Technical Specification

Carbon Steel Vessels

Project No:
338033




338033/4604-45ES-0005
Rvision Date
Page 1 of 9
07 15/07/2013





Technical Specification of
Carbon Steel Vessels









CLIENT: National Iranian Copper Industries Company

PROJECT: Sarcheshmeh Sulphuric Acid Plant Renovation &
Development Project Eng.




SIGNATURE

PREPARED BY : E.Mirbaha


Responsible
CHECKED BY : Y. Sadeghinejad


Engineering Management
APPROVED BY: M.Kianifard

Project Manager




19/10/2013


Technical Specification
Carbon Steel Vessels
Project No:
338033




338033/4604-45ES-0005
Rvision Date
Page 2 of 9
07 15/07/2013






07 14/10/2013

04 09/04/2013 1,2,3,5,8
SNC Italy .
05 08/05/2013 1,3,5,8

06 08/06/2013 1,6

07 14/10/2013 6,8











: /




REVISION INDEX


Technical Specification
Carbon Steel Vessels
Project No:
338033




338033/4604-45ES-0005
Rvision Date
Page 3 of 9
07 15/07/2013

Revision

Pages Revised

Remarks
# By App. Date
04
Y.Sadeghinejad M.Yousefi 09/04/2013 1,2,3,5,8 IFR
05
Y.Sadeghinejad M.Yousefi 08/05/2013 1,3,5,8 IFT
06
Y.Sadeghinejad M.Yousefi 08/06/2013 1,6 IFC
07
E.Mirbaha
Y.Sadeghin
ejad
14/10/2013 5,6,8 IFC
07
E.Mirbaha
Y.Sadeghin
ejad
17/10/2013 AFC

INSTRUCTION TO PRINT CONTROL (Indicate X where applicable)


Issued for Tender.
Issued for Approval.
Issued for Comment.
Issued for Information.
Approved for Tender.
Approved for Design.
X Approved for Construction.



























Technical Specification
Carbon Steel Vessels
Project No:
338033




338033/4604-45ES-0005
Rvision Date
Page 4 of 9
07 15/07/2013

TABLE OF CONTENTS

ITEM DESCRIPTION PAGE

1. SCOPE ........................................................................................................................................ 5

2. SERVICE ..................................................................................................................................... 5

3. MATERIAL .................................................................................................................................. 5

3.1 Plate ....................................................................................................................................... 5
3.2 Structural Members ............................................................................................................... 5
3.3 Nozzles .................................................................................................................................. 5
3.4 Pipe Fittings ........................................................................................................................... 5
3.5 Flanges shall conform to ANSI standard. .............................................................................. 5
3.6 Bolts and Nuts ....................................................................................................................... 6
3.7 Gaskets ................................................................................................................................. 6
3.8 Flanged and Dished Heads ................................................................................................... 6
3.9 Grout ...................................................................................................................................... 6
3.10 Level Indicator Dip Pipes for Pump Tanks .......................................................................... 6

4. WELDING .................................................................................................................................... 6

5. FABRICATION ............................................................................................................................ 7

5.1 General .................................................................................................................................. 7
5.2 Shell ....................................................................................................................................... 7
5.3 Grinding ................................................................................................................................. 7
5.4 Flanges .................................................................................................................................. 7
5.5 Mist Eliminator Tube sheet .................................................................................................... 7
5.6 Areas to be Rubber lined ....................................................................................................... 8

6. INSPECTION AND TESTING ..................................................................................................... 8

6.1 General .................................................................................................................................. 8
6.2 Radiography .......................................................................................................................... 8
6.3 Dye Penetrate Inspection ...................................................................................................... 8
6.4 Inspection .............................................................................................................................. 9

7. PROTECTION ............................................................................................................................. 9

8. IDENTIFICATION ........................................................................................................................ 9









Technical Specification
Carbon Steel Vessels
Project No:
338033




338033/4604-45ES-0005
Rvision Date
Page 5 of 9
07 15/07/2013

1. SCOPE

1.1 This specification covers the requirements for furnishing all materials, equipment, tools,
accessories, labor and supervision for fabrication and testing of the Carbon Steel Vessels.
1.2 The extent of the work is defined in the Scope of Work Specification 338033/4604-45EW-0004.

2. SERVICE


This Specification is applicable to the following equipment:
- Primary Drying Tower C-401
- Secondary Drying Tower C-402
- Final Absorbing Tower C-403
- Acid Stripping Tower C-404
- Interpass Absorbing Tower C-411
- 78% Acid Surge Tank T-401
-Tempered Water Tank T-901
- Primary Drying Acid Pump Tank V-401
- Secondary Drying Acid Pump Tank V-402
- Absorbing Acid Pump Tank V-403
- Product Acid Pump Tank V-404
- Process Gas Exit Stack including platforms

3. MATERIAL

3.1 Plate

Carbon steel to ASTM A516 Grade 70 or approved equal.
Stainless steel to ASTM A 167 or ASTM 240. Type 316L for stainless steel components, as indicated
on the drawings.

