b. Si-killed C Mn steel may be used at lower temperatures, where corrosion rates are lower.
6.2.7. Duties containing Naphthenic acids and a design temperature above 220°C (430°F)
At a design temperature above 220°C (430°F), 316L cladding with 2,5% min. molybdenum
content or type 317L shall be used (or higher Mo containing alloy depending on the Total Acid
Number (TAN) level).
6.2.8. Caustic service (sour or non-sour)

a. In sour, caustic service, carbon steel shall be subject to PWHT.
b. For non-sour service, where caustic soda is the only consideration, the requirement for
PWHT of carbon steel shall be as given on Figure 1, except that the concentration may be
based on the presence of either Sodium Hydroxide (NaOH) or Potassium Hydroxide
(KOH).
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3 May 2005 GIS 46-010
Figure 1 – Requirement for PWHT in caustic service

Source: NACE Corrosion Data Survey, sixth edition, 1985
AREA C
CARBON STEEL SHALL NOT BE USED
260 NICKEL ALLOYS TO BE CONSIDERED IN THIS AREA
125
240
220
AREA B 100
CARBON STEEL IS PERMISSIBLE.
200
STRESS RELIEF OF WELDS
IS NECESSARY
180
TEMPERATURE DEG C
TEMPERATURE DEG F
75
160
140
120 50
100
80
AREA A 25
CARBON STEEL IS PERMISSIBLE.
60 NO STRESS RELIEF IS NECESSARY.
40
0
20
0
10 20 30 40 50
CONCENTRATION NaOH, % BY WEIGHT
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6.2.9. Hydrofluoric acid

a. Material shall be to licensor and BP requirements, with restrictions on composition. Unless
otherwise agreed, it shall be to SA 516/516M Gr. 60 normalised with:
1. carbon equivalent ≤ 0,40%.
2. combination of Ni + Cu + Cr ≤ 0,15%.
3. S < 0,002%.
4. oxygen content < 0,002%.
5. P < 0,008%.
6. Nb (Cb) < 0,005%.
b. The steel shall not be calcium treated for shape control.
6.2.10. Propane and butane storage spheres

For propane or butane storage spheres:
a. The specified minimum tensile strength of C Mn steels shall not exceed 550 MPa (80 ksi).
b. Weldment hardness shall not exceed Hv10 248 (Brinell 237 HBW).
6.3. Bolting
6.3.1. Pressure part bolting materials

Bolting materials shall be as Table 1, unless specified otherwise.
Table 1 – Permissible bolting materials at different temperatures
Design Temperature °C (°F) Insulated Flanges Uninsulated Flanges

–196 (–320) to –102 (–151) SA-320, Gr. 8M, Cl. 1 studs N/A
SA-194, Gr. 8 nuts
1
–101 (–159) to –47 (–51) SA-320, Gr. L7 studs N/A
1
SA-194, Gr. 4 nuts
–46 (–50) to –30 (–21) SA-193, Gr. B7M studs N/A
SA-194, Gr. 2H nuts
–29 (–20) to 343 (650) SA-193, Gr. B7 studs SA-193, Gr. B7 studs
SA-194, Gr. 2H nuts SA-194, Gr. 2H nuts
344 (651) to 427 (800) SA 193, Gr. B16 studs SA-193, Gr. B7 studs
SA-194, Gr. 4 nuts SA-194, Gr. 2H nuts
428 (801) to 454 (850) SA-193, Gr. B16 nuts SA-193, Gr. B16 studs
SA-194, Gr. 7 nuts SA-194, Gr. 4 nuts
455 (851) to 482 (900) N/A SA-193, Gr. B16 studs
SA-194, Gr. 4 nuts
483 (901) to 510 (950) N/A SA-193, Gr. B16 studs
SA-194, Gr. 7 nuts
511 (951) to 816 (1500) N/A SA-193, Gr. B8, Cl. 1 studs
SA-194, Gr. 8A nuts
Note 1: It is assumed here that flanges are ferritic. If they are austenitic, bolts and nuts should be Gr. 8M/8.
This is because of thermal contraction of the flange relative to the bolts.
6.3.2. Bolting for special services

Bolting for amine, sour water, or wet H2S service that is exposed directly to the process fluid or
is buried, insulated, equipped with flange protectors, or otherwise denied direct atmospheric
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3 May 2005 GIS 46-010
exposure, shall meet the bolting requirements specified in BS EN ISO 15156-2, Annex A,
clause A.2.2.4 and be designated ‘M’ grade with restricted strength/hardness.
7. Design
7.1. General
7.1.1. Corrosion allowance

Corrosion allowance shall be added to the thickness required by the design calculations at each
surface exposed to the process fluid.
a. It shall apply equally to the exposed surfaces of non-removable internals but not to flange
gasket faces.
b. For fillet and seal welds on internal attachments, it shall be added to the required throat
thickness.
c. On vessels coated with a non-metal, it shall be provided on the base material.
d. Fabricated shell and/or head thickness, including corrosion allowance, shall not be less
than:
1. 6 mm (1/4 in) for carbon and low-alloy steels.
2. 5 mm (3/16 in) for stainless and high-alloy steels.
e. For carbon steel vessels, the as-built thickness of shell, heads, and skirt shall not be less
than 6 mm (1/4 in).
7.1.2. Hydraulic testing

Unless otherwise agreed, vessels shall be designed to permit application of a full hydraulic test
to the vessel in its operating position in the fully corroded condition. It may be assumed that the
wind loading during full hydraulic test does not exceed 25% of the design wind load.
7.1.3. Design by analysis

If design by analysis (i.e. that part of the design section of the code that is not design by
formula) is used, the selected mode(s) of failure shall be stated in the calculations.
a. Manual stress analysis may be verified by cross-reference to suitable texts.
b. The application of stress classification to the results of numerical methods shall be subject
to approval.
c. With elastic and inelastic FEA, the linearisation of the stresses shall be subject to approval.
d. Calculation to BS EN 13445-3 Annex B shall be subject to approval.
7.1.4. Experimental design verification

The purchaser shall be informed if a design is to be proven by experimental verification.
7.1.5. Vessels in cyclic service

If specified by the purchaser, the tolerances to which the vessel will be built shall be stated on
the drawings and checks shall be made that the as-built vessel meets those tolerances.
7.2. Loadings
7.2.1. Static
a. The design pressure shall be included as a design load considering the following:
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3 May 2005 GIS 46-010
1. Except as provided in (2), the design pressure shall be considered to be acting at the
top of the vessel and the design temperature shall be assumed applicable to the entire
vessel.
2. If the vessel is divided into pressure and/or temperature zones, the design pressure
and temperature for each zone shall be indicated on the vessel drawing.
3. The common component(s) of multi-chamber pressure vessels shall be designed for
the most severe combination of pressure and temperature conditions unless provisions
(e.g. a balancing line) are provided to ensure that only differential pressure is possible
during operation. In this case, the head may be designed for differential pressure.
Liquid head and vacuum acting adjacent to a pressurized chamber shall be
considered.
4. The pressure drop across internal components, as defined on the vessel drawing, shall
be used for design of such components and their supports. It shall be included as a
load condition.
b. Vessels and their supports shall be designed, as a minimum, for the following load
combinations. For these design load combinations, lateral deflection of the vessel shell and
skirt shall be a maximum of 1 in 200 of its length:
1. Vessel operating weight, external attachment loads, snow loads, and wind load.
2. Vessel operating weight, external attachment loads, snow loads, and earthquake load.
3. Hydrostatic test loads, vessel weight (including linings and insulation), vessel
internals weight, external attachment loads, snow loads, and 1/4 wind load.
4. Erection load: 1,5 times total weight of vessel during erection.
5. Localized stresses at support lugs, platform brackets, pipe supports, and nozzles due
to dead, live, thermal, and wind loads, as supplied by the purchaser or specified
herein.
6. Vessel transportation, if relevant.
7.2.2. Dynamic
a. Dynamic analysis, at normal operating conditions, shall be performed prior to fabrication
of vertical vessels if the height to diameter ratio of either the entire vessel or the top section
of the vessel is greater than or equal to 15:1.
b. Acceptable vessel critical wind velocities (first and second modes) shall be less than 7 m/s
(15 mph) or greater than 27 m/s (60 mph). For a vessel with critical wind velocities
between 7 m/s (15 mph) and 27 m/s (60 mph), a means of either preventing vortex
formation (e.g. by spoilers, piping, ladders or platforms) or vibration dampening shall be
provided.
7.3. Design against corrosion under insulation (CUI)
7.3.1. On all vessels

a. Insulation supports, stiffening rings, and external attachments shall be designed and
constructed to prevent the channelling and hold up of rainwater. They shall be naturally
draining. Drain holes or gaps to prevent the accumulation of rainwater shall be provided.
b. On vertical vessels, there shall be a continuous gap of not less than 10 mm (3/8 in)
between the vessel and the inside edge of the insulation support ring, see Figure 2. The
ring shall be either bolted or welded to clips that are welded to the shell.
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Figure 2 – Typical arrangement to prevent hold up of water at insulation rings
VESSEL
MIN GAP 10mm (3/8 in)
FLAT BAR
WELDED CLIP
c. Insulation details for sealing discs and plates on vertical vessels shall be either to Figure 3
or subject to approval. Figure 4 shows details for sealing horizontal nozzles.
d. Lifting lugs shall be removed after installation.
e. Pipe segments shall not be directly attached to a pressure boundary and used as supports
for any ladders, platforms, piping, etc.
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Figure 3 – Typical arrangements for sealing discs and plates on vertical vessels
2mm M
(3/32 in
IN
FULL FILLET WELD
MAX = FLANGE DIAMETER

MIN = PIPE OD + 50mm (2 in)
DEPENDS ON CLEARANCES
AVAILABLE FOR WELDING
NOZZLE TO VESSEL
DIMENSIONS OF SEALING DISC
2m /32 in
(3
m
MI
N
)
2mm MIN
(3/32 in)
SEALING DISCS INSTALLED

IN DIFFERENT LOCATIONS
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Figure 4 – Sealing detail on horizontal nozzles
CLADDING
NOTE THE ARRANGEMENT

OF THE CLADDING FOR
SHEDDING WATER
CLADDING
7.3.2. On vessels identified as potentially susceptible to CUI

a. Any vessel identified as potentially susceptible to CUI shall be prepared and painted in
accordance with an approved specification.
b. On insulated carbon steel vessels, the following shall be provided:
1. Nozzles DN 50 (NPS 2) and below operating in the range of 0–150°C (0–300°F) shall
be LFWN.
2. Nozzles shall be a minimum 75 mm (3 in) longer than insulation thickness.
3. Attachments shall be designed to ensure effective sealing of the insulation from water
ingress.
7.4. Design for non-intrusive inspection

If the vessel is to be designed for non-intrusive inspection:
a. The joint type and location of welds shall be checked for the extent and type of NDE that
can be effectively applied.
b. Integrally reinforced, butt welded nozzles shall be considered.
c. The number and size of external attachments should be kept to the minimum.
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3 May 2005 GIS 46-010
d. Pressure bearing welds should be suitable for UT from the outside of the vessel over the
maximum length possible.
e. The design of both fixed and removable internals shall be resistant to corrosion, erosion, or
any other type of deterioration expected in service.
7.5. Plate layout and weld design

a. The layout of weld seams shall be as follows:
1. Longitudinal seams in cylindrical and conical shells and all seams in spherical shells
and heads shall be located to clear openings.
2. Longitudinal and circumferential seams in vessel shells and heads shall, if possible,
be located to clear nozzle openings and reinforcing pads. If, however, a reinforcing
pad covers a seam:
a) This shall be subject to approval.
b) Alignment of the butted plates under the reinforcement pad shall be flush.
c) The seam weld shall be ground flush and given 100% RT for a length equal to
three times the diameter of the opening before attachment of the pad.
3. If two sections of unequal thickness are butt welded together, the inside (process face)
shall be flush.
4. Joints in horizontal vessels shall not be located at or across saddle supports.
5. If possible, structural attachment welds shall clear seam welds by at least four plate
thicknesses. If overlap is unavoidable, welds shall be made using one of these
options:
a) The portion of the seam weld to be covered shall be ground flush and given
100% RT before the attachment is welded on.
b) The structural attachment shall be coped or notched to bridge the weld seam.
The attachment weld shall be at least one plate thickness from the main seam
weld and the design shall be subject to approval.
6. Girth seams shall not be closer than 75 mm (3 in) to tray supports, stiffening rings or
vessel skirt. Similarly, longitudinal seams shall not be closer than 75 mm (3 in) to
downcomer bars, baffles or other longitudinal attachments.
7. Longitudinal seams shall be so located to give as much access as possible for internal
visual inspection, consistent with the presence of the internals.
8. Longitudinal joints shall be offset between courses by not less than five times the
plate thickness or 150 mm (6 in), whichever is greater.
b. In hydrogen service, spaces fully enclosed by welds (for example, continuous fillet welded
attachments) in ferritic material shall be avoided. If a space cannot be avoided, it shall be
vented.
7.6. Nozzles and manways
7.6.1. Construction details

a. Nozzles DN 40 (NPS 1½) and below shall be either LFWN or seamless pipe of minimum
(DN 50)(NPS 2) and min. thickness sch. 160 (per ASME B36.10M) welded to a forged
reducer of the required size.
b. Nozzles DN 50 (NPS 2) and larger shall be constructed using LFWN or seamless pipe.
Unless otherwise specified, the minimum wall thickness shall be standard wall.
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c. Nozzles DN 300 (NPS 12) and larger may be made from formed plate instead of pipe.
d. Nozzles should normally be of the set-in design and shall be double welded, i.e. from both
inside and outside. The welds shall be full penetration.
e. An integrally reinforced, butt welded nozzle shall be considered for:
1. high pressure applications; or
2. if thermal stress is high; or
3. if a reinforcing plate is to be avoided or
4. if the vessel is to be designed for non-intrusive inspection
f. In exceptional cases when set-in connections are not practicable, set-on nozzles may be
used subject to the following:
1. Edges of the holes in the shell plate shall be examined to prove that the plate local to
the connection is not laminated.
2. Examination shall be conducted before and after welding to ensure that lamellar
defects have not developed during welding.
3. MT and UT shall be used on ferritic material and PT on austenitic material.
g. Pipe couplings, socket welded, single fillet welded, studded or threaded connections are
not permitted without approval.
h. Unless otherwise specified, nozzles not directly connected to internals shall be flush with
the inside surface of the vessel wall. Nozzles in portions of vessels with refractory lining
shall have internal projections such that the nozzle end is flush with the lining. If a
retaining ring is fitted, the nozzle shall project beyond the lining equal to the thickness of
the retaining ring.
i. Nozzles in hydrogen service or services above 345°C (650°F) shall be extended
sufficiently such that flanges and bolting are outside vessel insulation.
j. Studded (or studding) pads are permitted if specified.
7.6.2. Reinforcing pads

a. Reinforcing pads shall not be used if any of the following conditions apply:
1. Operating temperature exceeds 300°C (572°F).
2. Material is chrome molybdenum steel.
3. Operating partial pressure of hydrogen exceeds 7 bar(ga) (100 psia) and operating
temperature exceeds 230°C (450°F).
4. Wet sour service (if the vessel is not clad internally with a corrosion resistant alloy).
5. Hydrofluoric acid service.
6. Design is for non-intrusive inspection.
7. Plate thickness exceeds 50 mm (2 in).
8. Ferritic vessels where operating temperature is below –50°C (–58°F).
9. Cyclic service.
b. Reinforcing pad thickness shall not exceed the vessel thickness.
c. Reinforcing pads shall be provided with a vent hole tapped 1/4 NPT located in the lower
portion of the pad with the vessel in its operating position.
1. Vent holes shall be left open during welding and PWHT.
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2. If a reinforcing pad consists of two or more plates welded together after fitting on the
vessel, a vent hole shall be provided for each sealed section.
3. On vessels insulated for hot service, vent holes shall be fitted with vent lines
projecting beyond the insulation.
4. On vessels insulated for cold service, vent lines shall not be fitted.
7.6.3. Allowable nozzle loads

