Section 7 — Pressure Vessels

Supplemental Requirements for Pressure Vessels

IPE Engineering Practice IPE-EP-7-1-4

Document number: IPE-EP-7-1-4 · Section: 7 — Pressure Vessels

SCOPE

This Practice covers supplemental requirements related to documentation, data, quality control, inspection, and shipping of pressure vessels and shell and tube, double pipe, and spiral heat exchangers.
Design, fabrication, inspection and testing of unfired pressure vessels are covered in EP 7-1-1. Supplemental requirements for shell and tube, double pipe and spiral heat exchangers are stipulated in EP 8-1-1, EP 8-1-5, and EP 8-1-6, respectively.
Additional requirements for pressure vessels with a thickness greater than two (2) inches, excluding weld overlay and cladding, are covered in EP 7-1-3.
Small commercial vessels that are not part of process equipment such as sandblast machines, paint sprayers and gunite machines shall be per manufacturer's standards.
Any deviation from this Practice must be approved by the procedure described in EP 1-1-3.
An asterisk (*) indicates that a decision by the Owner or Owner's Engineer is required, or that additional information is furnished by the Purchaser.
Table 1 records the vendor drawing and data requirements.
A Revision Bar indicates all changes made to this Revision.

2.0 REFERENCES

The latest edition of the following standards and publications are referred to herein.

STANDARDS AND PUBLICATIONS

STANDARDS AND PUBLICATIONS (CONT.)

IPE Engineering Practices (Cont.)
EP 8-1-6C Spiral Heat Exchangers Inspection Checklist EP 14-1-5 Export Protection and Packaging of Equipment EP 15-1-1 Shop Inspection and Testing of New Refinery Equipment EP 15-1-4 Positive Materials Identification (PMI)
ASME Codes
Sec VIIIPressure Vessels, Division 1 Sec VIIIPressure Vessels, Alternative Rules, Division 2

DEFINITIONS

ASME Code - Refers to the ASME Boiler and Pressure Vessel Code, Section VIII, Division 1 or Division 2, as applicable.
Certificates of Compliance - A document by which the material manufacturer (or Seller to the extent that the Code allows) certifies that the material represented has been produced and tested in accordance with the requirements of the basic material specification shown on the certificate. Objective evidence of compliance with the requirements of the material specification shall be maintained in the records of the material manufacturer. However, certificates of compliance shall include reports or results of tests required by the material specification or the Order.
Certified Material Test Report (CMTR) - A document, or documents, on which are recorded the results of tests, examinations, repairs, or treatments required by the Material Specification. Supplementary or special requirements, in addition to the requirements of the Material Specification, as required by the Purchase Order shall also be included on the CMTR. The specification of the material being represented including the year of issue and the material heat number shall also be included on the CMTR. All such documents shall identify the applicable Material Specification and shall be identified to the material represented.
Inspector - A IPE Engineering Company appointed engineer or inspector.
Manufacturer - The recipient of a direct or indirect purchase order for materials and/or equipment. In this context, a direct order is one issued to a manufacturer by a contractor or the Owner. An indirect order is one issued to a manufacturer by a vendor (recipient of a direct order) for materials, fabricated components, or subassemblies.
Owner - IPE Engineering Company.
Owner's Engineer - A IPE Engineering Company appointed engineer.
Purchase Order - The contractual document given to the Manufacturer to authorize a purchase.
Purchaser - The party placing a direct purchase order. The purchaser is the Owner's designated representative.

Quality Control Plan - The Manufacturer's job specific documented plan for ensuring that all specified technical requirements will be followed. The Quality Control Plan shall include, as a minimum, the following; fabrication schedule including all heat treatment requirements, forming and rolling procedures, and an inspection and test plan with a schedule identifying all inspection points required by the Owner.
Quality Control System - The Manufacturer's documented system for ensuring that all applicable code requirements for the manufacturing process including material handling and identification, design, fabrication, inspection and testing are followed.

DATA FURNISHED BY PURCHASER

The Purchaser shall provide the following information:
Procurement documents
Completed Vessel Data Sheet per EP 7-1-1DS and an outline drawing
Applicable IPE Engineering Practices with approved addenda.
Inspection Checklist per EP 7-1-1 C. For heat exchangers Inspection Checklists per EP 8- 1-1C, EP 8-1-5C, EP 8-1-6C, shall be used.
(*)As a minimum, a schedule for receipt of the following information and the required number of copies will be specified by the Purchaser.
Completed Vessel Data Sheet per EP 7-1-1DS. For heat exchangers, completed Data Sheets from EP 8-1-1DS, EP 8-1-6DS shall be provided.
Subvendor names and addresses.
Dimensional outline drawing - plan & elevation. For shell and tube heat exchangers, the dimensional outline drawing shall include the bundle weight and removal clearance
Center of gravity and foundation loading diagram.
Vessel Design Report per paragraph 6.2.
Quality control system.
NDE procedures.
Pressure Vessel record book per paragraph 6.3.
Detailed fabrication drawings in accordance with paragraph 6.1.1.
Recommended spare parts list.
For vessels constructed to the ASME Code, Section VIII, Division 2, a User's Design Specification shall be prepared by the Owner's Engineer. This specification shall include all requirements stipulated in paragraph AG-301 in this Code.