3.2 Structural Members

Carbon steel to ASTM A-36 or ST -37-2 or approved equal.

3.3 Nozzles

2" and smaller: Carbon steel, Sch. 80 seamless or ASTM A106 or API 5L Grade B.
2 to 12": Carbon steel, standard weight, seamless or ERW, beveled ends, to ASTM A-53 Grade B.
14" and larger: Fabricated from carbon steel plate, per Item 2.1.

3.4 Pipe Fittings

2" and smaller: Forged carbon steel, screwed, ANSI 3000 lb, ASTM A-105.

3.5 Flanges shall conform to ANSI standard.

10 and smaller: Forged carbon steel, slip-on, flat face, 150 lbs ASTM A 105.
12" and larger: Fabricated from carbon steel plate, per Item 2.1, slip-on, flat face, ANSI,150 lbs unless
noted otherwise.






Technical Specification
Carbon Steel Vessels
Project No:
338033




338033/4604-45ES-0005
Rvision Date
Page 6 of 9
07 15/07/2013
Manhole Flange and Cover Plate :Fabricated from carbon steel plate, per Item 2.1, slip-on, flat face.
Use outside diameter, bolt circle diameter and number of bolt holes as per ANSI 150 lbs standard.
Thickness and bolt size as per drawings.

3.6 Bolts and Nuts

All sizes: Regular unfinished square or hexagon head machine bolts ASTM A 193 GR B8M and heavy
semi-finished hexagon nuts, ASTM A194 GR 8M.

3.7 Gaskets

All Sizes: Spiral wound 316 S,S. metal rings with ceramic filler, 3 mm thick, complete with
bolt holes to suit ANSI 150 Ibs, flat face flange. The bolt hole diameter will be
specified on the drawings if different from the ANSI standard.
Garlock FLEXSEAL style RW or approved equal.

3.8 Flanged and Dished Heads

Flanged and dished heads are to be torispherical to ASME Code. The radius of the dish shall be equal
to the diameter of the head. The straight flange distance shall be 40 mm for all heads. The inside
corner radius is to be 100 mm for heads 1676 mm dia. and smaller, 150 mm for heads between 1676
mm and 2590 dia. and 200 mm for heads 2590 mm dia. And larger.

3.9 Grout

Non-shrink non-metallic grout EMBECO 636, Master flow 713 by Master Builder or equivalent. Grout
shall attain at least 40 MPa. Compressive strength at 28 days.

3.10 Level Indicator Dip Pipes for Pump Tanks
Materials are to be as noted on the drawings.

4. WELDING

4.1 Shop and field fabrication is to be carried out in accordance with the procedures outlined in Section 4
(Fabrication) of the latest edition of the A.P.I. Standard 620, except as modified herein or on the
drawings.

4.2 All welding procedures and welders are to be qualified in accordance with Section IX of the ASME
Boiler and Pressure Vessel Code, latest edition.

4.3 All welding is to be continuous unless noted otherwise. All welding shall be free of visible
imperfections, such as: cracks, excessive undercuts (0.8 mm max.) and surface slag inclusions.

4.4 Complete penetration and complete fusion of all plate work joints is required, unless noted otherwise
on the drawings.

4.5 The deposited weld metal shall have properties equal to or better than the parent metal.

4.6 All fillet welds shall be with equal legs. The leg of each weld shall be equal to or greater than the
thickness of the thinnest member being joined, except as noted.

4.7 Weld heat must be properly controlled to eliminate dimpling of the plates.





Technical Specification
Carbon Steel Vessels
Project No:
338033




338033/4604-45ES-0005
Rvision Date
Page 7 of 9
07 15/07/2013
4.8 In assembling and joining parts to the members, the procedure and sequence shall such as to
minimize distortion and shrinkage.

4.9 When welding carbon steel to 316 stainless steel, covered electrodes shall meet A.W.S. A5.11 Class
ENiCrFe-2 or approved equal requirements.

5. FABRICATION

5.1 General

All welds shall be continuous seal welds unless noted otherwise, and all external fitting attachments to
the vessels must have continuous welds. No lap or skip welds will be allowed. All sharp edges and
burrs shall be removed.

5.2 Shell

The shell must be circular. The maximum allowable out of roundness is 0.4% of the radius at inlets and
outlets and 1% for the balance of the vessel. Shell out of roundness of vessels in areas to be brick
lined is not to exceed plus or minus 12 mm on the diameter. Vertical joints in plates of adjoining
courses are to be a minimum of 600 mm apart. Misalignment of shell plates at joints in areas to be
brick lined is not to exceed 3 mm. The layout of the seams shall be such that longitudinal seams are
not behind any obstruction which prevents inspection of these welds. Circumferential seams shall be
located so they do not fall on an internal ring (40 mm is the nearest a ring can be to a seam). If
possible, nozzles and manholes shall not be located in any seams.