Unless otherwise specified, nozzles, shells, and supports shall be designed for the allowable
nozzle loads given below. Local load analysis is not required on either blind flange connections
or instrument connections.
a. The following notation applies:
D Nominal diameter of nozzle (mm).
D’ Nominal diameter of nozzle (in).
FR Positive or negative radial force (N).
F’R Positive or negative radial force (lbf).
ML Longitudinal moment on the cylinder (Nm).
M’L Longitudinal moment on the cylinder (ft-lbf).
MC Circumferential moment on cylinder (Nm).
M’C Circumferential moment on cylinder (ft-lbf).
MB Resultant bending moment on sphere (Nm).
M’B Resultant bending moment on sphere (ft-lbf).
P Internal pressure of the vessel (bar(ga)).
P’ Internal pressure of the vessel (psig).
b. The effect of torsion and shear forces on the shell shall be ignored.
c. The loads at the intersection of the axis of the nozzle with the mid-plane of the shell shall
be evaluated from the following formulae:
1. Radial Force (for Cylinders and Spheres)
FR = ± 20D1.2 + PD0.85
F’R = ± 218.09D’1.2 + 0.242P’D’0.85
The effect of both positive and negative values of the forces shall be evaluated.
2. Moment
For a cylinder: ML = MC = (1.75D1.4) + (5.0x10–6)PD2.9
M’L = M’C = (119.636D’1.4) + (3.018x10–3)P’D’2.9
For a sphere: MB = √2ML
M’B = √2M’L
7.6.4. Manways
Internal edges on manhole and inspection openings shall have a radius of at least 3 mm (1/8 in).
7.7. Flanges, gaskets, and bolts
7.7.1. Flanges
a. Connections shall be flanged with through studs unless approval for another type is given.
The dimensions and pressure-temperature ratings of flanges for nozzles and manways
DN 600 (NPS 24) and smaller shall be in accordance with ASME B16.5. For larger sizes,
they shall be in accordance with ASME B16.47 Series A.
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b. Nozzle flanges shall be weld neck except that slip-on flanges may be used on non-cyclic
duties with design temperature below 260°C (500°F) that are not flammable, toxic, or in
steam service.
c. Projection of flanged nozzles with external piping attached shall permit removal of bolting
from either side without removal of insulation.
d. Nozzles in hydrogen service or service above 345°C (650°F) shall be extended such that
flanges and bolting are outside vessel insulation.
e. Flanged joints shall be designed (see 7.7.3.a) such that hydraulic bolt tensioners can be
used on the following:
1. Joints with nominal bolt diameter 50 mm (2 in) and over.
2. Duties where the nominal bolt diameter is 40 mm (1½ in) and over, and the flanges
are either on hydrogen service or are PN 110 (Class 600) or over.
3. If specified by the purchaser for nominal bolt diameter 25 mm (1 in) and over.
7.7.2. Gaskets
7.7.3. Bolts
a. Bolts for bolt tensioning shall be extended by the length of one nut and protected by a cap
during service. Nozzles adjacent to shell girth flanges or horizontal vessel saddles shall be
located with clearance such that bolt tightening equipment can be used on the girth flange
bolts.
b. Bolts shall be uncoated unless otherwise specified.
c. For marine applications, the preferred coating for topsides bolting shall be hot dip spun
galvanising (with approximately 50 microns (2 mils) zinc).
7.7.4. Quick opening closures

a. The operation and maintenance of quick opening closures will be specified by the
purchaser.
b. The design of quick opening closures shall be subject to a review by the purchaser.
c. Requirements on operation or maintenance from the supplier shall be submitted for review
by the purchaser.
7.8. Welds
a. Main seam welds shall be full penetration and, if possible, double sided.
b. Nozzle to shell or head welds shall be full penetration.
c. If a weld seam and an attachment or nozzle weld intersect or lie within 40 mm (1½ in) of
each other (toe to toe) over a region, an examination of the seam weld shall be carried out
before making the attachment weld.
1. The examination shall be for a distance of 100 mm (4 in) or three times the shell
thickness, whichever is the greater, in both directions from the point or region where
the welds lie within 40 mm (1 ½ in).
2. The weld shall be fully examined within the region where they are less than 40 mm
(1 ½ in) apart.
3. The inspection shall be as shown in Table 2.
Page 30 of 87
3 May 2005 GIS 46-010
Table 2 – NDE required where welds lie within 40 mm (1 ½ in)
NDE applied to Preparation and Examination

complete vessel
Grind main weld flush and surface flaw detect (both sides for
Full RT or full UT full penetration welds). Examine with UT or RT. Surface flaw
detect both main seam and component weld on completion.
Spot X-ray As above but omit UT.
d. The minimum leg length of internal fillet welds shall be the larger of 5 mm (1/4 in) or the
calculated value for the applied loads, plus the corrosion allowance.
e. If required by fatigue design rules, butt welds may be ground smooth internally and
externally; and fillet welds ground so as to blend smoothly into the parent material.
f. In hydrogen service, either venting shall be provided behind welded attachments or the
attachments shall be made with full penetration welds.
g. In amine, HF, or wet H2S service, full penetration welds shall be provided on pressure
boundary parts and on downcomer bolting bars and segments, bed support beam seats, or
any load-carrying attachments.
7.9. Internals
a. All portions of the vessel including internals shall be completely self-draining.
b. Removable internals shall be designed to pass through vessel manways.
c. Agitator baffles shall be designed to pass through the agitator mounting flange.
d. The weight of the individual parts of components that are normally disassembled such as
tray decks, downcomers, distributor piping, baffles, minor beams, etc. shall not exceed
29 kg (65 lbs) including attached vapour-liquid contacting devices.
e. The weight of tray manways shall not exceed 22 kg (50 lbs).
f. Flanges for internal non-pressure piping may be slip-on or fabricated from plate.
g. Trays and other column internals shall be in accordance with GIS 46-040.
7.10. Supports
7.10.1. Skirts
a. Vertical vessels shall be designed to be self-supporting without guys or braces.
b. Support skirts shall be in accordance with Figures 5 and 6:
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3 May 2005 GIS 46-010
Figure 5 – Skirts on vertical vessels of moderate pressure and temperature

(for non-cyclic service)
D D
T T
TANGENT LINE TANGENT LINE

BUTTED WELD BLENDS BUTTED WELD BLENDS
SMOOTHLY INTO SMOOTHLY INTO
HEAD CONTOUR HEAD CONTOUR
t sk t sk
Dsk = D
STRAIGHT SKIRT DETAIL CONICAL SKIRT DETAIL
D
BACK
T BEVEL 20°
20°
RING WELDED TO SHELL

BEFORE MAKING SKIRT
tr = t sk ATTACHMENT WELD
TANGENT LINE BACK

BEVEL 20°
20°
t sk
LAP BAND SKIRT DETAIL
6mm GAP
(1/4 in)
Page 32 of 87
3 May 2005 GIS 46-010
Figure 6 – Skirts on high pressure, or high temperature, or cyclic service vessels
SHELL
HEAD / SKIRT
FORGING
UPPER SKIRT SECTION

(SAME MATERIAL AS VESSEL SHELL)
LOWER SKIRT SECTION

(CARBON STEEL)
FORGING OPTION
SHELL
HEAD
WELD BUILD-UP
(WITH ULTRASONIC EXAMINATION)
UPPER SKIRT SECTION

(SAME MATERIAL AS VESSEL SHELL)
LOWER SKIRT SECTION

(CARBON STEEL)
WELD BUILD-UP OPTION
c. For vessels with design temperature(s) 345°C (650°F) and above, a hot box shall be
provided at the junction between the skirt and shell.
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3 May 2005 GIS 46-010
d. For vertical vessels constructed from materials other than carbon steel, the material of the
top of the skirt for a length of 2 ,5 Skirt radius x skirt thickness or greater shall be
of the same grade as the vessel plate to which it is attached.
e. Nozzles in the bottom head shall be of welded construction with the first flange connection
outside the skirt.
7.10.2. Legs or column supports

a. Leg supports or columns shall not bear on the knuckle or crown of flanged and dished or
ellipsoidal heads.
b. The stress analysis of the legs on spheres shall be subject to review by the purchaser.
7.11. External attachments
7.11.1. Insulation supports and details

The distance between insulation support rings shall be approximately 3 000 mm (120 in), but
not more than 3 700 mm (145 in). Support ring design shall be subject to approval.
7.11.2. Fireproofing
a. The design and application of fireproofing shall ensure that the risk of corrosion beneath
the fireproofing in service is minimised. Of particular attention is the fireproofing of legs
on spheres. In all cases, the paint system used beneath the fireproofing system shall be
compatible with the fireproofing system.
b. If the supplier is responsible for both fireproofing and painting, the approval of the
manufacturer of the fireproofing to the painting system shall be obtained.
7.11.3. Nameplates
Nameplates shall be of stainless steel with the required data stamped or, preferably, engraved.
Lettering shall be a minimum of 4 mm (3/16 in) high. The nameplate shall show at least the
following information:
a. Order number.
b. Item number.
c. Date of manufacture.
d. Order placed by.
e. Supplier’s name.
f. Supplier’s serial number.
g. Design code and its date.
h. Design pressure at coincident design temperature.
i. Minimum design temperature.
j. Extent of volumetric weld NDE, inspection category or equivalent descriptor.
k. PWHT.
l. Test pressure new.
m. Test pressure corroded.
n. Total weight empty.
o. Any statutory markings required.
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3 May 2005 GIS 46-010
p. BP equipment tag number or a Works Identification Number (of nine digits).

q. Appropriate stamping.
7.11.4. Manway davits

a. Manway blind flanges shall be furnished with davits, but, subject to approval, hinges may
be substituted on vertical manway covers.
b. Davits shall comply with relevant statutory requirements.
1. Eyebolts shall be one piece forgings.
2. Davit capacity shall be specified on drawings and permanently posted on davit.
7.11.5. Lifting lugs and trunnions

Lifting lugs or trunnions shall be provided on vertical vessels to facilitate handling during
transport and erection at site.
a. The load factor for design shall be 1,5 unless otherwise specified.
b. Subject to approval, a lifting cover on a top head nozzle may be an alternative to a lifting
lug.
c. Attachment of the lifting lug shall ensure that water cannot be trapped between the vessel
and the lifting lug.
7.11.6. Other fittings

Vessels shall be fitted with two earthing (grounding) bosses.
7.12. Spheres
Nothing.
7.13. Pig launchers and receivers
7.13.1. Code selection

a. Launchers/receivers shall be designed as part of the pipeline and the test pressure and
normal operating pressure shall not be less than those for the pipeline.
b. Connections and quick opening closure components shall conform to the requirements of a
pressure vessel code. Further guidance is given in GP 43-50.
c. For cyclic service the design shall be to the fatigue rules of a vessel code.
7.13.2. Quick opening closures

The design, operation, and maintenance of quick opening closures shall be subject to separate
review by the purchaser.
8. Fabrication
8.1. General
a. Only stainless steel brushes, stainless steel grit, glass beads, or other high quality abrasive
that does not result in contamination of the surface shall be used to mechanically clean
stainless steel, high nickel alloy, titanium or zirconium surfaces.
b. Weld joints shall be prepared by machining, grinding, or thermal cutting. If thermal cutting
is performed, the joint surfaces shall be ground to sound metal prior to welding. Preheat
requirements for thermal cutting shall be the same as those specified in the WPS.
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3 May 2005 GIS 46-010
c. If a difference in thickness exists between shell sections or shells and heads, the inside
surface shall be aligned.
d. Fabrication aids, e.g. clips and brackets, shall not be hammered off but shall be removed
without damage to base metals.
1. Gouges from cutting tools shall be welded with an approved procedure and ground
flush and smooth.
2. Areas where attachments have been removed shall be subjected to examination by
DP/MT.
3. Temporary attachment removal and repairs shall be performed prior to PWHT and
hydrotest.
4. Peening is not permitted without approval.
e. If heads are formed in one piece from more than one plate, weld seams shall be fully
radiographed before forming and again in the knuckle region after forming. 100% surface
crack detection shall be made after forming.
f. In general, a weld subject to severe forming (i.e. in which the ratio of thickness to local
radius is greater than 5 percent) shall have full volumetric examination, i.e. RT or UT,
before forming and surface crack detection, i.e. MT or PT, after.
g. For site constructed vessels the method of construction and any implications for design,
inspection, and testing shall be submitted for approval.
h. The allowable flatness tolerances of gasket contact surfaces, after PWHT if required, shall
be as shown in Table 3 for the designated service condition.
Table 3 – Flatness tolerances of gasket contact surface
(1)
Vessel Diameter (mm (in)) Allowable Tolerance (mm (in)
(2)
Normal Service Special Service
< 380 (15) 0,75 (0,03) 0,075 (0,003)
> 380 (15) to 760 (30) 1,50 (0,06) 0,150 (0,006)
> 760 (30) to 1 140 (45) 2,25 (0,09) 0,225 (0,009)
> 1 140 (45) 3,00 (0,12) 0,300 (0,012)
Notes:
(1) Total tolerance on peripheral gasket contact surface shall not occur on less than a 0,35 radian (20 degree) arc.
(2) Design temperatures greater than 454°C (850°F), or a flange rating greater than ISO PN 110 (ASME Class 600).
8.2. Welding
8.2.1. Basic requirements

a. Welding shall follow an approved WPS.
b. Permanent weld backing is prohibited. Temporary weld backing is acceptable only if the:
1. Weld joint is accessible from the root side, and.
2. Backing is either weld metal, a non-metallic material such as flux or ceramic that
does not fuse with the root bead, or a metallic strip of the same nominal composition
as the base metal (and is removed by grinding, or gouging and grinding, before full
NDE of the weld and adjacent parent metal).
c. Arc strikes on the pressure shell shall be minimized. If they do occur, the surface shall be
conditioned to eliminate surface stress concentrations. Defects found shall be removed and
the surface repaired and re-examined.
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3 May 2005 GIS 46-010
d. Significant weld repairs shall be subject to approval.
8.2.2. Welding processes

The following welding processes are permitted:
a. Manual shielded metal arc with covered electrode (SMAW). SMAW of carbon and low
alloy steels shall be made using low hydrogen electrodes.
b. Submerged arc (SAW). WPS shall clearly indicate that the procedure is automatically
controlled.
c. Gas metal arc using solid wire (GMAW).
1. The type of metal transfer (short-circuiting arc, globular or spray transfer) shall be
stated on the WPS under electrical characteristics.
2. The process is applicable to carbon steel and weld overlay where a satisfactory level
of dilution is demonstrated.
3. GMAW using a short-circuiting arc may only be used for depositing metal that is
subsequently removed, e.g. tack welds, double welded joints.
4. Field welding is subject to approval.
d. Gas tungsten arc, manual or automatic (GTAW).
e. Gas shielded flux-cored arc (FCAW).
1. The type of metal transfer shall be stated on the WPS; globular or spray is acceptable
but using a short-circuiting arc is prohibited.
2. FCAW may be used for fillet welds of carbon steel materials only for non-pressure-
retaining parts limited to 10 mm (3/8 in) maximum leg length and not subject to
impact requirements.
3. Self-shielded FCAW shall not be used.
f. Metal cored wires. The use of metal cored wires is subject to specific approval.
g. Unless otherwise approved, welding consumables shall be of the same nominal
composition as the parent plate. Addition of alloys via the flux, other than that required to
make up for losses e.g. in the arc, is not permitted. Filler wire shall be homogeneous and
not of a self-shielding type.
h. Removable start-up and run-off tabs may be used for longitudinal welds. Tab materials
shall be of the same nominal composition as the base metal.
8.2.3. Weld procedure and welder qualification

a. WPS and PQR for welding by the supplier, their subcontractors or subsellers, shall be
submitted for review by the purchaser prior to start of welding. Changes shall also be
submitted. WPQ shall be made available for review upon request.
b. Repair procedures shall be submitted if the repairs could be detrimental to the material or
delivery of the vessel.
c. If the supplier has pre-qualified welding procedures that are directly applicable, this shall
be indicated in the bid together with details of the welding processes. If required by the
purchaser, procedures shall be specifically qualified.
d. Unless otherwise agreed, the position of the impact test specimens for tests of weld metal
and HAZ shall be: weld metal centreline; fusion line; fusion line plus 2 mm (1/16 in);
fusion line plus 5 mm (1/4 in).
Page 37 of 87
3 May 2005 GIS 46-010
8.2.4. Production welding

