MGM/cf GGP-1/Feb 96

GROUP OR BU
GENERATION
REFERENCE
GGSS 0552
REVISION
0
DOCUMENT TYPE SPECIFICATION DATE JULY 1996
TITLE
SPECIFICATION FOR PRESSURE VESSELS
PAGE 1 OF 18
THIS DOCUMENT HAS BEEN SEEN AND ACCEPTED BY
B Cooper Process Plant Design Manager
COMPILED BY
A W Baranowski
AUTHORIZED BY
T Spencer
CAPE - M
REVISION
0
DESCRIPTION OF REVISIONS
NWS 1133, NWS 1461 and NWS 1669 have all been incorporated into
GGSS 0552 Rev 0. The text of all three documents has been revised and
updated.
APPROVAL DATE
Mar96
See page 2 for CONTENTS
KEYWORDS
DATE OF LAST REVIEW March 1993
DATE OF NEXT REVIEW July 1999
NOTE These dates can be changed without affecting the
revision status of the document
CONTENTS
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Page
Introduction ....................................................................................................... 3
1 Scope ....................................................................................................... 3
2 Normative references ........................................................................................... 3
3 Definitions ....................................................................................................... 3
3.1 Inspection authority ...................................................................................... 3
3.2 Nameplate.................................................................................................... 4
3.3 Pressure vessel ............................................................................................ 4
3.4 Record book................................................................................................. 4
4 Requirements ....................................................................................................... 4
4.1 Eskoms responsibilities ............................................................................. 4
4.2 Consultant/designer responsibilities ........................................................... 6
4.3 Manufacturers responsibilities ................................................................... 6
4.4 Inspection authoritys responsibilities ......................................................... 6
4.5 Design ....................................................................................................... 7
4.6 Materials .................................................................................................... 7
4.7 Alternative offers ........................................................................................ 8
4.8 Manufacture and workmanship .................................................................. 8
4.9 Pressure vessel documentation ................................................................. 8
4.10 Pressure vessels: sulfur hexafluoride dry air nitrogen gasfilled switchgear 9
4.11 Pressure vessel nameplate........................................................................ 10
5 Tests .................................................................................................................... 12
5.1 Inspection and testing ................................................................................ 12
5.2 Certificate of inspection and test ................................................................ 13
6 Transport and storage .......................................................................................... 13
Annexes
A Information provided by a consultant/designer .................................................. 14
B Pressure vessels data book .............................................................................. 15
C Pressure vessel data sheets ............................................................................. 16
Figure
1 Example of pressure vessel nameplate ................................................................ 12
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Introduction
This specification has been written to assist power station personnel by setting out practices
which will ensure the correct preparation of all technical data, drawings, the vessel record
book and nameplate requirements which are necessary for the manufacture of pressure
vessels for Eskom.
1 Scope
This specification details Eskoms requirements for design, material selection, manufacture,
inspection, testing, documentation and certification of pressure vessels.
2 Normative references
The latest revisions or amendments to the following apply:
Occupational Health and Safety Act No. 85 of 1993.
BS 2815:1973, Specification for compressed asbestos fibre jointing.
BS 4504, Circular flanges for pipes, valves and fittings.
BS 5500:1991, Specification for unfired fusion welded pressure vessels.
SABS ISO 9000, Quality management and quality assurance standards Guidelines for
selection and use.
SABS ISO 9001:1987, Quality system Model for quality assurance in design development,
production, installation and servicing.
SABS ISO 9002:1987, Quality systems Model for quality in production and installation.
SABS ISO 9003:1987, Quality systems Model for quality assurance in final inspection and
test.
SABS 1123:1977, Steel pipe flanges.
SABS 1465-1:1988, Steel castings for feneral engineering applications, part 1: Carbon low-
alloy steel castings.
SABS 1465-2:1988, Steel castings for general engineering applications, part 2: Wear-
resistant carbon and low steel castings.
SABS 1465-3:1988, Steel castings for general engineering applications, part 3: Corrosion-
resistant and heat-resistant steel casting.
3 Definitions
3.1 inspection authority: Any organization, approved by the Chief Inspector, which
employs inspection engineers to carry out the prescribed functions with regard to design,
construction and manufacture of a pressure vessel.