MANUFACTURER'S RESPONSIBILITY

General
The Manufacturer shall assume responsibility for designing and fabricating the vessel in accordance with the specified design conditions.
The Manufacturer shall provide the information described in paragraph 4.2. The number of copies and schedule shall conform to the Purchaser's requirements.
Conflicting Requirements

The Manufacturer shall refer all conflicting requirements contained in the Purchase Order to the Purchaser in writing for clarification and resolution before proceeding with the manufacture or procurement of the affected part. The Manufacturer is not at liberty to assume which requirements govern.

Quality Control
(*)The Manufacturer shall operate a Quality Control System to ensure that the technical requirements of the pressure vessel code specified by the Owner's Engineer are achieved. The Owner's Engineer may require demonstration of the Quality Control System, but this may be waived if the system has been verified recently by an accreditation scheme acceptable to the Owner's Engineer.
The Manufacturer's Quality Control System shall be based on ASME Code, Section VIII. Appendix 10 for vessels constructed to Division 1 and Appendix 18 for vessels constructed to Division 2.
(*)The Manufacturer shall submit a Quality Control Plan that shall be reviewed and approved by the Inspector.
(*)Unless otherwise specified by the Owner's Engineer, a copy of the quality control plan signed by all inspection parties shall be submitted to the Owner's Engineer for approval prior to the start of fabrication.
The Manufacturer shall ensure that technical and quality assurance requirements specified in the Purchase Order are applied to all materials, equipment and services provided by subvendors and to any free-issue materials.
Marking
Stamping of all materials shall be with "low stress" steel stamps having round or "U" shaped cross sections or with "interrupted-dot" die stamps.
Marking paint or water insoluble ink for use on austenitic and high nickel alloy steels shall contain no substance (e.g., metallic pigments, sulfur or chlorides) which would be harmful to these materials at ambient or elevated temperatures. The Manufacturer shall submit analysis of marking material to the Purchaser. The submittal shall demonstrate (by chemical analysis and history of use) that the material meets these requirements.
Internals, clips, lugs, or other similar attachments that are removable and are to be assembled by others shall be marked with piece numbers or identification in assembly and match-marked.
For vessels that have been post-weld heat treated, the following sign shall be painted on the vessel after heat treatment. The sign shall be in letters approximately 4 inches high painted with white paint.
On vertical vessels, this sign shall be located on two opposite sides near the bottom tangent line and repeated at approximately each ten (10) feet of height, but rotated 90 degrees.
On horizontal vessels, the sign shall be located on both sides near the horizontal centerline.

"POST WELD HEAT TREATED . . . NO WELDING OR BURNING PERMITTED ON THIS VESSEL"

The North and East orientations shall be center-punched on the outside of each vertical vessel approximately 6 inches above the bottom tangent line and 6 inches below the top tangent line. The punch marks shall be circled with white paint.
The Purchase Order number and the vessel identification number shall be painted with white paint on the side of the vessel.
All temporary support components required for maintaining vessel roundness or shipping shall be painted yellow and marked with the following statement:

"SHIPPING/FABRICATION DEVICE . . . REMOVE BEFORE UNIT STARTUP"

Packaging and Shipping
Vessels shall be free of loose scale, dirt and foreign material. Liquid used for testing or cleaning shall be completely drained. Vessel openings shall be blanked. High alloy vessels shall be blown dry with air, and all nozzle, manhole, vent and connection openings shall be blanked, plugged or capped to prevent the entry of moisture.
The Manufacturer shall be responsible for suitably packaging each vessel or component and adequately supporting and securing all vessel internals to protect them from damage or loss during handling and shipment in accordance with the Purchase Order and the following requirements:
All material and methods of packing shall conform to the specifications referenced in the Purchase Order.
Packages shall include lifting lugs or designated lifting points.
Each vessel, crate, or bag shall be durably marked with the receiving address. Purchaser's vessel Item Number, and the complete Purchase Order Number. As a minimum, all markings shall be in the English language.
Special tools shall be separately boxed, shipped and identified with the vessel on which they are to be used, and the boxes marked as special tools.
The Manufacturer shall include a packing list in each shipment, listing the contents by assembly piece mark, individual piece mark, or by vessel number of each box, crate, bag, and skid. The list shall state whether the contents constitute complete or partial shipment.
(*)Vessels shall not be transported to the jobsite as above-deck cargo without prior written approval of the Purchaser.
(*)Where clearances for shipping require alteration or cutting off of vessel nozzles, clips, lugs, or other similar attachments, the Manufacturer shall submit loading diagrams showing the attachments which require reorientation or removal. No changes shall be made unless written approval has been obtained by the Purchaser.
Small parts of the vessel shall be shipped bagged, boxed, or otherwise protected from damage or loss. Spare gaskets shall be tagged with the equipment item number and location. Gaskets shall be boxed separately and shipped with the vessel.