Nothing.
8.2.5. Post weld heat treatment (PWHT)

a. There shall be no welding on the vessel after PWHT without specific approval.
b. On ferritic vessels subject to PWHT, the shell to nozzle welds on nozzles greater than
DN 200 (NPS 8) shall be subject to MT after PWHT.
8.2.6. Site constructed vessels or spheres

Any local PWHT shall be subject to approval. Field PWHT procedures shall detail the type of
heating, type and effectiveness of insulation, and means of determining metal temperature. The
design of the vessel shall be checked for adequacy during PWHT.
9. Inspection and testing
9.1. Preparation
a. The NDE schedule and NDE procedures shall be subject to approval.
b. Personnel concerned with inspection, interpretation, and NDE shall be qualified to at least
PCN Level 2 or ASNT Level 2 if the qualification has been obtained through examination
by an independent organisation. Evidence of the qualification shall be available to the
purchaser for verification.
c. The purchaser reserves the right to test and monitor the performance of any NDE operator
employed by the supplier, or his sub-supplier, and to exclude any that are deemed
unsatisfactory.
d. Calibration certificates for NDE equipment shall be available for inspection at all times.
e. Before fabrication, materials shall be visually inspected for defects on accessible surfaces.
Heads and shell sections that are annealed or normalized shall be free of mill scale (by
sand blasting or pickling) prior to inspection.
f. Materials for marking, painting, or inspection on stainless or nickel based alloys shall not
contain chlorine, bromine, or other halogens, sulphur, zinc, or any low melting point
metals.
9.2. Surface examination of welds

a. Welds shall be free from surface breaking defects.
b. Pressure welds in ferritic materials, not subject to RT or UT, shall be examined by MT at
back-chipped surface and at finished weld surface. Skirt attachment welds of ferritic
materials shall be examined by MT.
c. On ferritic vessels subject to PWHT, the shell to nozzle welds on nozzles greater than
DN 200 (NPS 8) shall be subject to MT after PWHT.
d. Magnetic particle inspection techniques liable to damage the vessel by arcing are not
permitted.
9.3. Volumetric examination of welds

a. RT shall be carried out only by X-ray.
b. The longitudinal seams of nozzle necks fabricated from plate shall be subject to 100% RT.
Page 38 of 87
3 May 2005 GIS 46-010
c. For ferritic materials where the plate thickness exceeds 50 mm (2 in), UT of longitudinal
and circumferential seam welds shall be made. If RT is mandatory, the vessel shall be
subject to RT and UT before PWHT, and UT after.
9.4. Fracture mechanics assessment of weld flaws

Fracture mechanics assessment of weld flaws shall not be used without approval.
9.5. Hydrostatic test

a. Prior to final inspection and hydrostatic test, the inside and outside of the vessel shall be
thoroughly cleaned and shall be free from slag, scale, dirt, grit, weld splatter, and pieces of
metal, paint, oil, etc. Welds shall be free of slag, oil, grease, paint, and other foreign
substances that might prevent interpretation of the required tests.
b. Test temperature shall be such that there is no risk in ferritic materials of brittle fracture.
c. Water shall contain not more then 10 PPM suspended solids. After testing, water shall be
drained. Standing water shall be wiped dry (not allowed to evaporate to dryness).
d. Stacked vessels shall be assembled and hydrostatically tested together.
e. Reinforcing plates shall be air tested at 1 bar(ga) (15 psig).
9.6. Positive materials identification and datum thickness readings
9.6.1. PMI
a. PMI shall be performed to the extent specified by the purchaser. If an item fails PMI, all
items from that heat shall receive PMI.
b. PMI procedure shall be subject to approval prior to beginning work and shall include
description of testing equipment, minimum personnel qualifications, calibration
verification, and required surface preparation.
c. Materials that have been PMI verified shall be marked and recorded.
1. Marking shall be done immediately after PMI either by low-stress (round bottomed)
stamps, paint marking each item, vibro-etching, or wire tagging of each item if item is
too small for stamping.
2. Items too small for stamping/marking shall receive 100% PMI.
9.6.2. Datum (baseline) thickness readings

If specified, datum (baseline) thickness readings shall be taken by supplier.
10. Internal non-metallic coating or refractory lining
Internal coating or refractory will be specified by purchaser.
11. External coating
a. External surface preparation, priming and painting shall only be carried out after pressure
tests have been satisfactorily completed.
b. Austenitic alloy steel and nickel-iron-chromium alloy material parts with design metal
temperatures above 400°C (750°F) shall not be painted.
c. External coating will be specified by purchaser.
Page 39 of 87
3 May 2005 GIS 46-010
12. Insulation
Insulation will be specified by purchaser.
13. Packing and shipping
a. Vessels shall be despatched clean and dry, with rust preventative on machined surfaces of
ferritic materials.
b. Equipment or materials that contain or are coated with any of the following shall be
prominently tagged at openings to indicate nature of contents and precautions for shipping,
storage, and handling:
1. Insulating oils.
2. Corrosion inhibitors.
3. Antifreeze solutions.
4. Desiccants.
5. Chemical substances.
6. Hydrocarbon substances.
c. Regulated substances shall have a Material Safety Data Sheet (MSDS).
d. MSDS shall fully comply with regulations for MSDS preparation specified by entity that
has jurisdiction and shall include a statement that the substance is considered hazardous by
regulation.
e. If any products are exempt from regulation, a statement to that effect shall be included.
f. Before shipment, MSDSs shall be forwarded to the receiving facility.
g. At shipment, MSDS in protective envelopes shall be affixed to the outside of the shipment.
h. Reinforcing plate vent holes on ferritic vessels shall be plugged with heavy grease.
14. Documentation
Documentation per GIS 46 020 shall be supplied with the vessel unless otherwise agreed.
15. Spares
Spares will be specified by purchaser.
Page 40 of 87
3 May 2005 GIS 46-010
Annex A
(Normative)
Additional requirements for vessels in carbon steel or carbon-
manganese steel
A.6 Materials
A.6.1 Specification for Z-quality steel plate
A.6.1.1 Scope
This section defines the requirements when purchasing steel to achieve enhanced resistance to
wet H2S service.
A.6.1.2 Designation
Z-quality steel plate shall be designated as: BS EN 10028-3 Grade P275NH + EN 10164, Z35.
Alternative specifications may be: ASME A516/A516M Grade 70 (or equivalent) + EN 10164,
Z35; or BS 1501: 224 Grade 430 + EN 10164, Z35.
A.6.1.3 Material
A.6.1.3.1 Standards
The plate shall meet BS EN 10028-3, BS 1501, or equivalent steel grades together with the
following supplementary requirements.
A.6.1.3.2 Steel making process

Steels shall be made by a low sulphur and low phosphorus refining process, for example, in an
electric furnace with double de-slagging or in the basic oxygen furnace. The steel shall be
vacuum degassed while molten by means of a BP approved process.
A.6.1.3.3 Chemical composition

The following supplementary requirements shall apply:
Check Analysis %
Carbon 0.20 max.
Sulphur 0.008 max.
Phosphorus 0.025 max.
Carbon Equivalent (International Institute of Welding) 0.43 max.
The carbon equivalent value shall be calculated by the following formula:
CE = C + Mn + Cr + Mo + V + Ni + Cu
6 5 15
A.6.1.4 Inspection requirements for plate
A.6.1.4.1 Ultrasonic examination

Plate shall be ultrasonically examined and meet BS EN 10160 quality classes S1/E1 or
equivalent.
A.6.1.4.2 Through-thickness tensile test

a. Each plate shall comply with acceptance class Z35 of BS EN 10164 or equivalent.
Page 41 of 87
3 May 2005 GIS 46-010
b. BP may agree to a retest after consideration of information supplied. The through-

thickness test shall be made after the completion of all heat treatments.
c. In addition to the above, the tests required by the relevant material specification shall be
carried out.
A.6.1.5 Weld repair of plate

Plate shall not be weld repaired without approval and shall be subject to an agreed repair
procedure before repair.
A.6.2 Specification for Hydrogen-Induced Cracking (HIC) resistant steel plate
A.6.2.1 Scope
This section defines requirements for the manufacture and testing of steel plates with maximum
resistance to hydrogen-induced cracking/stepwise cracking for pressure vessels.
A.6.2.2 Manufacturing requirements
A.6.2.2.1 Standards
Plates shall meet one of the following: BS EN 10028-3, SA516 (normalized), BS EN 10028-6
(Q+T) or SA 841/841M (TMCP), together with the requirements of this GIS.
A.6.2.2.2 Process
Steels shall be made by a low sulphur and low phosphorus refining process, for example in an
electric furnace with double de-slagging or in the basic oxygen furnace. The steel shall be
vacuum degassed while molten.
A.6.2.2.3 Heat treatment

Plates shall be in the Normalized, Q+T or TMCP condition.
A.6.2.2.4 Chemical composition

The following requirements shall apply:
Check Analysis %
Carbon 0.20 max.
Sulphur 0.002 max.
Phosphorus 0.008 max.
Oxygen 0.003 max.
Carbon Equivalent (International Institute of Welding) 0.43 max.
Specific chemical compositions offered by steel makers shall be indicated at the inquiry stage
and shall be subject to approval.
A.6.2.3 Testing
A.6.2.3.1 Ultrasonic examination

Plate shall be ultrasonically examined and meet BS EN 10160 quality classes S1/E1 or
equivalent.
A.6.2.3.2 HIC/SWC test

a. Tests shall be made in accordance with NACE TM0284, in the NACE TM0284 Test
Solution A (i.e. 5 wt. % NaCl + 0.5 wt. % glacial acetic acid).
b. One set of 3 specimens shall be tested from each thickness of plate from each heat.
Page 42 of 87
3 May 2005 GIS 46-010
c. BP acceptance values are as follows unless otherwise agreed:

< 10% CLR (crack length ratio),
< 3% CTR (crack thickness ratio) and
< 1% CSR (crack sensitivity ratio) unless otherwise agreed with the purchaser.
d. Following exposure, the test coupons shall be ultrasonically tested for evidence of
hydrogen-induced cracking/stepwise cracking before sectioning. Additional sections for
microscopic examination shall be prepared through any suspect locations, as approved by
the purchaser.
A.6.2.4 Weld repair of plate

Plate shall not be weld repaired.
A.7 Design
Corrosion allowance shall be 3 mm (1/8 in) unless otherwise specified.
A.8 Fabrication
Cold-formed heads shall be normalized prior to welding to shell unless otherwise approved.
A.9 Inspection
A.9.1 Low temperature service

a. If minimum design temperature is below 0°C (32°F), NDE inspections shall include the
following:
1. Plate shall be subject to UT per code as specified in Annexes AA and BB.
2. Welds, including external and internal non-pressure containing welds, shall be subject
to 100% surface inspection (by MT or PT). If PWHT is applied, this shall be after
PWHT.
3. Main seams only shall be subject to volumetric NDE, i.e. RT or UT or both.
b. If minimum design temperature is below –20°C (–4°F), the following additional
requirement applies: pressure containing welds shall be subject to volumetric NDE. If
PWHT is applied, this shall be made after PWHT.
A.9.2 Hydrogen service

NDE inspection shall be made per paragraph A.9.1.a.
A.9.3 Amine, caustic, anhydrous ammonia, cyanides, hydrofluoric acid, sour water, or
wet H2S service
A.9.3.1 Requirements
In addition to the NDE in A.9.1, hardness testing per A.9.3.2 and additional surface inspection
per A.9.3.3 shall be conducted.
A.9.3.2 Hardness testing (for the severe services of A.9.3)

a. Hardness of weld metal shall be measured on the vessel after final PWHT and shall not
exceed 200 HBW. If possible this should be carried out on the internal wetted surface, but
if this is not possible because of the (small) vessel size, hardness readings may be taken on
the outside of the vessel. One set of readings shall be taken for each pressure boundary
weld and each internal attachment weld.
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3 May 2005 GIS 46-010
b. HAZ hardness shall be measured at the weld procedure qualification stage and Vickers
hardness measurements taken with a requirement to meet NACE RP0472, which specifies
a limit of 248 Hv10 maximum.
A.9.3.3 Additional surface inspection after hydrotest (for the severe services of A.9.3)
a. MT shall be made after hydrotest on external welds and the location of any temporary
welds.
b. Internal welded surfaces and HAZs, including pressure boundary welds, internal
attachment welds, and the location of any temporary welds may be inspected by WFMT
after PWHT and hydrostatic test. Any indication revealed by WFMT shall be removed.
c. If a repair is required, repair area shall be given PWHT after welding, equipment shall be
hydrostatically re-tested and repaired area shall be re-inspected by WFMT.
d. Surface preparation for WFMT inspection shall be accomplished by:
1. Blasting to SSPC-SP 5/NACE No. 1 (white metal) with fresh (not reused) aluminium
oxide or coal slag grit.
2. If approved, power wire brushing or grinding to a clean metal surface for limited
areas not accessible for sandblasting.
e. For small pressure vessels where internal inspection after hydrostatic testing is impractical,
the following shall apply:
1. Welds identified for WFMT shall be inspected by WFMT prior to making final
closure seam.
2. Inaccessible welds shall be inspected by UT from outside surface after hydrostatic
testing.
A.9.4 Vessels in which plate thickness is equal to or more than 50 mm (2 in)
A.9.4.1 Components
a. Plate of thickness 50 mm (2 in) and above shall be subject to UT check for laminations.
The edges of plates and heads shall be examined for laminations by UT and MT or PT.
b. Forgings shall be subject to a 100% UT check for subsurface defects.
A.9.4.2 Fabrication
An IPWHT shall be made at 540 – 590°C (1 000 – 1 100°F) with a 30 minute minimum hold.
Alternatively, a local DHT (dehydrogenation heat treatment or hydrogen bake-out) may be
used; the DHT shall be at 315 – 370°C (600 – 700°F) with a two hour minimum hold.
A.9.4.3 Weld inspections

a. Weld inspection shall be made by NDE per A.9.1.a.
b. Major repair welds to base material shall be subject to RT and UT. Minor repairs, as a
minimum, shall be subject to MT.
c. Radiographs for welds whose thickness is 90 mm (3-1/2 in) or less, and which are not
required to have IPWHT or DHT, shall be taken, for acceptance, not less than 48 hours
after weld completion.
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Annex B
(Normative)
Additional requirements for vessels in Cr Mo material
B.1 General
This annex gives the requirements for the main Cr Mo and Cr Mo V steels.
B.2 Materials
B.2.3 Materials for 2¼Cr 1Mo vessels (enhanced and normal)

Materials for 2¼ Cr 1 Mo vessels (enhanced and normal) shall be made by the electric furnace
or basic oxygen process.
B.6 Materials
B.6.1 Materials general

a) For the non-Vanadium grades, the grades of material and relevant specifications are shown
in Table B.1 against PD 5500 and ASME VIII.
Table B.1 – Specifications for Cr Mo steels
Vessel code PD 5500/BS EN 13445 ASME Section VIII

1¼Cr ½Mo - SA 387 11 Cl 1
SA 336 F11 Cl 1
SA 182 F11 Cl 1
2¼Cr 1Mo BS EN 10028-2 10 Cr Mo 9-10 SA 387 22 Cl 2
SA 336 F22 Cl 3
SA 182 F22
Enhanced 2¼Cr 1Mo PD 5500 Enquiry Case 5500/73 SA 542 Type B Cl 4
or BS EN 10028-2 11 Cr Mo 9-10 SA 508 F22 Cl 3
SA 541 F22 Cl 3
b) For the Cr Mo V grades, the specifications are listed in Table B.2
Table B.2 – Specifications for Cr Mo V steels
2¼Cr 1Mo ¼V 3Cr 1Mo ¼V 3Cr 1Mo ¼V

(contains Ti – B) (contains Cb – Ca)
SA 336 F22V SA 336 F3V SA 336 F3VCb
SA 182 F22V SA 182 F3V SA 182 F3VCb
SA 541 F22V SA 508 3V SA 508 3VCb
SA 542 Type D Cl 4a SA 541 3V SA 541 3CCb
SA 832 Gd 22V SA 542 Type C Cl 4a SA 542 Type E Cl 4a
SA 832 Gd 21V SA 832 Gd 23V
c. Limits on chemistry
1 For 1¼Cr ½Mo, Residual elements in the parent materials shall be limited as follows:
a) P < 0,008%.
b) Sn < 0,008%.
2 For 2¼Cr 1Mo, enhanced 2¼Cr 1Mo, 2¼Cr 1Mo ¼V and 3Cr 1Mo ¼V
a) Residual elements in the parent materials shall be controlled such that:
J = (Si + Mn) x (P + Sn) x 10 000 < 100
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where Si, Mn etc. are the compositions of each element in weight %.