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3.2 nameplate: A plate to bear the particulars of a pressure vessel.
3.3 pressure vessel: Means any vessel of which the interior or jacket is under pressure or
in which a cushion of gas or vapour can form above the liquid at a pressure in excess of that
of the atmosphere, including a diving bell, but does not include:
a) a boiler;
b) a vessel in which the pressure is exerted by a liquid below its boiling point at
atmospheric pressure;
c) the working cylinders or chambers of a steam, heat or air engine;
d) a vessel under pressure which forms an integral operating part of a motor vehicle, as
defined in the Road Traffic Act, 1989 (Act No 29 of 1989);
e) a portable gas container;
f) a pressurised system;
g) a vessel of which the product of the design pressure in pascals and the capacity in cubic
metres is less than 15 000;
h) a vessel of which the design pressure is less than 40 000 pascals gauge pressure;
j) a vessel with a nominal internal diameter of less than 150 mm. (OHSA)
3.4 record book: An official document which details the composition and construction of the
pressure vessel and any events relating to that vessel.
4 Requirements
Requirements for the pressure vessel(s) will be given in an enquiry document/purchase order
in the pressure vessel data sheet, an example of which is given in annex C of this
specification.
In cases of conflict, the drawing(s) shall take precedence over this specification.
The responsibilities of the parties to an agreement are defined below.
4.1 Eskoms responsibilities
Eskom shall be responsible for providing the following information to the pressure vessel
designer.
a) the diameter and tan to tan length or the nominal capacity of the vessel;
b) dimensioned concept drawing(s) giving details of the type, class and position of any
fittings or mountings;
c) the relative density of the liquid to be stored;
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d) the normal working condition of the required vessel, together with details of any transient
cyclic and/or adverse conditions in which the vessel is required to operate and any
special requirements for re-service inspection;
e) the corrosion protection required on internal and external surfaces;
f) whether welding procedure drawings are required;
g) whether the test to be carried out shall be hydraulic or pneumatic;
h) whether a test certificate is required;
j) any special statutory or other regulations with which the finished vessel is required to
comply;
k) the name of the inspecting authority to be appointed;
l) whether any treatment is required for the removal of mill scale;
m) whether or not integral saddle supports are to be supplied for a horizontal vessel or legs
or skirt for a vertical vessel;
n) the diameter, number and position of any manholes required;
p) the material to be used for a full-force manhole gasket; and
q) whether the capacity of the vessel is to be calibrated.
As Eskom is not recognized as an inspection authority for the initial construction of vessels
under pressure, Eskom, or the manufacturer, in agreement with Eskom, shall appoint an
inspection authority approved by the Chief Inspector.
Where the inspection authority is nominated by Eskom, Eskom shall be responsible for
ensuring that any information which the manufacturer is to supply, is made available to the
inspection authority.
Eskom shall be responsible for review, comments, registration and submission of the
drawing(s) to the inspection authority for final approval.
Eskom shall be responsible for keeping on the power station two record books which shall be
in accordance with pressure vessel documentation and which shall be open to inspection by
an inspector.
Where Eskom elects to perform the design function for the vessel or engages a consultant
for this purpose, Eskom shall be responsible for maintaining a complete design dossier for
the vessel and for ensuring that all the design information which the manufacturer needs to
construct and test the vessel is provided before the manufacture is started.
In addition to the above, Eskom shall be responsible for the accuracy of all design
calculations for the vessel.
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4.2. Consultant/designers responsibilities
The designer shall be responsible for the completeness and accuracy of all design
calculations and for compliance with all applicable requirements and the specified standard
for the whole vessel.
Before the start of manufacture, the designer shall submit for review, registration and
comment by Eskom, four fully dimensioned prints of all drawings showing the pressure
portions of the vessel.
The following information shall also be provided:
a) a statement that the vessel is to be constructed in accordance with applicable
specifications and regulations;
b) specification(s) with which material(s) shall comply;
c) welding procedures to be adopted for all parts of the vessel;
d) large-scale dimensional details of the weld preparation for the longitudinal and
circumferential seams, and details of the joints for branch pipes, seating, etc., and the
position of these seams and other openings;
e) heat treatment procedure;
f) non-destructive testing requirements;
g) test plate requirements;
h) design pressure(s) and temperature(s) and major structural loadings; and
j) test pressure(s).
