ggss pressure vessels

8/11/2019 GGSS Pressure Vessels

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GROUP OR BU

GENERATION

REFERENCE

GGSS 0552

REVISION

0

DOCUMENT TYPE SPECIFICATION DATE JULY 1996

TITLE

SPECIFICATION FOR PRESSURE VESSELSPAGE 1 OF 18

THIS DOCUMENT HAS BEEN SEEN AND ACCEPTED BY

B Cooper Process Plant Design Manager

COMPILED BY

A W BaranowskiAUTHORIZED BY

T SpencerCAPE - M

REVISION0

DESCRIPTION OF REVISIONSNWS 1133, NWS 1461 and NWS 1669 have all been incorporated intoGGSS 0552 Rev 0. The text of all three documents has been revised andupdated.

APPROVAL DATEMar96

See page 2 for CONTENTS

KEYWORDSDATE 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 ...................................................................................... 33.2 Nameplate.................................................................................................... 43.3 Pressure vessel............................................................................................ 43.4 Record book................................................................................................. 4

4 Requirements ....................................................................................................... 4

4.1 Eskoms responsibilities ............................................................................. 44.2 Consultant/designer responsibilities ........................................................... 64.3 Manufacturers responsibilities ................................................................... 64.4 Inspection authoritys responsibilities ......................................................... 64.5 Design ....................................................................................................... 74.6 Materials .................................................................................................... 74.7 Alternative offers ........................................................................................ 84.8 Manufacture and workmanship .................................................................. 84.9 Pressure vessel documentation ................................................................. 84.10 Pressure vessels: sulfur hexafluoride dry air nitrogen gasfilled switchgear 94.11 Pressure vessel nameplate........................................................................ 10

5 Tests .................................................................................................................... 12

5.1 Inspection and testing ................................................................................ 125.2 Certificate of inspection and test ................................................................ 13

6 Transport and storage .......................................................................................... 13

Annexes

A Information provided by a consultant/designer .................................................. 14B 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 practiceswhich will ensure the correct preparation of all technical data, drawings, the vessel record

book and nameplate requirements which are necessary for the manufacture of pressurevessels 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 forselection 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 andtest.

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, whichemploys 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 orin 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 atatmospheric 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, asdefined 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 cubicmetres 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 thepressure vessel and any events relating to that vessel.

4 Requirements

Requirements for the pressure vessel(s) will be given in an enquiry document/purchase orderin the pressure vessel data sheet, an example of which is given in annex C of thisspecification.

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 vesseldesigner.

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 anyfittings 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 transientcyclic and/or adverse conditions in which the vessel is required to operate and anyspecial 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 tocomply;

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 legsor 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 vesselsunder pressure, Eskom, or the manufacturer, in agreement with Eskom, shall appoint aninspection authority approved by the Chief Inspector.

Where the inspection authority is nominated by Eskom, Eskom shall be responsible forensuring that any information which the manufacturer is to supply, is made available to theinspection authority.

Eskom shall be responsible for review, comments, registration and submission of thedrawing(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 byan inspector.

Where Eskom elects to perform the design function for the vessel or engages a consultantfor this purpose, Eskom shall be responsible for maintaining a complete design dossier forthe vessel and for ensuring that all the design information which the manufacturer needs toconstruct 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 designcalculations for the vessel.


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4.2. Consultant/designers responsibilities

The designer shall be responsible for the completeness and accuracy of all designcalculations 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 andcomment by Eskom, four fully dimensioned prints of all drawings showing the pressureportions of the vessel.

The following information shall also be provided:

a) a statement that the vessel is to be constructed in accordance with applicablespecifications 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 andcircumferential seams, and details of the joints for branch pipes, seating, etc., and theposition 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) shallbe submitted to Eskom. This plastic film shall bear the approval stamp and signature of theinspection authority.

4.3 Manufacturers responsibilities

After completion of construction and before delivery to site, the manufacturer shall supply tothe inspection authority for verification, three pressure vessel record books which conform topressure 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 forthe conditions specified by Eskom;

b) that the vessel has been constructed and tested in accordance with the specifiedspecification 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 toensure the integrity of the vessel design against the risk of plastic deformation, incrementalcollapse and collapse through buckling using materials specified in 4.6.

The minimum thicknesses or dimensions for particular components of vessels under internalpressure shall be calculated in accordance with the BS 5500.

The corrosion protection for internal and external surfaces of the vessel shall comply with theEskom 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 integralattachments shall take into account the suitability of the material with regard to fabricationand 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 Eskomand 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 constructionmethods 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 thewritten approval of Eskom.

4.8 Manufacture and workmanship

The workmanship and erection shall be such that all requirements of BS 5500 are met andsubjected to close inspection by the inspection authority.

Each flanged nozzle and fitting shall be supplied complete with one set of bolts and nuts andone insertion piece (gasket) of the appropriate diameter and made of a material that issuitable 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 ofcarbon steel and cast iron flanges shall conform to the requirements of SABS 1123, and thedrilling of flanges made of stainless steel or other material shall conform to the requirementsof BS 4504: Part 1, as applicable, appropriate to the class of pipe specified, and the flangesshall 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 inaccordance 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 certainrecords approved by an inspection authority.

The manufacturer, having compiled the necessary record books, shall forward three copiesfor verification, two of these copies shall be forwarded to Eskom and one copy retained bythe inspection authority.

4.9.2 Submission of documentation

The final inspection and test certificates issued by the inspection authority for any pressurevessels shall be submitted to Eskom for review by the inspector of machinery at least fourweeks prior to commissioning of the plant or equipment.

Record books shall be forwarded to Eskom within four weeks of commissioning of the plantor 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 upto and including the first flange or valve connection.

e) Welding procedures or a schedule of applicable welding procedures if manufacturermaintains 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 maintainsstandard 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 detailedmanufacturers 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 OccupationalHealth 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 lowmoisture content at a pressure of approximately 20 MPa is used as a driving and circuitinterrupting medium. This exemption does not embrace the associated vessels to thisequipment 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 poweringmechanisms where compressed nitrogen gas is used as an energy storage medium. Thenormal 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 inspectionauthority indicating that the enclosures have been designed, tested and manufactured to anapproved code of practice in accordance with provisions of clause C 72 of the Act. Theinspection authority shall confirm that the records requirements of 4.9.3 of this specificationare 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 inaccordance with this specification.

4.11.1.2 A typical example of a pressure vessel nameplate is illustrated in figure 1 of thisspecification.

4.11.1.3 The lettering and numbering used shall be of a type which will allow a reasonablepencil 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 areasonable pencil rubbing.

4.11.3.4 Fixing of nameplate

The pressure vessel nameplate shall be secured at the corners by 5 mm rivets. Rivet holesshall be countersunk so that their heads are flush with the plate. The inspection authoritysstamp shall be visible on the diagonal rivet heads prior to vessel despatch.

5,5

10

3

130

110

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

10

150

130 1010


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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 testingcomply in all aspects with the BS 5500.

Each pressure vessel shall have a permanently attached nameplate conforming to thepressure vessel documentation.

5.2 Certificate of inspection and test

Duplicate certificates are required for each pressure vessel as defined in the OccupationalHealth 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 hasbeen 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 forinstallation.


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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 in6 above for protection prior to transportation.

6.4 The packaging of the equipment for transport to the power station shall be subject to theapproval of Eskom.

6.5 The equipment shall be stored indoors or under ventilated covers. The storage areashall 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 whilethe design is being done and the manufacturer provides required information for the databook(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

ggss pressure vessels

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