Cu = 0,2% max and Ni = 0,3% max.
C shall be less than 0,17%.
b) In weld metal, the following shall apply:
X = (10P + 5Sb + 4Sn + As)/100 < 15
where P, Sb etc. are the compositions of each element in ppm.
d) Charpy V impact testing of plate, forgings, weld metal, and HAZ shall give 55 J (40 ft-lb)
avg. energy absorption, 47 J (35 ft-lb) min. at –29°C (–20°F).
1. Mils of lateral expansion and percent shear shall be reported for each specimen in the
weld metal and HAZ.
2. Impact test specimens shall be oriented in the transverse direction for plates and
tangential direction for forgings. Specimens shall be taken at mid-wall.
e) Each plate for heads and shells and each forging shall be qualified at the mill.
1. Tensile tests shall be taken from both ends of each normalized and tempered plate.
2. Forgings whose maximum finished diameter is greater than 760 mm (30 in) shall
have, from each forging, two tensile tests taken diametrically apart.
3. Forgings 760 mm (30 in) or less in finished diameters shall have one tensile test taken
from at least one forging of each size for each heat treatment charge and for each
heat.
4. The axis of the specimens shall be in the tangential direction.
5. In addition, two full thickness samples shall be provided of each forging or plate for
the purchaser to make two sets of two tensiles, two bends, and three Charpy impact
test specimens per set and material for microscopic examination.
f) The hardness of base materials shall not exceed:
Cr-Mo steels 225 HBW (HRB 97,6).
Cr-Mo-V steels (Vanadium modified) 235 HBW (HRB 99).
g) PWHTmin and PWHTmax shall be established. Two sets of weld procedure specimens
shall be heat treated, one for each time. The strength of the vessel shall be such that at least
two PWHT cycles remain available for the purchaser in service, except that if the closing
seam of the vessel requires an additional PWHT, only at least one remaining PWHT cycle
shall be available for the purchaser.
h) Materials for reactor vessels 25 mm (1 in) and above shall be vacuum degassed.
i) API RP 934 may be used as a reference document for reactor vessels in 2-1/4Cr or 3Cr-
Mo, or Mo-V grades.
B.6.2 Materials for 1¼Cr ½Mo vessels

a. For high temperature service, Class 1 of SA 387/387M 11 is required to 440°C (825°F)
but, for other duties, the higher strength Class 2 may be offered for approval.
b. Material to SA 387/387M may be purchased either normalised and tempered or quenched
and tempered, but the latter give superior properties. Normalized and tempered plate and
forgings shall have a minimum tempering temperature of 620°C (1 150°F), but shall not be
less than the temperature for PWHT.
c. The measured tensile strength, as recorded on the material test certificate or report, shall be
limited to 585 MPa (84,8 ksi) for plate and 655 MPa (95 ksi) for forgings.
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B.6.3 Materials for 2¼Cr 1Mo vessels (enhanced and normal)

a. Material to SA 387 22 shall be purchased either normalised and tempered or quenched and
tempered; both classes 1 and 2 are acceptable.
b. For plate and forgings:
1. The measured tensile strength shall not exceed 690 MPa (100 ksi).
2. Hot tensile tests at design temperature are required.
3. Test specimens shall be taken from the transverse ¼ t locations.
c. Plates shall be fine grain with a grain size of five (5) per ASTM E112 or finer, i.e. having a
higher number than 5.
d. Resistance of the base metal and weld deposit to temper embrittlement shall be checked by
a step cooling test as follows:
1. Heat to 595°C (1 100°F), heating rate above 315°C (600°F) at 55°C (100°F)/h max
Hold samples for 1 h at 595°C (1 100°F).
2. Cool to 540°C (1 000°F) at 6°C/h (10°F/h) and hold for 15 h.
3. Cool to 525°C (975°F) at 6°C/h (10°F/h) and hold for 24 h.
4. Cool to 495°C (925°F) at 6°C/h (10°F/h) and hold for 60 h.
5. Cool to 470°C (875°F) at 2,5°C/h (5°F/h) and hold for 100 h.
6. Cool to 315°C (600°F) at 28°C/h (50°F/h) and then air cool.
The initial 55 J (40 ft-lb) Charpy V transition temperature + 2,5 x the increase in that
temperature shall be less than 10°C (50°F).
B.6.4 Materials for 2¼Cr 1Mo ¼V and 3Cr 1Mo ¼V vessels

Steel plates and forgings shall be vacuum degassed, quenched, and tempered.
B.7 Design
a. Corrosion allowance shall be 3 mm (1/8 in) unless otherwise specified.

b. Permanent clips, skirts, and structural supports shall be attached by full penetration welds.
c. Integral internal supporting rings (nubs) (see figure 6 showing skirts) shall be either forged
or made by weld metal build-up.
d. Nozzles shall be integrally reinforced.
B.8 Fabrication
B.8.1 Fabrication general

a. The plate edge preparation for welding shall be by flame cutting and grinding or by
machining. Nozzle openings shall be made by machining.
b. Material for starting and run-off plates for longitudinal automatic welding shall be of the
same chemical composition as the base material.
c. The hardness of weld crown and root surfaces, and HAZs shall not exceed:
Cr-Mo steels 225 HBW (HRB 97,6).
Cr-Mo-V steels (Vanadium modified) 235 HBW (HRB 99).
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d. A fabrication sequence with IPWHT, DHT, and final PWHT, including temperature and
holding times shall be submitted with the quotation. NDE inspections shall be referenced
on the fabrication sequence.
e. Procedure qualification tests shall be made on plates or forgings of the same material
specification, grade, class, and thickness as the vessel using filler metal, flux, and/or inert
gases of the same type, brand, nominal chemistry, and size to be used on the actual work.
f. Two production test specimens shall be produced to test the weld metal and HAZs. One
test specimen shall simulate the weldment between two shell courses, and one test
specimen shall simulate the weldment between nozzle forging and shell.
g. The qualification test coupons shall be in the same heat treated condition as the base
material prior to welding. Test coupons shall undergo the heat treatments (IWHT/PWHT)
anticipated for the completed vessel before testing. The 0,2 percent proof strength shall be
determined.
h. The temperature and maximum amount of PWHT time is applicable to base material and
welding procedure qualification testing.
1. The maximum amount of time available for IWHT and PWHT shall be established.
2. Probable times for IWHT and final PWHT to fabricate the vessel shall be reported.
3. These times shall be subject to approval prior to the start of work.
i. Temporary shop attachments such as aids for handling and fitting shall be as follows:
1. Attachments shall be preheated (as specified for the material) with the base metal
local to the attachment.
2. If temporary attachments are of a material different from the base metal, welds shall
be alloyed to match the base metal, not the attachment. After welding, the material
shall be allowed to air cool to ambient temperature.
4. Attachment welds shall be cut above the weld during removal of the attachment.
5. The remaining stub shall be ground flush with the base material surface.
6. The surface shall be MT inspected to confirm that it is free from defects.
j. Material for starting and run-off plates for longitudinal automatic welding shall be of the
same chemical composition as the base material.
k. One subsize production weld for chemistry and mechanical properties verification shall be
made for each heat of electrode and flux combination.
B.8.2 Fabrication of 1¼Cr ½Mo vessels

a. Head or shell plate welds shall not be subjected to an austenitizing heat treatment without
specific approval.
b. Minimum preheat temperature throughout thickness shall be 150°C (300°F). The actual
interpass temperature for WPS qualification tests shall be determined and defined on PQR
documents. Welding preheats shall be maintained until IPWHT has been preformed.
c. IPWHT shall be a dehydrogenation heat treatment (DHT) at a temperature of 315 – 340°C
(600 – 650°F) with a minimum hold time of two hours or an intermediate stress relief of
565 – 590°C (1 050 – 1 100°F) with a minimum hold time of 30 minutes.
B.8.3 Fabrication of 2¼Cr 1Mo vessels (normal and enhanced)

a. Welding wire heats and electrode and flux lots shall be selected and tested to confirm that
tensile, impact and step cooling requirements specified in B.6.3 are met in both the
PWHTmin and PWHTmax conditions.
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b. The following minimum preheat temperatures shall be maintained during welding, but may
be allowed to drop by 55°C (100°F) below these temperatures after completion of the
welding operation and prior to placing into the stress relieving furnace.
1. 175°C (350°F) for all welding.
2. 120°C (250°F) for machining.
3. 150°C (300°F) for manual weld overlay.
4. 150°C (300°F) for thermal cutting operations.
c. The actual maximum interpass temperature for WPS qualification tests shall be determined
and defined on PQR documents, but shall not exceed 300°C (570°F).
B.8.4 Fabrication of 2¼Cr 1Mo ¼V and 3Cr 1Mo ¼V vessels

Nothing
B.9 Inspection and testing
B.9.1 General
a. UT checks for laminations shall be made on all plate.
b. Forgings shall be subject to a 100% UT scan.
c. Plate edges after bevelling, but prior to welding root passes in shell, heads, and nozzles,
weld build-ups on shell and heads, background surfaces, skirt to head or shell attachment
welds, fillet welds, attachment welds and temporary welds after removal of attachments,
shall be subject to MT.
d. Welds, including external and internal non-pressure containing welds, shall be subject to
100% surface inspection (by MT or PT) after hydrotesting.
e. Pressure containing welds and skirt attachment or support welds shall be subject to RT or
UT after hydrotesting. Radiographs shall be taken within 48 hours after weld completion.
f. Full penetration welds shall be subject to MT on the back-chipped surface and on finished
weld surfaces prior to overlay.
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Annex C
(Normative)
Additional requirements for clad vessels
C.1 General
Requirements are given for vessels made from roll bonded or explosion bonded plate, or by
weld overlay. Titanium clad vessels, however, are solely specified in annex G.
Non-metallic coatings are specified in clause 10.
C.6 Materials
C.6.1 Clad plate

a. Clad plate shall be manufactured by a process such as roll bonding or explosive cladding
as agreed with or specified by the purchaser. A continuous metallurgical bond shall be
achieved between the base material and the cladding. Linings, made by strips fillet welded
to the shell, are not permitted. Typical metal linings are listed in Table C.1.
Table C.1 – Typical metal linings (by weld overlay or cladding)
Corrosion Resistant Alloy Type

Ferritic stainless steel 405; 410S (0,08C max)
Austenitic stainless steel 304, 304L (0,03C max); 316, 316L (0,03C max);
317L, 321,347
Alloy 400 400 (Annealed)
Alloy 600/625 600 (Annealed); 625 (Annealed)
b. A check of the bond between the alloy cladding and the base plate shall be carried out to
acceptance level S7 of ASTM A578 by UT. 100% of the interfacial area shall be
examined.
c. Material that is to receive a PWHT shall comply with clause C.9.1.b.
d. If unacceptable lack of bond occurs, the cladding shall be removed and the area weld
overlaid.
e. If specified by the purchaser, the surface of the cladding shall be subject to PT.
f. If specified by the purchaser, clad plate shall be purchased with shear test requirements.
1. Shear strength tests of the clad interface shall be conducted for 11%-13% chrome
steel (AISI Type 405, 410, 410S), austenitic stainless steel, nickel alloy, and copper-
nickel integrally clad base materials.
2. The shear strength test requirements of the standard against which the plate is
purchased shall apply.
C.6.2 Components made by weld overlay