5.3 Grinding

All corners in the vessel interior, in areas to be brick or membrane lined are to be ground to a
6 mm radius.
All interior welds in areas to be brick or membrane lined are to be ground smooth, weld spatter
removed and .contain no porosity, holes, high or low spots. These areas are to have no surface
irregularities. High spots due to welding are to be ground to within 3 mm of the plate surface. The
transition between the ground weld and the adjacent plate surfaces must be smoothly contoured.

5.4 Flanges

Ranges are to be fixed square to the axis of the vessels with bolt holes straddling vessel
centre lines.
The faces of fabricated flanges are to be rough machined after being welded to the nozzles.
Companion faces of blind fabricated plate flanges shall be rough machined. Slip-on flanges are to be
positioned so that the distance from the face of the flange to the pipe end is to be equal to the nominal
pipe wall thickness, plus approximately 3 mm. The welds are to be applied in a manner that will not
require refacing of the flange. Vertical tank pump ports are to have a continuous filler plate around the
openings and are to be completely seal welded. The flanges of the pump nozzles must be flat and
level in all directions within 0.75 mm.

5.5 Mist Eliminator Tube sheet

Mist eliminator tube sheet must be reasonably flat. The maximum tolerance for the tube sheet flatness
is plus or minus 3 mm.
Flatness of the gasket surface at the element openings shall not vary more than 0.75 mm from a
straight edge placed between any two adjacent bolt holes, 1.5 mm between any three adjacent bolt
holes and will not vary more than 5 mm from a plane surface on the tube sheet.
Mist eliminator tube sheet weld seams shall not pass through element openings or gasket areas.
Where this is not possible, all welds within the element gasket are shall be ground flush and level with
the top surface of the tube sheet to assure a proper gasket seal.



Technical Specification
Carbon Steel Vessels
Project No:
338033




338033/4604-45ES-0005
Rvision Date
Page 8 of 9
07 15/07/2013

Tolerance for spacing of the mist eliminator openings is plus or minus 3 mm (non-cumulative). The
openings are to be plus or minus 1.5 mm at 250 RMS finish.

5.6 Areas to be Rubber lined

The following special requirements are to be followed in areas to be rubber lined:

5.6.1 All welds shall be continuous. Splatter, jagged heads or other irregularities shall be ground off.

5.6.2 All metal edges and corners shall be ground to a smooth minimum radius of 6 mm on convex
surfaces and 10 mm on concave surfaces.

5.6.3 Welds shall be ground smooth following completion. No gouging, weld porosity, blowholes, weld
spatter, sharp edges, burrs, projections or other similar irregularities will be acceptable. All such
areas shall be repaired.

5.6.4 All butt welded joints to be rubber lined must be beveled on the surface and ground flush.

5.6.5 The face of flanges to be rubber lined must be machined flat and free from surface irregularities.


6. INSPECTION AND TESTING

6.1 General

The inspector shall have free access to the areas where the work on equipment is being
performed.
Vendor shall notify CE & MC in advance (minimum one week) of scheduled vessel testing to allow
reasonable time for the inspector to arrange to be at the test site before testing begins. All welds must
be sound and free of cracks.

6.2 Radiography

Five percent (5%} of all welds in all vessels shall be examined by spot radiography in accordance with
the details as outlined in Section 5 of the API Standard 620, 11
th
Edition . Radiographs shall be
interpreted to Para. UW-51 of the Boiler and Pressure Vessel Code, Section VIII, Division1, 2010
edition. Radiography shall be progressive with schedule to be approved by inspector.

6.3 Dye Penetrate Inspection

In addition to the radiography requirements noted above, the following welds are to be 100%
dye penetrate inspected:
All stainless steel welds and dissimilar metal welds.
All stainless welds at the junction of the vessel sidewall and base plate on flat bottomed vessels.
All welds in the floor of dished bottom towers that are not pneumatically tested and all welds in the
floor of any flat bottomed vessels.
All interior welds on pump tanks except for welds on the roof of vertical tanks or welds that are
pneumatically tested.
All welds in the bottom sidewall from the junction of the base plate up to 18 inches above the highest
acid level shown on the vessel drawing.
Dye penetrate shall be in accordance with Appendix 8 of ASME Boiler and Pressure Vessel Code
Section VIII, Division I, latest edition.






Technical Specification
Carbon Steel Vessels
Project No:
338033




338033/4604-45ES-0005
Rvision Date
Page 9 of 9
07 15/07/2013

6.4 Inspection

Mill test certificates for all materials are to be reviewed to confirm compliance with materials ordered
and with this specification. All fillet weld sizes must be checked against design and shop drawings. All
radiographs which have been taken are to be examined by inspector.

7. PROTECTION

All open nozzles and flanged connections shall be covered and protected against damage during
transit and installation.

8. IDENTIFICATION

Parts sent loose to site will be clearly tagged showing equipment number.