The Manufacturer shall provide any special protection or packaging, and details of any storage, shelf life, or maintenance instructions which are not within the scope of the Purchase Order but which pertain to the Manufacturer's guarantee or are otherwise necessary for protection of the vessel.
Protection for flange faces, threaded connections, weld bevels, etc., shall be as follows:
(*)All machined and threaded surfaces of carbon steel and ferritic alloy steel materials, except weld bevels, shall be coated with a rust preventive approved by the Purchaser.
(*)Weld bevels shall be free of dirt, oil, grease, scale, rust, and other foreign materials. All weld bevels of carbon steel and ferritic alloy steel materials shall be coated, after cleaning, on the inside and outside for a distance of approximately 3 inches from the end of the weld bevel with a weldable rust preventive approved by the Purchaser.
All weld bevels shall be closed with metal or plastic caps to prevent damage and entrance of foreign materials.
All socket-weld ends and plain ends shall be closed with metal or plastic protectors that fit either inside or outside to prevent damage and entrance of foreign materials.
Threaded openings shall be plugged with round headed threaded plugs of the same material as the connected part and sealed with tetrafluoroethylene tape thread sealant.
Flanged openings shall be protected and made waterproof with plastic flange covers or full size No. 10 gage minimum thickness steel covers and 1/8 inch thick rubber gaskets between the flange and cover. When steel flange covers are furnished, they shall be secured with appropriately sized machine bolts as follows: For flanges having 4 to 28 bolt holes, a bolt shall be placed in at least every other hole, with a minimum of 4 bolts. For flanges having more than 28 bolt holes, bolts shall be placed in at least every fourth bolt hole.
(*)Austenitic stainless steels used in vessels shall not be exposed to wetting by salt water or salt spray. Protective coatings used to prevent such exposure are required and shall be approved by the Purchaser.
The following additional requirements shall be met for shell and tube heat exchangers.
Longitudinal leaf seal strips shall not be creased or mishandled. Bundles with this type of seal shall be shipped with wooden blocks wired or strapped to the bundle to protect the seal strips during lifting.
Eyebolt holes used for lifting lugs located in the periphery of the stationary tubesheet shall be plugged with a stiff grease.
Additional requirements for export packaging are covered in EP 14-1-5.
Spare Parts
Two (2) sets of spare gaskets shall be furnished for all vessel girth and manway flanges.
An additional 10% of stud bolts for all vessel girth and manway flanges shall be furnished.

DOCUMENTATION

Final Fabrication Drawings
The final or "as-built" fabrication drawings shall include, but shall not be limited to, the following:
All applicable information on the pressure vessel datasheet, see EP 7-1-1DS.
Dimensions of all vessel components
General vessel details including all nozzle details
Gasket and flange details including flange face finishes
Internal construction details including all shell attachments and location
Full scale drawing of the vessel nameplate
Support and other appurtenance details including an anchor bolt template
All weld joint details in cross section, weld map, and applicable welding procedures
Clad and weld overlay details, when applicable
Heat treatment requirements
Weld hardness requirements
Non-destructive testing requirements
Identification of pressure limiting components
For shell-and-tube heat exchangers, bundle details and tube layout details.
For double-pipe heat exchangers, bundle details, tube layout details, and special fittings and joint details that are not ANSI standard.
For spiral heat exchangers, end closure details and internal details such as channel dimensions, plate spacer size and arrangement, plate welding details, etc.
Fabrication drawings shall use the English System of units.
Fabrication drawings with proprietary clauses are unacceptable.
(*)After the Owner's Engineer approval and final revision, approved fabrication drawings shall be furnished to the Owner's Engineer. The number of copies of approved fabrication drawings will be specified by the Purchaser.
(*)If modifications to the approved fabrication drawings are required during fabrication, one reproducible and four copies of "as-built" drawings (only those affected) shall be issued to the Owner's Engineer. Modification shall not be made to the approved design without receiving approval from the Owner's Engineer and the Inspector.
Vessel Design Report
A Vessel Design Report shall be provided for each vessel. This report shall include the following:
All mechanical design calculations required to demonstrate compliance to the ASME Code. For components falling beyond the scope of the ASME Code, the Manufacturer shall be responsible for providing adequate calculations to justify the design. The English system of units shall be used by the Manufacturer for drawings and calculations (pressure and stress shall be expressed as lb/in2, length as inches, and force as lbs).
A completed data sheet per paragraph 4.1 of EP 7-1-1 or EP 7-1-2, as applicable, corrected to reflect the as-built conditions.
For vessels constructed to ASME Division 2, the Manufacturer's Design Report per paragraph AG-302 of this Code.