Materials for weld overlay shall conform to Table C.2 in C.8.2.
C.7 Design
C.7.1 General
a. Corrosion resistant weld overlay or cladding shall not be considered in calculating required
pressure boundary thickness.
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b. Internal fillet welds shall be kept to the minimum in clad vessels. If the design temperature
is greater than 300°C (570°F), full penetration welds shall be used.
c. On vessels made from clad plate, lightly loaded attachments (e.g. tray support rings) may
be welded directly to the cladding without stripping back to the base material providing:
1. The weld is essentially unidirectional (e.g. at a tray support ring) and not multi-
directional (e.g. at a bracket); and
2. The area is checked with UT for lack of bond prior to welding.
d. If the conditions of C.7.1.c are not met, the cladding shall be cut back. The attachment
shall be directly welded to the shell by an appropriate procedure before cladding re-
instatement. PWHT may be required depending upon the material of the shell.
e. On vessels with weld overlay, except as specified in C.7.2.a below, internals may be
welded to the overlay without stripping back to the base material. A check shall be made
that the loading on the internals is not excessive.
f. Clad nozzles may be manufactured from clad plate or by weld overlay. Internal surfaces of
the nozzle and the flange face shall be clad. Loose linings are not permissible.
g. Small diameter, solid alloy nozzles may be used instead of clad nozzles if the design
temperature is less than 300°C (570°F). However, the risk of through wall cracking is
increased if the material is susceptible to environmental cracking and a check of the
thermal stresses with solid alloy nozzles shall be made for use at higher temperatures.
C.7.2 Design of hydroprocessing reactors

a. Hydroprocessing reactors are those with design temperature above 300°C (570°F) and
partial pressures of hydrogen from 20 to 150 bara (300 to 2000 psia), e.g. hydrocrackers
and hydrofiners. In such vessels, major supports for catalyst beds shall comprise integral
rings rather than brackets welded to the base material. The rings shall be made either by
forging or by weld build-up.
b. Flanges shall be raised face and gaskets shall be graphite filled spiral wound. or oval ring
type. Octagonal ring type joints shall not be used.
c. The cladding of hydroprocessing reactors shall be made by weld overlay.
d. External skin thermocouple attachments shall be provided with a 6 mm (1/4 in) thick,
minimum, carbon steel pad in the shop to facilitate field welding a half coupling for
attaching the skin thermocouple. The carbon steel pad shall have at least one 6 mm (1/4 in)
vent hole and shall be postweld heat treated with the vessel.
C.8 Fabrication
C.8.1 Required weld quality

a. Weld overlay shall generally provide a minimum of 5 mm (3/16 in) thickness with a
guaranteed undiluted chemistry to a depth of 3 mm (1/8 in) from the surface.
b. The weld overlay shall be applied in such a manner that the weld beads run
circumferentially around the vessel.
1. The surface contour shall be relatively smooth. Adjacent weld beads shall fuse and
blend to create a flat surface without any interbead grooving.
2. Waviness is permissible but without notches and undercuts that might act as stress
raisers.
3. The beads may run longitudinally for nozzles with an inside diameter of 300 mm
(12 in) and smaller and for pipe elbows if followed by blend grinding.
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c. If specified by the purchaser, the maximum hardness of the weld deposited overlay shall
comply with the requirements of NACE MR0103. Unless more stringent requirements are
specified, the maximum base material hardness shall be 248 Hv10 (237 HBW) for sour
service and 325 Hv10 (308 HBW) for non-sour service.
d. With ASS, the chemical composition of the final surface on both weld overlay and
cladding re-instatement shall comply with that of the corresponding AWS welding
consumable classification.
e. Welding consumables used for ASS weld overlays that are subject to PWHT shall be
selected to minimise sigma phase formation during the heat treatment; they shall be “L”
grade, or stabilized with additions of Ti or Nb (Cb).
f. The ferrite content of ASS overlays, with the exception of type 904L (which is fully
austenitic), shall be in the range 3 - 8% in the as-welded and post-weld heated condition.
g. Vessels with Alloy 400 weld overlay designated for HF acid service shall have the
following:
1. Overlay shall contain a maximum of 5% iron (Fe) in the top 1,6 mm (1/16 in) of the
final deposit.
2. Overlays, deposited by manual processes, shall have a minimum of three layers.
3. ERNi–1 filler metal is required for the first pass when welding with the GTAW or
GMAW process. The maximum diameter of SMAW electrodes shall be 3 mm
(1/8 in).
C.8.2 Weld consumables

a. Unless otherwise agreed with the purchaser, the consumables to be used for different
claddings are shown in Table C.2. The initial layer may be deposited with a more highly
alloyed welding consumable than that employed for the subsequent layer(s) in order to take
into account dilution of the cladding by the base material.
Table C.2 – Filler metal requirements for clad plate and weld overlaid plate
st nd
Cladding or Weld Filler metal material 1 Pass electrode 2 Pass electrode
Overlay material
AISI Type 405, 410S Stainless steel E/ER 309L E/ER 309L
(clad material only) E/ER 309 E/ER 309
Alloy 625 ERNiCR-3 ERNiCR-3
Alloy 625 ERNiCRFe-2 ERNiCRFe-2
ERNiCRFe-3 ERNiCRFe-3
AISI Type 304 AISI Type 308 E/ER 309 or E/ER 308
304L 308 E/ER 309L E/ER 308L
AISI Type 316 AISI Type 316 E/ER 309 or E/ER 316
316L 316L E/ER 309L E/ER 316L
317L 317L E/ER 317L
AISI Type 321 or AISI Type 347 E/ER 309 or E/ER 347
347 E/ER 309L
Alloy 400 Alloy 400 E/ERNi-1 E/ERCu-7
Alloy 600/625 Alloy 600 ERNiCR-3 or ERNiCR-3 or
ENiCRFe-2 ENiCRFe-2
Alloy 625 ERNiCR-3 or E/ERNiCRMo-3
E/ERNiCRMo-3 or
ENiCRFe-2
b. For any low-carbon (L, LC, or ELC) grades of ASS, carbon content shall not exceed
0,03 percent. Also, for columbium (niobium) bearing grades (e.g., 347 and 309 Cb) the
columbium to carbon ratio of the deposited metal shall not exceed 16:1.
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C.8.3 Welding processes

a. If a single layer overlay is offered, metallurgical and analytical evidence shall be produced
to demonstrate its acceptability.
b. For weld cladding, the welding process shall not transfer alloying elements via the flux to
achieve the specified weld metal composition. Flux shall not be re-used unless agreed with
the purchaser.
c. Each batch of welding consumables, including each batch of submerged arc or electroslag
flux, shall be tested in accordance with the approved weld overlay procedure to ensure that
the resultant overlay complies with the specified microstructure and chemical analysis.
C.8.4 Cladding re-instatement only

a. The typical detail applied in cladding re-instatement local to a seam is shown in
Figure C.1.
Figure C.1 – Cladding re-instatement at a vessel seam
0.8mm MAX. 12mm MIN. 0.8mm MAX. 5mm MIN.

(1/32 in) (1/2 in) (1/32 in) (3/16 in)
AFTER GOUGING
CHIPPED OR
GOUGED SURFACE
(a) MACHINING (b) ROOT PASS
CHIPPED OR
GOUGED SURFACE
COMPLETED WELD 12mm MIN. 2 ND PASS 1 ST PASS

IN BASE MATERIAL. (1/2 in) ELECTRODE ELECTRODE
GRIND FLUSH BEFORE
DEPOSITING ALLOY
(c) MAIN FILL & (d) BACK FILL &
BACK GOUGE CLADDING
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Notes:
1. Used for materials with design temperature above 232°C (450°F)
2. Strip back cladding to a minimum of 12 mm (1/2 in) as shown in Figure C.1(a). Chipped, gouged, or ground surface shall be
cleaned of all residual alloy and its removal verified with a CuSO4 etch. Depth of base material below clad interface shall not
exceed 0,8 mm (1/32 in).
3. If chip back or gouge is done from inside, as shown in Figure C.1(b), 5 mm (3/16 in) minimum shall be left between edge of
chipped or gouged surface and cladding. Final base material weld deposit from inside shall not contact cladding and shall be
ground flush before depositing alloy.
4. If initial welding is done from inside, space between edge of base material weld deposit and edge of cladding shall not be less
than 3 mm (1/8 in), as shown in Figure C.1(c). Completed weld on the inside shall be ground flush before alloy welding.
5. Weld shall be completed with alloy rod 1st and 2nd electrode, per Table C.2, see Figure C.1(d).
b. Weld seams that require radiographic inspection shall be tested before cladding re-
instatement.
c. For 11-13% chrome (405, 410S) clad vessels, each main seam shall be spot radiographed
after cladding re-instatement in addition to before it.
C.8.5 Weld procedures

a. Qualified welding procedures for weld overlay and cladding re-instatement shall be
submitted for approval. Once approved, no changes to the essential variables shall be made
without prior approval.
b. The base material for the test pieces shall be of the same grade as the vessel.
1. The same heat treatment batch of welding wire or electrode as that to be used in
production welding shall be used and the same type and brand of flux.
2. The temperature range used on the overlay qualification test plates for PWHT shall be
the same as that used in production.
3. The postweld heat treatment time at temperature for the qualification test plates shall
be greater than that used in production in order to leave at least one heat treatment
available for the purchaser.
c. Welding procedures shall be qualified in accordance with the design code. The weld
overlay shall be subject to chemical analysis throughout its depth to confirm that the
required purity (see C.8.2.1) has been achieved.
d. The test welds shall be subject to 100% PT per C.9.3, and, for weld overlay, the procedure
test pieces shall also be subject to the UT.
e. The achievement of the required weld overlay thickness shall be demonstrated.
f. A macro section of the overlay shall be prepared and a series of hardness measurements
(Hv10) shall be made across the interface at three separate locations.
g. The measurement of ferrite content shall be by metallographic determination and an
instrumental technique. The chemical analysis results shall be used to calculate the ferrite
content per the Schaeffler-DeLong diagram. The allowable range is as stated in C.8.1.
C.9 Inspection and testing
C.9.1 Inspection - specific to clad plate

a. Following forming and any associated heat treatment, the knuckle region of heads pressed
or spun from clad plate shall be subject to UT and PT, and weld overlay seams shall be
inspected by UT for lack of bond at the weld to clad interface along the entire seam length.
b. Clad plate that is to receive a PWHT shall have indications that show a 50% or greater loss
of back reflection marked and recorded prior to heat treatment. Subsequent to PWHT,
integrally clad material shall be re-examined ultrasonically in locations of previously
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recorded discontinuities and other indications that resulted in 50 percent or greater loss of
back reflection.
C.9.2 Inspection - applying to both weld overlay and cladding re-instatement
C.9.2.1 PT
a. 10% of the first layer of weld deposit overlay or back cladding shall be subject to PT.
Inspection shall include as many “T” joints as possible.
b. If specified, the surface of weld deposited cladding shall be subject to 100% PT in
accordance with ASTM E165 following any PWHT, but prior to hydraulic testing.
C.9.2.2 Ferrite content

If specified, the ferrite content of ASS weld deposited overlays shall be directly measured by an
instrument subject to approval.
a. Secondary standard Ferrite Number (FN) blocks shall be available to confirm the
calibration of the equipment.
b. Filler metal shall be selected to achieve an FN of 3 to 10.
c. Ferrite measurements shall be made adjacent to analytical checks on the as-deposited weld
metal and these measurements repeated following any PWHT.
d. The Ferritescope shall be calibrated using AWS A4.2M/A4.2.
C.9.3 Inspection - specific to weld overlay
C.9.3.1 UT
a. Weld deposited overlay shall be subject to UT in accordance with ASTM A578 primarily
to establish the presence of any lack of fusion between the weld deposit and the base
material.
1. 10% of the overlay deposited during each shift shall be examined.
2. Any area of lack of fusion or other defect that cannot be contained within a 25 mm
(1 in) diameter circle shall be cause for rejection and 100% of the overlay completed
during the shift by the equipment/operator concerned shall be examined.
3. Defects shall be repaired by an approved procedure and re-examined.
b. After the DHT or IPWHT, the stainless steel overlay shall be spot checked for bond
consistency by UT on strips 75 mm (3 in) wide over the vessel length at four equispaced
positions on the circumference.
1. Any lack of fusion causing a loss of back reflection accompanied by an echo
indication from the plane of the interface of the overlay and base metal and having an
area greater then that of a 25 mm (1 in) diameter circle shall be repaired. This area
may be of any shape.
2. If any repair is needed, 100% of the surface shall be checked as above.
C.9.3.2 Chemical analysis

The surface of weld overlay shall be subject to chemical analysis; the technique and equipment
used shall be subject to approval.
a. A minimum of two checks shall be made in each shell course and each head with a
minimum of one check for each 5 m (16 ft) length of main seam.
b. A minimum of one check shall also be made at each nozzle attachment weld.
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c. The test locations shall be selected by the purchaser.
C.9.3.3 Ferrite content

If specified, for ASS weld overlay, 10% of the analytical checks in the previous paragraph,
subject to a minimum of two samples, shall be performed on a bulk sample removed from the
weld deposit. The chemical analysis shall be used to calculate the ferrite content per the
Schaeffler-DeLong diagram in order to meet the limits in C.8.1.f.
C.9.4 Inspection - specific to cladding re-instatement

a. Cladding re-instatement at main seam, nozzle and internal attachment welds shall be
subject to chemical analysis; the technique and equipment used shall be subject to
approval.
b. A minimum of one check analysis shall be made for each 5 m (16 ft) length of seam weld
and one check shall be made at each nozzle and each internal attachment weld. The test
locations shall be selected by the purchaser.
C.9.5 Hydraulic testing

a. For ASS clad vessels, the test fluid shall not contain more than 50 ppm chlorides.
Providing the vessel is thoroughly washed out using chloride free water as soon as testing
is complete, a chloride content of up to 100 ppm may be permitted subject to approval.
c. ASS vessels shall be dried within 48 hours of draining, using swabs or a flow of air at
ambient temperature. Heat shall not be applied.
C.16 High temperature embrittlement in service
Before any welding for repair or modification is undertaken on 12 Cr clad vessels subject to
long term exposure at high temperature (circa 400°C (750°F)), the following shall be carried
out:
a. The design of the repair or modification shall be reviewed to ensure that residual stress
from the welding is minimised.
b. The base material shall be kept above an appropriate minimum temperature (in excess of
20°C (70°F)) until the vessel returns to service.
c. If possible, a hardness survey should be made across a section of the clad plate and the
impact properties in the base material checked.
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Annex D
(Normative)
Additional requirements for vessels in austenitic stainless steel (ASS)
D.1 General
Stainless steel shall be protected from contamination by chloride during fabrication and
shipment. It shall also be protected from contamination by carbon steel.
D.6 Design
a. Corrosion allowance shall be zero unless specified otherwise. Shell and head thicknesses
shall not be less than 4 mm (3/16 in).
b. On vessels with a skirt support, the top 600 mm (24 in) of the vessel skirt shall be in alloy
material and the rest may be in carbon steel.
D.8 Fabrication
D.8.1 Forming
a. Formed heads shall be solution annealed after forming unless otherwise approved.
b. Grinding and cleaning of stainless steels shall be done with tools that do not leave
detrimental deposits. Examples of acceptable tools are aluminum oxide and silicon carbide
grinding wheels and austenitic stainless steel wire brushes not previously used on other
types of materials.
D.8.2 Welding
a. The content of delta ferrite in ASS weld metal shall be per C.8.1.f. It shall be measured in
accordance with C.9.2.2. If specifically requested, ferrite checks shall be made on a
minimum percentage of the welds, e.g. 5%.
b. Comparable low carbon austenitic filler materials shall be used when welding low carbon
grade austenitic base materials.
D.8.2.4 Heat treatment

PWHT of ASS vessels shall only be with approval.
D.9 Inspection and testing
a. Welds shall be free from cracks and fissures. The extent of PT on welds shall be as
specified by the purchaser.
b. The test fluid for ASS vessels shall not contain more than 50 ppm chlorides.
c. ASS vessels shall be dried within 48 hours of draining, using swabs or a flow of air at
ambient temperature. Heat shall not be applied.
d. Unless directed otherwise, ASS vessels that operate in the range 50 – 150°C (120 – 300°F)
shall be painted externally to purchaser’s specification.
e. Insulated ASS vessels operating below 50°C (120°F) shall be painted externally to
purchaser’s specification.
f. Equipment shall be protected such that chloride contamination cannot occur during
shipment.
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Annex E
(Normative)
Additional requirements for vessels in duplex stainless steel (DSS)
E.6 Material
E.6.1 General
DSS with 22% Cr shall be specified as UNS S32205 or as dual certified UNS S31803/S32205.
Nitrogen for UNS S31803 shall be 0,14% - 0,20%. Supplier shall be subject to approval.
E.6.2 Heat treatment by the material supplier and microstructure

a. Materials shall be delivered solution annealed and quenched in water. Rapid cooling is
necessary.
b. The permissible quantity of ferrite shall be 35% - 65%. Measurement may be made by
point counting in accordance with ASTM E562.
c. The microstructure of the material shall be free from grain boundary carbides and no
sigma, chi or Laves’ phases shall be present after solution heat treatment. Metallographic
examination at not less than 400X magnification shall be undertaken to confirm freedom
from such phases.
d. ASTM A923 Test Method B (impact test) shall be used for detection of unacceptable
intermetallic phases in DSS. Acceptance criteria for 22% Cr DSS are provided in
ASTM A923. For 25% Cr DSS, acceptance criteria will be specified by the purchaser.
e. Dished heads, whether hot formed or cold formed, shall be solution heat treated. If levels
of cold strain exceed 15%, such as in the knuckle region, intermediate solution heat
treatment shall be made unless otherwise agreed with the purchaser.
f. Solution heat treatment shall consist of heating the head rapidly to a temperature generally
in excess of 1 020°C (1 870°F), a hold period and then rapid cooling in air or water. The
solution heat treatment temperature and hold period vary depending on the grade of
material and guidance should be sought from the steel supplier.
g. The inside and outside surfaces of the knuckle area shall be subject to full PT.
h. To confirm the properties of DSS heads, test samples shall be subjected to similar levels of
mechanical working and heat treatment.
1. These samples shall be subject to impact testing as specified in E.6.3.a and b.
2. Metallographic and hardness assessment in accordance with E.6.2.c shall also be
undertaken.
E.6.3 Mechanical properties

a. Irrespective of the design temperature, Charpy V impact tests shall be carried out for
pressure part materials of thickness ≥ 12 mm (½ in).
1. Testing frequency shall be per cast, per heat treatment lot, per size/wall thickness.
2. In the case of fittings and flanges, where the destruction of a full component is
required, the alternative option of testing of a “representative sample” shall be subject
to approval.
b. The required impact values and test temperature shall be per code (see Annex AA or BB).
1. If the minimum design temperature is ≥ 0°C (32°F), the impact tests shall be
performed at 0°C (32°F).
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2. If the minimum design temperature is below 0°C (32°F), the impact tests shall be
performed at minimum design temperature.
c. If a hardness limit is considered necessary for the application, BS EN ISO 15156-3 shall be
applied.
E.6.4 Other issues

a. Plates shall be pickled to remove scaling.
b. The pickling and passivation method to be used for the removal of oxide scale produced in
heat treatment shall be subject to approval.
E.8 Fabrication
E.8.1 General
a. DSS shall be segregated from carbon, carbon manganese and low alloy steels during
fabrication.
b. Mechanical working equipment shall be thoroughly cleaned and precautions taken to
ensure that contaminants are not rolled or pressed into the surface during fabrication.
E.8.2 Welding
E.8.2.1 Basic requirements
E.8.2.2 Welding processes