Eskom shall register and submit drawings to the inspection authority for final approval.
After approval of drawing(s) by the inspection authority, a plastic film of the drawing(s) shall
be submitted to Eskom. This plastic film shall bear the approval stamp and signature of the
inspection authority.
4.3 Manufacturers responsibilities
After completion of construction and before delivery to site, the manufacturer shall supply to
the inspection authority for verification, three pressure vessel record books which conform to
pressure vessel documentation and annex B of this specification.
4.4 Inspection authoritys responsibilities
The inspection authority shall be responsible for verifying
a) that all parts of the vessel have been designed in accordance with the requirements for
the conditions specified by Eskom;
b) that the vessel has been constructed and tested in accordance with the specified
specification and regulations; and
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c) that any alternative materials are approved.
The inspection authority shall be responsible for:
a) approval of the final drawing(s) and
b) countersigning a certificate of compliance on completion of the vessel.
4.5 Design
Calculations shall be performed to establish the minimum thicknesses or dimensions to
ensure the integrity of the vessel design against the risk of plastic deformation, incremental
collapse and collapse through buckling using materials specified in 4.6.
The minimum thicknesses or dimensions for particular components of vessels under internal
pressure shall be calculated in accordance with the BS 5500.
The corrosion protection for internal and external surfaces of the vessel shall comply with the
Eskom corrosion protection specification stated in the data sheet.
4.6 Materials
4.6.1 General
The selection of materials for construction of pressure containing parts and their integral
attachments shall take into account the suitability of the material with regard to fabrication
and to the conditions under which it will operate.
4.6.2 Plates for shell and ends
a) vessels shall be constructed of carbon or carbon-manganese steel plate in the fine-
grained normalized conditions in accordance with the requirements of:
SABS 1465: grade C2; L3; E1; E2 Part 1 1988, or
SABS 1465: grade CRS3; CRS5; CRS6; CRS7; CRS8; CRS9; CRS10; CRS12; HRS9;
and HRS12;
b) vessels shall be constructed from such equivalent steel as is agreed between Eskom
and the manufacturer; and
c) any alternative materials shall comply with:
Department of Labour instruction number OS/BV 0025 dated 29 August 1977.
4.6.3 Vessel attachments
Materials used for the fabrication of vessel attachments shall be in accordance with 4.6.2.
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4.7 Alternative offers
Vessel manufacturers are invited to quote prices on alternative materials and construction
methods if cost of other aspects make it reasonable to do so. (See 4.6).
All deviations from this specification, the purchase order, or the drawing(s) shall have the
written approval of Eskom.
4.8 Manufacture and workmanship
The workmanship and erection shall be such that all requirements of BS 5500 are met and
subjected to close inspection by the inspection authority.
Each flanged nozzle and fitting shall be supplied complete with one set of bolts and nuts and
one insertion piece (gasket) of the appropriate diameter and made of a material that is
suitable for the fluid conveyed, maximum test pressure and maximum temperature. CAF
3 mm gaskets conforming to BS 2815 are preferred.
All flanges shall be drilled and mounted off-centre unless otherwise stated. The drilling of
carbon steel and cast iron flanges shall conform to the requirements of SABS 1123, and the
drilling of flanges made of stainless steel or other material shall conform to the requirements
of BS 4504: Part 1, as applicable, appropriate to the class of pipe specified, and the flanges
shall be the flat face, slip-on type (plate flanges).
Lifting lugs shall be provided where called for.
The supports and mountings for vessel(s) shall be designed and manufactured in
accordance with BS 5500.
4.9 Pressure vessel documentation
4.9.1 It is mandatory in terms of the Occupational Health and Safety Act to keep certain
records approved by an inspection authority.
The manufacturer, having compiled the necessary record books, shall forward three copies
for verification, two of these copies shall be forwarded to Eskom and one copy retained by
the inspection authority.
4.9.2 Submission of documentation
The final inspection and test certificates issued by the inspection authority for any pressure
vessels shall be submitted to Eskom for review by the inspector of machinery at least four
weeks prior to commissioning of the plant or equipment.
Record books shall be forwarded to Eskom within four weeks of commissioning of the plant
or equipment and shall include a copy of the final inspection/test certificate.