Vessel design calculations made with the use of computer programs must either be accompanied by the appropriate program documentation or substantiated by detailed hand calculations.
Pressure Vessel Record Book
On completion of construction of each vessel the Manufacturer shall assemble and deliver with the vessel, two copies of a Pressure Vessel Record Book, which as a minimum, shall contain the information in Table 1.
Where applicable, the Manufacturer shall furnish the Owner's Engineer with all correspondence relating to the approval of state special designs as required by the local government jurisdiction. This information shall be included in the Pressure Vessel Data Book.
All documentation is to be in the English language or should indicate English translation.
Unless otherwise specified in the Purchase Order, the Manufacturer shall retain the Pressure Vessel Record Book for five (5) years.

7.0 INSPECTION AND REJECTION BY PURCHASER

All vessel fabrication is subject to inspection and rejection by the Owner in accordance with the requirements of the Purchaser and EP 7-1-1. Additional requirements for inspection and rejection of heat exchanger components are covered in EP 8-1-1, EP 8-1-5, and EP 8-1-6, as applicable.

8.0 TABLES

TABLE 1 DOCUMENTATION REQUIREMENTS

FOR PRESSURE VESSELS FROM EP 7-1-4

Item	Description	Format (1)	As-Built
1	Manufacturer's Data Report (for ASME Code, Division 1, U-1 Form, for ASME Code, Division 2, A-1 Form). The user's name and the plant location where the vessel is to be installed shall be specified on the Manufacturer's Data Reports by the Manufacturer.	See EP 2-5-2	Yes
2	Photocopy or rubbing of the vessel nameplate.	See EP 2-5-2	Yes
3	The Vessel Design Report per paragraph 6.2.	See EP 2-5-2	Yes
4	Quality Control Plan including; fabrication sequence including all heat treatment requirements, forming and rolling procedure, an inspection and test plan with schedule identifying all inspection points required by the Owner, and signed inspection reports.	See EP 2-5-2	Yes
5	Fabrication drawings prepared in accordance with paragraph 6.1.	See EP 2-5-2	Yes
6	Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), weld map and welder or welding operator qualification test results.	See EP 2-5-2	Yes
7	Personnel qualification certificates for all nondestructive examinations.	See EP 2-5-2	Yes
8	All reports required by EP 7-1-1 and the ASME Code stating the results of nondestructive inspection and testing including radiographic examination, ultrasonic testing, magnetic particle examination, liquid dye penetrant examination and hardness tests.	See EP 2-5-2	Yes
9	Pyrometer charts or other detailed records for all heat treatment performed, such as post-weld, normalizing, and heating for forming.	See EP 2-5-2	Yes

TABLE 1 (CONT'D) DOCUMENTATION REQUIREMENTS

Item	Description	Format (1)	As-Built
10	All non-conformance reports including resolution and a detailed description of any repairs including a sketch, photo, or drawing indicating the location and size of the repaired area.	See EP 2-5-2	Yes
11	Charts or other records of required hydrostatic, pneumatic, or other tests. Test logs shall include the test date, testing fluid, duration of the test, temperature of the test fluid, test pressure, a traceable identifying number such as a shop order number and equipment item number, and the signature of the Manufacturer's shop inspector witnessing the test.	See EP 2-5-2	Yes
12	*Certified Material Test Reports or Certificates of Compliance that fully identify the specific materials they represent. Certified Material Test Reports are required for all pressure boundary and internal components. If approved by the Owner's Engineer, Certificates of Compliance are permitted in lieu of Certified Material Test Reports for bolting, or for carbon steel internals.	See EP 2-5-2	Yes
13	The PMI report for all materials subject to PMI examination, see EP 15-1-4.	See EP 2-5-2	Yes
14	A completed inspection checklist per EP 7-1-1C.	See EP 2-5-2	Yes
15	Results of all Impact Testing (when applicable).	See EP 2-5-2	Yes

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