Autogenous (without filler metal) welds are not permitted.
E.8.2.3 Welding procedure testing

a. Welding should be carried out in such a way to ensure a satisfactory metallurgical structure
in the weld and HAZ so as to maintain corrosion resistance and mechanical properties i.e.
avoidance of extremes in austenite/ferrite balance as discussed in E.6.
b. Welding procedures shall be qualified for the specific grade, UNS number, or trade name
of the alloy.
1. Details of specific consumables to be used, together with details of the supplier, shall
be stated.
2. Welding procedures and welders shall be qualified as required by the code (see
Annex AA or BB).
c. WPS/PQR should be in accordance with ASME Section IX or other equivalent applicable
standard.
1. WPS should include.
a) Welding process.
b) Specific welding consumables.
c) Details of tack-welding where applicable.

d) Electrical characteristics of welding.
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e) Heat input range.

f) Travel speed.
g) Maximum interpass temperature.
2. The average heat input for each welding process used in a PQR shall be recorded.
That heat input shall be used to specify a heat input range for any referenced WPS.
Unless otherwise approved, the heat input range shall be as shown in table E.2
Table E.2 – Range of average heat input during welding
Average heat input during welding

kJ/mm (kJ/in)
Grade Minimum Maximum
22% Cr 0,8 (20) 2,5 (63,5)
25% Cr 0,8 (20) 1,5 (38)
3. The maximum interpass temperatures shall be:

a) 150°C (300°F) max. for 22%Cr duplex SS.
b) 125°C (260°F) max. for 25%Cr duplex SS.
4. Weld procedure qualification should include:
a) Testing to ASTM A923 B or C.
b) Typical microstructure.
c) % ferrite point count for parent metal, HAZ, and weld metal.
d) Hardness survey.
d. When formulating welding procedures the possibility of delayed hydrogen cracking should
be recognised. Appropriate steps, such as consumable drying in accordance with supplier’s
recommendations or low temperature preheating, i.e. 50°C (120°F), shall be taken to
restrict the hydrogen potential of the welding technique.
e. Welding procedures for materials with thickness ≥ 12 mm (½ in) shall be subject to
Charpy V impact testing.
1. For material thicknesses up to 22 mm (7/8 in), the specimens shall be cut so that one
face of the specimen is substantially parallel to, and within 3 mm (1/8 in) of, the top
surface of the weld.
2. At thicknesses greater than 22 mm (7/8 in), two sets of specimens shall be taken to
sample the root and cap regions.
3. Specimens shall, as a minimum, be notched on the weld metal centre line, at the
fusion boundary, and at the fusion boundary plus 2 mm (1/16 in) position.
4. The required impact values and test temperature shall be per code (see Annex AA or
BB).
f. For all procedures, a transverse section taken across the weldment shall be subject to
metallographic evaluation.
1. The etchant used shall enable the ferrite, austenitic, and any sigma phase present to be
clearly identified.
2. The ferrite-austenite balance shall be determined by a systematic point counting
procedure, per ASTM E562.
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a) The phase balance shall be measured: on both sides of the weld in the root HAZ;
in the root weld metal, at the HAZ and in the weld centre at mid-thickness and
cap positions.
b) Acceptable ferrite levels shall lie in the range 35% – 65%.
c) Measurement by a Ferritescope or similar instrument is not considered a suitable
alternative to point counting.
g. Hardness measurements (Hv10) shall be performed on all procedures.
1. Hardness traverses shall sample the HAZ and weld metal in the root, mid thickness
and cap regions.
2. The maximum hardness shall not exceed 280 Hv10.
h. Corrosion testing to ASTM G48 or similar procedure may be specified as an integral part
of the welding procedure qualification by the purchaser.
E.8.2.4 Production welding

Welds shall be cleaned by hand held stainless steel wire brushes. Rotary wire brushes or other
power tools shall not be used for surface cleaning.
E.9 Inspection and testing
Hardness testing using Vickers hardness testing for parent metal, HAZ, and weld metal during
WPQ and of weld deposit for production welds using Telebrineller.
a. PT of back gouging and of completed welds.
b. Ferrite number check for production welds is usually with Ferritescope that is calibrated
during WPQ against point count results.
E.10 Painting
Painting requirements for DSS vessels shall be subject to approval.
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Annex F
(Normative)
Additional requirements for vessels in high nickel alloys
F.1 General
Typical alloys relevant to this annex are listed in Table F.1 below.
Table F.1 – Typical nickel alloys
UNS No. Composition Name

N04400 67 Ni 30 Cu Alloy 400
N06022 55 Ni 21 Cr 13,5 Mo Alloy C-22
N06600 72 Ni 15 Cr 8 Fe Alloy 600
N06625 60 Ni 22 Cr 9 Mo 3,5 Nb (Cb) Alloy 625
N08020 35 Ni 35 Fe 20 Cr (Cb) Alloy 20
N08800 33 Ni 21 Cr 42 Fe Alloy 800
N08810 33 Ni 21 Cr 42 Fe Alloy 800H
N08811 33 Ni 21 Cr 42 Fe Alloy 800HT
N08825 42 Ni 21.5 Cr 5 Mo 2,3 Cu Alloy 825
N10276 54 Ni 16 Cr 16 Mo 6 Fe 4 W Alloy C276
N10665 65 Ni 28 Mo 2 Fe 4 W Alloy B2
N10675 65 Ni 2 Cr 29,5 Mo 2 Fe Mn W Alloy B3
F.6 Materials
a. The material manufacturer’s requirements for each specific alloy shall be taken into
account. The following may be items requiring agreement with the purchaser:
1. Material chemistry depending on the application.
2. Selection of optimum welding consumable to maximise corrosion resistance.
3. Hot forming temperature range and cooling requirements.
4. Heat treatment temperature after working to enhance properties/stabilisation.
5. Selection of heat treatment temperature depending on intended service temperature
and required grain size.
6. Heat treatment to minimise high temperature cracking.
7. Restricted maximum temperature of application to avoid embrittlement.
b. The top 60 mm (2-3/8 in) of vessel skirts shall be of the same material specification as the
pressure components. The remainder of the skirt may be of ferritic steel.
F.7 Design
F.7.1 General
The minimum shell and head thickness, as built, shall be 5 mm (3/16 in).
F.7.2 Nozzles
a. Type of flange shall be subject to approval.
b. Unless otherwise specified, blind flanges shall have:
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1. A minimum of 3 mm (1/8 in) finished thickness of corrosion resistant material

permanently attached to a carbon steel backing plate.
2. The vessel item number hard stamped on the edge of the backing plate for
identification purposes along with the words ‘CLAD BLIND’.
3. A chain attaching the cover to the nozzle flange.
F.8 Fabrication
F.8.1 General
a. The cutting, forming, and heat treatment procedure of materials shall be submitted for
approval before fabrication commences.
b. Prior to the forming of plates, working surfaces of the material and tools shall be
completely free of ferrous chips, scale, dirt and other foreign matter. It is essential that
there is no metal contamination from tools and machines, or contamination by sulphur
compounds.
c. Temporary or permanent fabrication or erection aids, if used, shall be of matching
composition to the component to which they are attached.
d. The direct welding of carbon steel or stainless steel attachments is not permitted.
F.8.2 Heat treatment

Unless otherwise agreed, if materials have been hot-formed or subject to cold forming they shall
be re-solution heat treated within the recommended temperature range of the particular alloy.
F.8.3 Welding general

a. Welding materials shall be selected to either produce welds with an identical nominal
composition to the parent plate or over-alloyed weld consumables may be used.
b. Welding shall be carried out using approved, qualified operators and procedures.
c. The use of resistance flash-butt welding techniques, such as a stud gun, for the attachment
of studs or other fittings required for the support of insulation or refractories either internal
or external to a vessel is not permitted.
d. Weld defects shall be removed only by grinding and machining.
F.8.4 Welding specific

Welding shall be carried out using SAW, SMAW, or GTAW, except that SMAW is not
permitted with UNS N10665 and UNS 10675 materials. Other welding processes shall be
subject to prior approval.
F.8.5 Welding procedures

a. Weld procedures shall be qualified in accordance with the design code.
b. Stringer bead deposition of weld metal shall be utilised with minimal use of weaving.
c. Pre-heat shall only be used to remove moisture from the surface of base metal.
d. Interpass temperatures shall be limited to 100°C (210°F) if the specified minimum
percentage content of molybdenum is greater than 10% and 150°C (300°F) if it is less than
10%.
1. Additional cooling methods may be used between weld passes to speed up the
welding operation.
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2. When attaching external attachments to thin wall vessels, additional cooling on the
inside of the vessel should be used to minimise heat affected zone effects.
e. If possible, welding shall be carried out in the flat downhand position. Vertical welding
with SMAW especially with UNS N10665 should be avoided.
F.9 Inspection and testing
a. Welds and HAZ shall be subject to a ‘Full’ X-ray and 100% PT internally and externally.
The acceptance standard shall be in accordance with the design code.
b. On UNS N10665 vessels, where attachment welds are deposited on the outside of the
vessel walls, the corresponding areas on the process side shall be subject to PT.
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Annex G
(Normative)
Additional requirements for vessels in titanium
G.1 General
This annex contains general requirements applicable to both solid and clad titanium vessels. It
also gives requirements specific to chemical plant reactors.
G.6 Materials
G.6.2 Titanium clad components

a. Clad plate shall be to ASME SB 898. Cladding shall be commercially pure titanium to
ASME SB 265 Gr. 1. Base material shall be to ASME SA 516/516M Gr. 70 or equivalent.
b. Thickness of cladding as bonded shall be 90% of nominal thickness specified on the data
sheets or 2 mm (0,075 in), minimum, whichever is the greater.
c. Bond shear strength shall be not less than 138 N/mm2 (20 000 psi) and tested after heat
treatment of clad plate.
d. Approval of clad plate supplier and cladding procedure shall be obtained from purchaser.
If any butt welds are made in the plate prior to bonding, the purchaser shall be notified.
e. For the explosion bonding process, each plate shall be given a heat treatment at 607°C ±14
(1 125°F ±25) for 1 hour, minimum, plus 15 minutes per 25 mm (1 in) above 25 mm (1 in)
of composite thickness in a gas-fired oxidizing atmosphere furnace. Removal of titanium
surface oxide penetration shall be accomplished by means of sand blasting with virgin 100-
180 Grit Silica 10, 99,756% Silica Dioxide, 0,020% iron oxide, or power buffing with a
120 Grit alumina “Flap-Wheel.”
f. Bonded plate shall be ultrasonically inspected per requirements of ASME SA 435.
1. Total of unbonded areas shall be limited to 5% of rough plate area, with maximum
size of any one area limited to 625 cm2 in one m2 (9 in2 in one ft2).
2. Purchaser shall be advised of size, shape, and location of any unbonded area that
exceeds 45 cm2 (7 in2), by plate sketch, before proceeding with plate forming.
a) If accepted by purchaser for fabrication, such plates shall again be examined
ultrasonically after forming.
b) Plates having such unbonded areas that have increased in size as a result of
forming operation are subject to rejection and shall be referred to purchaser
representative for decision as to possibility of usage in fabrication.
g. Except as noted on the vessel data sheet, fabricated internals shall be made in titanium
plate to ASME SB 265 and with the minimum thicknesses listed in Table G.1.
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Table G.1 – Grade and minimum thickness for titanium internals
Component Thickness
Vertical Baffles Gr. 2 10 mm (0,375 in)
Nozzle Liners Gr. 1 3 mm (0,109 in)
Nozzle Flange Facings Gr. 1 or 2(a) 5 mm (0,190 in) After machining
Blind Flange & Manway Cover Facing (Clad) Gr. 1 or 2 (a) 3 mm (0,125 in) Min. after machining
Blind Flange & Manway Cover Facing (Loose) Gr. 1 or 2 (a) 6 mm (0,250 in) Min. after machining
Cover Straps Gr. 1 3 mm (0,125 in)
Supports and Brackets Gr. 1 or 2 Depending upon design
Note (a): If specified by purchaser, Grade 7 or 11 shall be used.
G.7 Design
G.7.1 General
Welding of internal attachments to vessel walls shall be continuous.
G.7.2 Solid titanium components

Any carbon steel fabrications in contact with solid titanium, e.g. saddle supports, shall be
electrically insulated from the titanium.
G.7.3.1 Butt welds