4.9.3 Requirements for pressure vessel data books
4.9.3.1 Exterior label giving the following information:
a) Eskom order/contract number;
b) project;
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c) vessel description;
d) manufacturers serial number; and
e) government serial number.
4.9.3.2 Contents
a) A numerical index.
b) Certificate of construction and tests issued by the inspection authority.
c) Quality assurance plan.
d) Material index and certificates used in the construction of the vessel and all pipework up
to and including the first flange or valve connection.
e) Welding procedures or a schedule of applicable welding procedures if manufacturer
maintains standard welding procedures.
f) Welding procedure qualification record(s).
g) Statement relating to welder qualifications and NDE operator qualifications.
h) NDE procedures or a schedule of applicable NDE procedures if manufacturer maintains
standard NDE procedures.
j) Heat treatment certificates indicating heating and cooling rates, holding temperatures
and times. Copies of heat treatment charts where applicable.
k) A schedule of all approved concessions, listing the numbers of the concessions granted.
l) Outline drawing approved by the inspection authority with cross reference to detailed
manufacturers drawings.
m) Non-destructive and destructive test results.
n) Hydraulic test certificate.
p) Copy of name plate.
q) Inspection certificate.
r) Release note(s).
4.10 Pressure vessels: sulfur hexafluoride dry air and nitrogen gasfilled switchgear
4.10.1 The chief inspector has exempted from clauses C73 to C86 of the Occupational
Health and Safety Act, Act No.6 of 1983, the following applications:
4.10.1.1 Enclosures containing sulfur hexafluoride normally pressurized up to 500 kPa.
4.10.1.2 Enclosures in circuit-breakers of the airblast type in which compressed air of low
moisture content at a pressure of approximately 20 MPa is used as a driving and circuit
interrupting medium. This exemption does not embrace the associated vessels to this
equipment in which air in its natural or moisture saturated condition is stored.
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4.10.1.3 Hydraulic accumulators incorporated in pneumo-hydraulic circuit-breaker powering
mechanisms where compressed nitrogen gas is used as an energy storage medium. The
normal operating pressure may be in the region of 35 MPa.
4.10.1.4 Record books will not be required by Eskom for the above applications. However,
a certificate of inspection and test (2 copies) is required from an approved inspection
authority indicating that the enclosures have been designed, tested and manufactured to an
approved code of practice in accordance with provisions of clause C 72 of the Act. The
inspection authority shall confirm that the records requirements of 4.9.3 of this specification
are maintained by the manufacturer.
4.11 Pressure vessel nameplate
4.11.1 General
Nothing in this specification shall lessen the manufacturers obligation to Eskom for the
nameplate, as detailed below:
4.11.1.1 All pressure vessels supplied to Eskom shall have a manufacturers nameplate in
accordance with this specification.
4.11.1.2 A typical example of a pressure vessel nameplate is illustrated in figure 1 of this
specification.
4.11.1.3 The lettering and numbering used shall be of a type which will allow a reasonable
pencil rubbing of the nameplate to be obtained at any stage of the pressure vessels life.
4.11.2 Nameplate information
The following particulars are required on a pressure vessel nameplate:
a) vessel type (e.g. vertical air receiver), contained fluid, if toxic, flammable or explosive;
b) manufacturers name;
c) country of origin (country in which the vessel was manufactured);
d) manufacturers serial number;
e) year of construction;
f) maximum permissible working pressure in kPa or MPa;
g) design temperature in C;
h) capacity in cubic metres; and
j) the name and number of code manufacture (and issue date of the standard used).
4.11.3 Fabrication of nameplate
4.11.3.1 Size
Approximately 150 mm by 130 mm. Minimum thickness 3 mm.
4.11.3.2 Material
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Bronze, brass or stainless steel.
4.11.3.3 Lettering
The minimum height of the lettering shall be 5 mm and it shall be backfilled in black.
The size of the lettering has been chosen to enable the manufacturer to provide a
reasonable pencil rubbing.
4.11.3.4 Fixing of nameplate
The pressure vessel nameplate shall be secured at the corners by 5 mm rivets. Rivet holes
shall be countersunk so that their heads are flush with the plate. The inspection authoritys
stamp shall be visible on the diagonal rivet heads prior to vessel despatch.