1. Continuity of cladding at carbon steel butt weld joints shall be provided by overlapping
titanium cover straps that are fillet-welded to the cladding. See Figure G.1.a.
a. Cover straps shall have rounded corners with a minimum radius of 16 mm (5/8 in).
b. Fillet welds shall be deposited in multiple passes and the finished weld shall be a full
fillet, convex in cross-section.
c. The exposed area at weld joints shall first be filled with titanium strip with a partial
penetration weld to the cladding. The use of copper strip that is brazed to the titanium
cladding or any other option shall be subject to approval.
2. Preformed, tightly fitted, cover plates, welded to cladding and cover straps, shall be
provided at the junctions of the longitudinal and circumferential joints and at the open joint
of each circumferential cover strap.
3. Voids behind cover straps on each circumferential and longitudinal joint shall be isolated
from voids behind adjoining straps.
a. Each isolated void shall be provided with two DN 6 (NPS 1/4) telltale holes through
the base metal to the cover straps.
b. Telltale holes shall be located as closely as possible to high and low points of
longitudinal joints and to each end of each cover strap segment of circumferential
joints.
c. Each telltale hole shall be provided with a DN 6 (NPS 1/4) forged steel screwed half-
coupling attached to vessel outer surface with a continuous fillet weld. Use a stainless
steel nipple with both ends threaded and install a “street ell” or bent pipe with the end
turned down outside the insulation.
d. In vacuum services, vents shall be capped with a threaded end piece.
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4. If a flush process surface is required, e.g. in the shell of a shell and tube heat exchanger,
the requirements as described in G.7.3.1-3 apply but the titanium strap shall be fitted into a
machined groove in the cladding as shown in figure G.1.b and then welded to the cladding.
Figure G.1 – Typical butt weld detail for titanium clad heat exchanger shell
1mm MAX.
(0.04 in)
a. Cladding projects into bore b. Cladding flush with bore
G.7.3.2 Nozzle/manway details

a. Preferred method of cladding the nozzle crotch shall be indicated in the quotation.
1. Preferred methods for lining nozzles and studding pads are shown in Figures G.2a) to
k). The types of flange attachment are as follows.
2. In Type W, the titanium face piece extends to an outside diameter 6 mm (1/4 in) less
than the flange outside diameter. It is secured by a continuous fillet weld of silver or
other material subject to approval. The weld to the nozzle liner is made with a
backing strip, either as a butt weld or as a fillet weld, figures G.2g) and h)
respectively.
3. In Type S, the titanium face piece is extended to the outside diameter of the flange
and attached to the carbon steel base material by titanium countersunk screws, with
one screw fitted between each flange bolt. See figures G.2i) and j). The heads of the
screws are covered with titanium weld overlay and the whole flange face is machined
finally.
4. In Type C, the flange facing is clad plate, with titanium explosion bonded to carbon
steel, and the latter is continuously fillet welded to the flange base material. See
figure G.2k).
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Figure G.2 – Preferred details for titanium lined nozzles
Figure G.2a – Two alternative cladding arrangements for nozzles DN 80 (NPS 3) and larger
TYPE S TYPE W
SEE DETAIL 1
Ø6 (NPS 1/4) HALF COUPLINGS

1 - IN THE NOZZLE NECK
1 - IN THE VESSEL WALL
LOCATED 180° APART (TYPICAL).
Ø6mm (1/4 in) HOLE (TYP)
100mm
(4 in)
SEE TABLE FOR RADIUS
Figure G.2b – Nozzles DN 50 (NPS 2) and smaller
TYPE W SEE DETAIL 2
100mm
SEE TABLE
(4 in)
FOR RADIUS
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Figure G.2c – Nozzles DN 150 (NPS 6) and smaller
TYPE C
Figure G.2d – Two alternative cladding arrangements for studding pads DN 80 (NPS 3) and larger
TYPE S TYPE W
SEE DETAIL 1
2 - Ø6 (NPS 1/4) HOLES,

LOCATED 180° APART.
TAPPED FOR NPS 1/4 PIPE
(TYPICAL).
50mm
(2 in) SEE TABLE FOR RADIUS
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Figure G.2e – Studding pads DN 50 (NPS 2) and smaller
SEE DETAIL 2 TYPE S
50mm SEE TABLE FOR RADIUS

(2 in)
Radius table
Radius
DN (NPS) Nozzle Sizes mm in
40 (1 ½) and smaller 12 1/2
50 to 150 (2 to 6) 19 ¾
200 to 500 (8 to 20) 1 25
Over 500 (20) 32 1 1/4
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Figure G.2f – Studding pads DN 100 (NPS 4) and larger
TYPE C
Figure G.2g – Detail 1 Butt weld of flange facing to bore liner
TITANIUM BACKING
RING TYPICAL
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Figure G.2h – Detail 2 Fillet weld of flange facing to bore liner
TITANIUM BACKING
RING TYPICAL
Figure G.2i – Type S Screw attachment in section
TITANIUM WELD OVERLAY
DRILL & TAP FOR 6mm (1/4 in)

COUNTERSUNK SCREWS
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Figure G.2j – Type S Screw attachment – plan view
TITANIUM SCREWS
SEE DETAIL 3 & NOTE 4
C/L BOLT HOLES
T /2
T/
2
Figure G.2k – Type C flange made from clad plate
TITANIUM FACING, EXPLOSION

BONDED TO CARBON STEEL PLATE
TITANIUM BACKING
RING
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b. Tightly fitted titanium components shaped to overlap vessel interior and flued to contour of
inside of nozzle neck shall be provided. Flued (shaped) section shall be sized to provide an
overlap on vessel interior of 100 mm (4 in) from the outside surface of long weld neck
nozzles. See typical arrangement in figure G.2a. The overlap shall be joined to the vessel
cladding by multiple pass full fillet welds convex in cross-section.
c. The unclad shell area at the nozzle attachment weld shall be covered with titanium rings or
other purchaser approved materials in such a manner as to provide a surface flush with the
interior surface of vessel cladding.
e. Nozzles made from clad plate shall have vent holes to provide access for purging at the
rear of the plate.
f. For nozzles requiring greater liner length than can be provided as an integral part of flued
section, cylindrical extensions shall be attached by butt welding.
G.7.3.3 Flange details

a. Liners shall be vented through 6 mm (1/4 in) diameter telltale holes extending through the
base metal to the liner with one located in the nozzle neck and one located in the shell
radians (180 degrees) apart.
b. In nozzle and manway reinforcing pads, telltale hole shall be in lower area of pad when
vessel is in its normal operating position.
G.7.3.4 Blank flanges

a. Blind flange and manway covers shall be fabricated from titanium-clad steel plate or
titanium liner attached to steel plate.
b. Integral cladding shall extend to within 6 mm (1/4 in) of the periphery of the cover plate.
c. Titanium plate liners shall either:
1. Extend to periphery of cover and be secured with M 6 (1/4 in) titanium countersunk
screws covered with titanium weld overlay; or
2. Extend to 6 mm (1/4 in) less than periphery and be secured with a continuous fillet
weld of silver or other approved material.
G.8 Fabrication
G.8.1 General
a. A clean area or a separate fabrication facility shall be provided.
1. Tools and brushes shall be stainless steel and restricted to titanium use only.
2. Rolls (plate and head rollers) shall be cleaned and covered to prevent contamination
of the titanium.
3. A minimum of 1,5 mm (1/16 in) shall be ground from any cut face in titanium.
4. Before welding, edge preparations and filler wires shall be degreased with acetone.
5. A cleanliness procedure shall be submitted for approval.
b. Weld procedures shall be qualified prior to starting fabrication. Prequalified weld
procedures may be accepted subject to approval.
c. The maximum hardness in the weld metal shall be as shown in Table G.2. To ensure an
adequate margin for an increase in hardness during welding, the plate shall be purchased to
the values shown.
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Table G.2 – Maximum permitted hardness of weld metal and plate
Weld max. hardness Plate max. hardness

Grade 1/2 200 Hv5 170 Hv5
Grade 3 200 Hv5 190 Hv5
d. Welding shall use gas shielding on both sides of the joint.

1. Only high purity (99,998%) argon and/or helium shall be used.
2. Gas purity shall be checked regularly and dew point shall be below –51°C (–60°F).
e. Welds shall be visually inspected on completion; any colour greater than light straw shall
not be accepted.
f. In addition to primary shielding of the weld pool, secondary shielding i.e. back purging
shall be used until the titanium surface temperature falls below 300°C (570°F).
G.8.2 Solid titanium components

a. The procedure for the forming or heat treatment of components in titanium shall be
submitted for approval.
b. Unless otherwise agreed, thin heads in solid titanium shall be cold formed without any
further heat treatment. Heads in clad plate shall be warm pressed at about 600°C (1 110°F)
without any further normalising treatment.

a. After nozzle welding is completed and again after hydraulic testing, welds in sleeve linings
of nozzles shall be tested with dry air (1,5 bar(ga) [22 psia] minimum) applied behind the
linings and soap suds. Any indication of air leakage shall be considered unacceptable.
b. The alignment tolerance for longitudinal seams shall be 1,5 mm (1/16 in). The
circumferential seam tolerance shall be 1,5 mm (1/16 in) up to and including 19 mm
(3/4 in) plate thickness and 3 mm (1/8 in) for plates over 19 mm (3/4 in). Joint alignment
tolerance measurements shall be made from and apply to the clad side.
c. Approval of details of weld joints, joint fit-up procedures, weld surface preparation
procedures, and welding procedures shall be obtained from purchaser.
d. First weld pass of carbon steel joints shall be made by GTAW (TIG) method and liquid
penetrant examined. Repairs from the clad side shall be made by GTAW method.
e. Fusion welding of titanium shall be done with inert gas shielded arc-welding equipment.
1. Shielding with high-purity (99,975%) welding-grade argon or helium with a
maximum dew point of –51°C (–60°C) shall be provided to weld area.
2. Heat-affected zones shall be protected against atmospheric contamination with
shielding gas until metal temperature is below 538°C (1 000°F).
f. Titanium welding shall be done away from drafts, open windows, and doors, etc., in a
clean area completely separated from other shop activities. Titanium cladding shall be
protected from any possible form of damage, deterioration, or contamination during all
phases of vessel fabrication.
g. Titanium surface areas to be welded shall be buffed with a 120 grit set up wheel and wire
brushed with a 0,13 mm (0,005 in) diameter stainless steel wire brush. Immediately prior
to welding they shall be cleaned with ethanol, propanol, or purchaser approved alternate.
h. Methanol and chlorinated solvents such as triochlorethylene or carbon tetrachloride shall
not be used for cleaning titanium.
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3 May 2005 GIS 46-010
i. Before welding internal supports to clad plate, plate shall be ultrasonically tested in weld
area and for 50 mm (2 in) on each side of weld. No lack of bond shall be permitted.
j. Prior to start of titanium cover strap or nozzle liner welding to clad, a weld sample shall be
made consisting of a cover strap welded to a clad plate. This weld sample, when accepted
by purchaser, shall serve as a colour guide for acceptance of titanium welding.
k. Fillet weld size and contour shall be as described in this GIS. In general, a bright metallic
silver or gold colour is acceptable, whereas a blue or dull grey colour is indication of an
excessively contaminated weld which shall be removed.
l. Titanium weld wire shall meet AWS A.5.16/A5.16M Class ERTI-1 and shall be subject to
the same cleanliness required of base metal.
1. Filler wire shall be kept wrapped when not in use.
2. When welding, heated end of wire shall be held under inert gas blanket at all times.
3. Before each start of welding at least 10 mm (3/8 in) of filler wire end shall be cut off.
m. Tubing used in handling shielding gases shall not allow contamination of gas.
n. New welder’s gloves, or gloves that are free of lint and washed with water and ethanol,
shall be used for welding.
o. If any contact occurs between tungsten electrode and filler wire in arc, welding shall be
stopped immediately, tungsten electrode changed or redressed, and contaminated area
removed before welding is resumed.
p. Repairs to titanium clad surface shall be made only after an acceptable procedure has been
approved by purchaser. The following criteria shall be followed:
1. Scratches, notches, tool marks, etc., shall be ground smooth.
2. Ground areas not exceeding 0,75 mm (0,030 in) in depth need not be weld repaired.
3. Areas that exceed 0,75 mm (0,030 in) in depth but not more than 1,3 mm (0,050 in) in
depth shall be weld repaired. Do not grind weld repairs.
4. Areas that exceed 1,3 mm (0,050 in) in depth shall be repaired by welding a 3 mm
(0,125 in) thick titanium patch to the clad. Any patch larger than 32 cm2 (5 in2) shall
be vented to the outside and a DN 6 (NPS 1/4) half coupling furnished.
q. Finished titanium welds shall be left in as-welded condition with no wire brushing or
buffing unless approved by purchaser.
r. PWHT
1. Heat treatment details shall be subject to approval.
2. If PWHT is required by Code.
a) Heating and cooling rates between ambient and PWHT temperatures shall not
exceed 55°C (100°F) per hour, and
b) Maximum temperature shall not exceed 565°C ±14 (1 050°F ±25). PWHT shall
be performed prior to titanium welding.
3. Severely formed (beyond 5% elongation) titanium liner and cover components shall
be heat treated at 538°C (1 000°F) for one hour. Heat treatment shall be done in a gas
muffled furnace with no direct gas impingement.
s. Inspection.
1. All phases of fabrication, examination, and testing shall be subject to review and
approval. Approval of procedures for tests and examinations shall be obtained from
purchaser.
Page 76 of 87
3 May 2005 GIS 46-010
2. Butt welds and flues in titanium prefabricated nozzle liner assemblies and cover
straps shall be liquid penetrant inspected on both surfaces prior to installation in
vessel.
3. Head and shell joints shall be radiographed before application of material used to
provide bearing for titanium cover straps.
4. Butt welds in titanium prefabricated nozzle liner assemblies and weld cover straps
shall be full radiographed. Acceptability of porosity in titanium welds shall be judged
per Code, with the exception that clustered porosity and aligned porosity of any size
shall not be permitted.
5. Prior to internal pressure testing of completed vessels, the following examinations
shall be performed.
a) Liquid penetrant examination of first weld pass in carbon steel longitudinal,
circumferential, and nozzle joints.
b) Liquid penetrant examination of titanium welds. Surfaces required to be
examined shall be free of surface defects.
c) Soap testing of completed titanium welds with clean, filtered air at a nominal
pressure of 34,5 kPag (5 psig) applied through the telltale holes.
d) Leaks and defects shall be repaired and repairs reexamined before proceeding
with testing.
e) Magnetic particle examination shall be performed on the completed welds
around the periphery of nozzles and manways and fillet welds around
reinforcing pads.
G.9 Inspection and testing
a. Welds in loose sleeve linings shall be tested using soapy water with dry air applied behind
the linings.
b. The following tests shall be performed on completed vessels in order given:
1. Helium mass spectrometer test.
a) Helium mass spectrometer test is at 25% of design pressure or 345 kPag
(50 psig), whichever is less.
b) This test shall be per Section V, Article 10, Appendix IV of ASME Code or
equivalent.
2. Hydrostatic test.
3. Pneumatic test, using 173 kPag (25 psig) air and a suitable leak-detecting solution, on
reinforcing pads.
4. PT test of titanium welds.
G.16 Specific to chemical plant reactors
a. After completion of testing and prior to shipment, the following examination and cleaning
shall be performed.
1. Pickle internal titanium clad surfaces with a solution of 30% HNO3 plus 3% HF at 8
to 22°C (46 to 73°F) and rinse with clean potable tap water or a cleaning procedure
approved by purchaser.
Page 77 of 87
3 May 2005 GIS 46-010
2. Ferroxyl test for iron on titanium surfaces, and as necessary, buff and retest until free
of iron indications.
3. Liquid penetrant examination of titanium surfaces. Surfaces are required to be free of
surface defects.
4. Wipe titanium surfaces with ethanol or propanol as necessary for cleanliness
immediately before closing up for shipment.
b. If at any time during examination and testing it is found necessary to make repairs to
vessel, approval of repair procedure shall be obtained from purchaser and that portion of
examination or testing sequence repeated after repair is completed.
c. Consideration should be given to a hot gas cycle test.
Page 78 of 87
3 May 2005 GIS 46-010
Annex H
(Informative)
Additional requirements for vessels in zirconium
H.6 Materials
a. Two grades mainly used are: ‘702’ (UNS R60702) and ‘705’ (R60705). ‘705’ is permitted
for pressure parts provided heat treatment is completed within 14 days of the
commencement of welding.
b. The requirements of Annex F.6 apply also to zirconium.
H.7 Design
a. The requirements of Annex F.7 apply also to zirconium.

b. The allowable stresses shall be used to determine the hydrostatic test pressure.
Components of which the vessel is constructed shall then be designed to withstand this
hydrostatic test pressure.
H.8 Fabrication
H.8.1 General
The requirements of Annex F.8.1 apply.
H.8.2 Welding
a. The requirements of Annex F.8.3 apply.
b. GTAW only is permitted.
c. Grinding shall be such as to avoid contamination and to avoid temperatures exceeding
315°C (600°F).
d. Welding shall be performed with the base metal above 15°C (60°F). The interpass
temperature shall not exceed 110°C (230°F).
e. Welding shall be in an inert atmosphere chamber or with supplementary inert gas cover on
the whole weld including the underside of the welded area.
f. The shielding and backing gases shall be high purity helium or argon (99,998% pure). Inert
gas cover shall remain until the weld has cooled sufficiently to prevent rejectable
discolouration when exposed to air.
g. The as-deposited weld metal surface and the adjacent 1 mm (0,04 in) of base material shall
have a shiny silver or light straw appearance after weld runs.
1. Any dark straw, blue, black, or grey colouration necessitates that sufficient metal
shall be removed to ensure the removal of contamination.
2. The weld surface shall not be ground or dressed until the as welded surface has been
inspected for discolouration.
h. Welding procedures and welders shall be qualified to the design code or equivalent, except
that two bend tests shall be completed and tested in addition to radiography for welder
qualification. Welding procedures shall be subject to approval prior to manufacture
commencing.
Page 79 of 87
3 May 2005 GIS 46-010
H.9 Inspection and testing
Welds and HAZ shall be subject to 100% X-ray, and 100% PT internally and externally. The
acceptance standard shall be in accordance with the design code.
Page 80 of 87
3 May 2005 GIS 46-010
Annex AA
(Normative)
Requirements for vessels to the ASME Code
AA.1 General
a. Paragraphs AA.1, AA.6, AA.7, AA.8, and AA.9 of this annex refer to Section VIII
Divisions 1 and 2; AA.16 refers to Division 3.
b. Supplier shall operate a quality control system in accordance with Section VIII Division 1
Appendix 10 or Division 2 Appendix 18 as appropriate.
c. If the requirements regarding ASME U or U-2 stamping or National Board Registration are
not specified, clarification shall be obtained from purchaser.
AA.6 Materials
a. Materials shall be made only by the steel making processes listed in SA 20/20M,
paragraph 5.1.
b. If MDMT is not specified it shall be obtained from purchaser.
c. Carbon steel plate of thickness 50 mm (2 in.) and greater shall meet the requirements of
SA 20/20M including the Charpy V-Notch impact test values specified in
Tables A.1.15/A.2.15.
d. Carbon steel pipe, nozzles, and flanges with governing thicknesses greater than 30 mm
(1-1/4 in) shall be impact tested per SA 333/333M or A350/350M, as applicable, and the
test values shall satisfy Table 4 in those standards.
e. Lateral expansion in m (mils) and percent shear fracture for each impact test specimen
shall be reported to purchaser.
f. Each plate or forging shall be stamped in accordance with the ASME Specification.
Stamping shall be done before final PWHT and with low stress (round bottom) stamps.
g. Unless otherwise stated, clad materials shall conform to SA 240/240M or SA 263/263M
for ferritic stainless steel, SA 264/264M for ASS, and SA 265/265M for nickel alloys.
AA.7 Design
AA.7.1 General
a. Maximum allowable stresses shall be taken from Section II, Part D.
b. The minimum nozzle wall thickness shall be as shown in Table AA.1. Clad nozzles shall
have a base material thickness at least equal to the thicknesses shown in Table AA.1 with
zero corrosion allowance.
Table AA.1 – Minimum thickness of nozzles
1
Material Size (DN (NPS)) Minimum thickness
Carbon Steel & Low Alloy, 25 to 100 (1 to 4) Sch 160
Clad Steels Larger than 100 (4) XS
High Alloy & 50 (2) or smaller Sch 80
Non-ferrous Materials Larger than 50 (2) STD
Notes: (1) Pipe wall thickness designations per ASME B36.10M.
Page 81 of 87
3 May 2005 GIS 46-010
AA.7.2 Division 1
a. ASME torispherical heads (knuckle radius not less than 6% of crown radius and L/t ratio
not more than 500) are acceptable for vessels with a design pressure of 5 barg (75 psig) or
less, where vessel head is not providing support to vessel or auxiliary equipment. Heads
providing support to vessel, agitators, pumps, or other equipment shall be 2:1 ellipsoidal or
hemispherical.
b. If the diameter to thickness ratio of an ellipsoidal, torispherical, or toriconical head, or of a
toriconical transition exceeds 70 for stainless steel and 200 for carbon steel, a check shall
be made to ensure that buckling or wrinkling during hydrotest does not occur.
c. Cylinder-to-cone transitions shall be made using toriconical sections when any of the
following conditions apply:
1. Vessel is in cyclic or hydrogen service.
2. Section is subject to a major support reaction (for example, skirt-to-cone attachment).
3. Shell thickness is over 30 mm (1-1/4 in).
4. All loadings per Code Appendix 1, paragraph 5 or 8, whichever is applicable, are not
available.
d. The maximum allowable working pressure (MAWP) to be stamped on the vessel
nameplate shall be the calculated maximum working pressure at the top of the vessel in the
corroded condition. The maximum coincident temperature at this MAWP shall be stamped
on the vessel nameplate.
e. Horizontal drums on saddle supports shall be investigated for buckling and local stresses.
The method of L.P. Zick may be used for this investigation.
AA.7.3 Division 2
a. The following vessel components shall be subject to analysis and the results included in
the Manufacturer’s Design Report in accordance with paragraph AG-302 of Division 2:
1. Thermal and stress analysis of vessel and skirt attachment region.
2. Localized stress analysis of internal and external attachments to the shell.
3. Localized stress analysis of nozzles subject to piping loads.
4. Thermal analysis of nozzles, skirt, and appurtenances where thermal gradients may be
induced into the shell.
a) Information from this analysis shall be used to determine the need for a fatigue
evaluation, per AD-160.
b) If the vessel is exempt from fatigue evaluation the results of the thermal analysis
shall be included as part of the User’s Design Specification.
b. Openings shall be reinforced in accordance with requirement of Article D-5 and
reinforcement calculations furnished to purchaser. Exceptions per Paragraph AD-510 are
not permitted.
c. Nozzles connected to external piping shall be the integrally reinforced, fully
radiographable type to Figure AD-613.1 (c) or (c-1). The transition radii shall be in
accordance with Figure AD-560.1.
d. If access to the interior of the vessel is impracticable, inspection openings shall be
provided per Article D-10 of the Code. The location of these openings shall be such that
representative shell joints and critical parts of the interior of the vessel can be inspected
through them.
Page 82 of 87
3 May 2005 GIS 46-010
e. The procedures for design based on stress analysis and fatigue evaluation in appendices 4
and 5, respectively, shall be used to evaluate compliance of the stresses due to local loads.
For small nozzles, WRC 107 may be used to determine the stresses and, for large nozzles,
WRC 297.
AA.8 Fabrication
AA.8.2 Weld procedures

Welding of vessels, including appurtenance welds, shall conform to Section IX.
AA.8.3 Heat treatment

Maximum preheat and interpass temperature for P-8 materials (ASS) are suggested to be 175°C
(350°F).
AA.8.4 Dissimilar welds between austenitic stainless steels and ferritic steels
a. Welds joining austenitic stainless steels to ferritic steels shall be made with filler metal as
follows:
1. For services not exceeding 340°C (650°F), use ASME SFA-5.4 classification E309L,
SFA-5.9 classification ER309L, or the filler metals given in 2, below.
2. For services exceeding 340°C (650°F), use ASME SFA-5.14 classification ER NiCr-3
(comparable to INCO 82), or use ASME SFA-5.11 classification E NiCrFe-3
(comparable to INCO 182) or E NiCrFe-2 (comparable to INCO A) unless another
filler is specified. Approval is required for dissimilar welds in services exceeding
340°C (650°F).
b. The preheat shall be based on the ferritic material. The first layer of weld overlay deposits
shall be made using the preheat required for the base plate. Subsequent weld layers may
use the preheat required for the alloy deposits.
AA.9 Inspection and testing
AA.9.1 Plates and forgings

a. For ferritic plates, UT inspection shall be in accordance with SA-578/578M, including
Supplementary Requirements S1, S2, S3, and S4. Acceptance standard shall be Level 1.
b. For ferritic plates of thickness 50 mm (2 in) and above, UT inspection shall be per
SA-435/435M.
c. For ferritic forgings, UT shall be per SA-541/541M including Supplementary
Requirement S2.
AA.9.2 Component and weld inspections

a. Minimum extent of RT shall be spot radiography.
1. Radiographic film shall be fine grain.
2. Film density shall be in the range 2,0 to 3,5.
3. Radiographic quality level shall be 2-2t as defined in ASTM E94.
4. If practicable, radiographs shall be made with 15 MEV Betatron or equivalent.
b. Use of ASME Code Case 2235 is subject to purchaser and, if applicable, regulatory
authority approval.
Page 83 of 87
3 May 2005 GIS 46-010
AA.9.3 Hydrostatic testing

a. The membrane stress in the vessel during the test may not exceed 90% of minimum
specified yield strength for the material at test temperature.
b. Hydrostatic test pressure shall be held for 15 minutes, minimum.
AA.16 Division 3
a. If Division 3 is specified, additional requirements will be indicated by the purchaser.

b. Supplier shall operate a quality control system in accordance with Division 3 Appendix 2.
Page 84 of 87
3 May 2005 GIS 46-010
Annex BB
(Normative)
Requirements for vessels to PD 5500
BB.7 Design
a. The method for combining the stresses at nozzles due to pressure and local loads shall be
that in PD 5500 Annex G.
b. The fatigue rules in Annex C of PD 5500 deal comprehensively with the design of welds
under cyclic loading. If required, allowance may be made for the effect of toe burr grinding
to improve fatigue life.
c. Hydrostatic test pressures shall be calculated for both the corroded and uncorroded
conditions.
BB.8 Fabrication
BB.8.2 Welding
BB.8.2.3 Weld procedure and welder qualification

a. Approval of welders for shall be in accordance with BS EN ISO 9606:
1. Part 4 for nickel and nickel alloys.
2. Part 5 for titanium and titanium alloys, zirconium and zirconium alloys
b. Welders engaged on site fabrication of vessels shall be performance tested at site under
representative conditions to the requirements of BS EN 287-1 and shall be approved on the
basis of X-ray examination.
BB.9 Inspection
BB.9.1 Component inspection – ferritic materials

a. UT inspection of plate shall be in accordance with BS EN 10160. The required quality
classes shall be S1 for the through thickness check (on 100 mm grid) and E1 for the edge
check, unless otherwise specified by the purchaser.
b. Forgings shall be MT tested to BS EN 10228-1 and the required quality class shall be
class 3 unless otherwise specified by the purchaser.
c. Forgings and pipe shall be UT tested per BS EN 10228-3. The required quality class shall
be class 3 unless otherwise specified by the purchaser.
BB.9.2 Component inspection – austenitic and duplex materials

Inspection of forgings by PT shall be to BS EN 10228-2 and the required quality class shall be 3
unless otherwise specified by the purchaser. Inspection by UT shall be to BS EN 10228-4 and
the required quality class shall be class 3 unless otherwise specified by the purchaser.
BB.9.3 Weld and component inspection

Minimum inspection category shall be Class 2. Examination of set-on or set-in nozzles by UT,
shall be in accordance with BS EN 1714 Part 1 level 2.
Page 85 of 87
3 May 2005 GIS 46-010
Annex CC
(Normative)
Requirements for vessels to BS EN 13445
CC.1 General
There is only one English version of the standard but it is sold by all the national standards
organisations in the EU and each one prefixes it with the letters of that organisation. For
convenience, the British version, BS EN 13445, is used here as the reference.
CC.6 Materials
CC.7 Design
a. For cyclic loading beyond 500 full pressure cycles, a fatigue check shall be made.
Page 86 of 87
3 May 2005 GIS 46-010
Bibliography
American Petroleum Institute (API)

[1] API RP 579 Fitness-for-Service.
British Petroleum
[2] BP RP 52-1 Thermal insulation.
Engineering Equipment and Material Users Association (EEMUA)

[3] EEMUA 179 A working guide for carbon steel equipment in wet H2S service.
British Standards Institute (BSI)

[4] BS 7910 Guide on methods for assessing the acceptability of flaws in metallic structures.
NACE International (NACE)

[5] NACE MR0175 Standard Material Requirements
Metals for Sulfide Stress Cracking and Stress Corrosion Cracking Resistance in Sour Oilfield
Environments
Welding Research Council (WRC)

[6] WRC 342 Welding Research Council Bulletin Number 342 Stainless Steel Weld Metal:
Prediction of ferrite Content, April 1989.
Other
[7] Niemi E., Fricke W., Maddox S.J. Structural hot-spot stress approach to fatigue analysis of welded
components, International Institute of Welding, Doc, XIII-1819-00, 2003.
[8] UK HSE HSE Guidance Note GS 4 Safety in pressure testing.
BP Corrosion and Materials Guideline documents

[9] Corrosion Under Insulation, A Guide to the Prevention and Detection of Corrosion Beneath
Insulation.
[10] Technical Bulletin: Corrosion Protection – Topsides bolting:

http://northsea.bpweb.bp.com/corrosion/techbull/bolting.pdf
BP
[11] GIS 46-020 Guidance on Industry Standard for Supplementary Vessel Purchasing
Specification.
[12] GP 06-60 Guidance on Practice for Coating of Metal Surfaces and Equipment (BP
GS 106-2).
[13] GP 32-30 Guidance on Practice for Inspection and Testing of Equipment in Service –
Management Principles.
[14] GP 46-01 Guidance on Practice for New Pressure Vessels.
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Document No.

Guidance on Industry Standards for

10. Internal non-metallic coating or refractory lining ................................................................... 39

C.7 Design ................................................................................................................................. 50

AA.9.3 Hydrostatic testing .................................................................................................... 84

Table 1 – Permissible bolting materials at different temperatures ................................................. 21

American Petroleum Institute (API)

American Society of Mechanical Engineers (ASME)

SA 350/350M Carbon and Low-Alloy Steel Forgings Requiring Notch Toughness

American Society for Testing and Materials (ASTM)

American Welding Society (AWS)

British Standards Institute (BSI)

GP 06-20 Guidance on Practice for Sour Service Design (GS 136-1).

International Organization for Standardization (ISO)

NACE International (NACE)

The Society for Protective Coatings (SSPC)

Welding Research Council (WRC)

The following definitions apply to different duties:

hydrofluoric acid service

integrally reinforced, butt welded nozzle

positive material identification

sour water, wet H2S, or wet sour service

4. Symbols and abbreviations

ASS austenitic stainless steel

ASNT American Society for Non-Destructive Testing

CUI corrosion under insulation

DHT dehydrogenation heat treatment

DN nominal pipe diameter

DSS duplex stainless steel

FCAW flux cored arc welding

FEA finite element analysis

FN Ferrite number (per Welding Research Council Bulletin Number 342)

GMAW gas metal arc welding

GTAW Tungsten inert gas welding

HAZ heat affected zone

HIC Hydrogen-induced cracking

HRB Rockwell hardness number, B scale, tested with a steel ball

LFWN long forged weld neck flange

MDMT minimum design metal temperature

MT magnetic particle testing

NDE non-destructive examination

NPS nominal pipe size

PCN Personnel Certification in Non-Destructive Testing

PMI positive material identification

PQR procedure qualification record

PT liquid or dye penetrant testing

Q+T Quenched and tempered

PWHT post-weld heat treatment

SMAW shielded metal arc welding

SAW submerged arc welding

TMCP Thermo-Mechanical Control Process

WFMT wet fluorescent magnetic particle testing

WPQ Welder/Welding Operator Performance Qualification

WPS Welding Procedure Specification

5. Introduction, codes, legislation, and quality assurance

5.3. Quality assurance