5,5
1
0
3
1
3
0
1
1
0
5
Vessel type
Manufacturers name
Country of origin
Makers number
Year of construction
Max perm working pressure kPa
Design temperature C
Capacity m
3
Code of manufacture
1
0
150
130
10
10
12 GGSS 0552 REV. 0
Figure 1 Example of pressure vessel nameplate
5 Tests
5.1 Inspection and testing
Each pressure vessel shall be inspected by the inspection authority during construction.
Sufficient inspections shall be made to ensure that the materials, construction and testing
comply in all aspects with the BS 5500.
Each pressure vessel shall have a permanently attached nameplate conforming to the
pressure vessel documentation.
5.2 Certificate of inspection and test
Duplicate certificates are required for each pressure vessel as defined in the Occupational
Health and Safety Act.
The certificate of inspection and test shall include the following information:
a) power station/distribution station;
b) Eskom order/contract number;
c) certificate inspection number;
d) capacity in cubic metres;
e) manufacturers name;
f) makers serial number;
g) year of construction;
h) design code (name and numbers of code of manufacture);
j) maximum permissible working pressure in pascals;
k) hydraulic test pressure in pascals;
l) design temperature;
m) drawing number; and
n) inspection authoritys hard stamp.
The certificate shall be signed by an authorized person to certify that the pressure vessel has
been manufactured in accordance with all the requirements of the relevant design code.
6 Transport and storage
6.1 On delivery the equipment shall be dry internally and externally and ready for
installation.
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6.2 The equipment shall be protected against any damages during transportation.
6.3 Each flanged nozzle shall be protected with a wooden blank using the jointing material in
6 above for protection prior to transportation.
6.4 The packaging of the equipment for transport to the power station shall be subject to the
approval of Eskom.
6.5 The equipment shall be stored indoors or under ventilated covers. The storage area
shall be clean, dry and dust free.
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Annex A
(informative)
Specification for pressure vessels
A1 Pressure vessel data book
Client: Eskom...............................Power station
Order number:....................................................
Vessel description:.........................................................
Identification number:.....................................................
Manufacturers comment:................................................
Government serial number:............................................
A2 Contents
a) certificate of construction and test;
b) quality assurance plant;
c) material index and certificate;
d) welding procedure specification(s);
e) welders qualification(s);
f) welding procedure qualification record(s);
g) testing records;
h) copy of name plate;
j) heat treatment chart(s);
k) inspection report;
l) release note(s); and
m) as built drawing(s).
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Annex B
(informative)
Specification for pressure vessels
B1 Checklist for pressure vessels.
B.1.1 Purpose of checklist.
To ensure that the designer considers all aspects for the design of a pressure vessel while
the design is being done and the manufacturer provides required information for the data
book(s) after the vessel is completed.
B.1.1.1 Conceptual drawing(s) with the following information:
a) the diameter and length or the nominal capacity of the vessel;
b) the diameter of manhole(s) required;
c) the grade and properties of material(s) to be used for vessel and attachment; and
d) the details of the type, class and position of any fitting or mountings.
B.1.1.2 The minimum and maximum design pressure.
B.1.1.3 The minimum and maximum design temperature.
B.1.1.4 Details of any transient cyclic and/or adverse conditions under which the vessel will
operate.
B.1.1.5 Corrosion allowance.
B.1.1.6 Corrosion protection specification.
External.
Internal.
B.1.1.7 The name of inspection authority.
Information calculations.
B.1.1.8 Design calculations.
B.1.1.9 Welding procedures.
B.1.10 Welders qualification(s).
B.1.11 Welding procedure qualification record(s).
B.1.12 Testing records
preumatic or hydraulic.
non-destruction test.
B.1.13 Test certificate.
B.1.14 Heat treatment procedure.
B.1.15 Certificate of construction.
B.1.16 Integral saddle supports.
B.1.17 Quality assurance plan.
B.1.18 Copy of nameplate.
B.1.19 As built drawing(s).
Annex C
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(informative)
List of data sheets
The following data sheets form part of this annex:
Number Title
DSB 001 Mechanical Tank Vessel
DSB 002 Mechanical Vertical Vessel or Column