S-OIL ONSAN REFINERY

EXPANSION PROJECT

ES No.

ENGINEERING SPECIFICATION
FOR
INSPECTION & TESTS OF
VESSELS AND HEAT EXCHANGERS

D-202

Revision

PAGE 1 OF 1

*REVISION HISTORY SHEET*

REV.NO.

DATE

DESCRIPTION

Aug/21/2008

For Approval [SEP-LH/SH-T-GEN-0045]

Oct/24/2008

For Approval [SEP-LH/SH-T-GEN-0273]

PDF file was modified to word file.

Nov/14/2008

For Approval [SEP-LH/SH-T-GEN-0450]

Dec/23/2008

For Approval [SEP-LH/SH-T-GEN-0733]

(1.2.1)
(1.5.4)
(3.6.3)

The Related spec D-119 was modified toD-121

Double quotation marks was inserted to use
Purchasers inspector in this words
The words or Local Regulation, whichever is stringent
was added.

Attachment#1

(Class 1)
Typographical error MN-Ho-Ni was modified to
Mn-Mo-Ni
(Figure 1-1)
T : Tube-to-tubesheet welds (seal and strength welded
joints) The the word seal and was deleted

Attachment#2

Notes (3) Attachment #2 Page 4/5

(3) The word or by the Code was added
Notes (10) Attachment #2 Page 4/5
applicable. Vessel Class applicable Vessel Class
(Period was deleted)

Attachment#3

Page format "Attachment #3" start from the new page.

Attachment#4

Use the thicker line in the drawing for the Clear

Recognition.
"Unit : mm" was specified.

Attachment#5
(Figure 5-1)

The description was modified as of TEMA 9th Edition

(2007)
G Max 1.5 -> 1/16 (1.6)
2.5 -> 3/32 (2.4)
5 -> 3/16 (4.8)
6 -> 1/4 (6.4)

Jan/05/2009

(3.5.9)

Issue as Approved [SEP-SH/LH-M-GEN-0665]

The word O-301 was modified to O-304

S-OIL ONSAN REFINERY

EXPANSION PROJECT

ENGINEERING SPECIFICATION
FOR
INSPECTION & TESTS OF
VESSELS AND HEAT EXCHANGERS

ES No.
Revision

D-202
4

PAGE 1 OF 8

*CONTENTS*
1.GENERAL.2
1.1

Intent.2

1.2

Scope2

1.3

Referenced Codes and Standards..2

1.4

Vendor's Inspection Procedure2

1.5

Inspection by Purchaser2

2. INSPECTION AND TEST RECORDS3

2.1 Records and Data Required3
3. INSPECTION AND TEST ITEMS, PROCEDURES AND ACCEPTANCE STANDARDS4
3.1 General..4
3.2 Inspection and Examination of Materials.4
3.3 Inspection of Welding.4
3.4 Non-Destructive Examination of Welds.5
3.5 Visual and Dimensional Inspection.6
3.6

Hydrostatic Test.7

3.7 Other Leak Test..7

3.8 Charpy Impact Test8
Attachment #1 CLASSIFICATION AND CATEGORY
Attachment #2 SUPPLEMENTAL INSPECTION AND TESTING REQUIREMENTS
Attachment #3 WELDING PROCEDURE QUALIFICATIONS
Attachment #4 TOLERANCES FOR PRESSURE VESSELS
Attachment #5 TOLERANCES FOR HEAT EXCHANGERS

S-OIL ONSAN REFINERY

EXPANSION PROJECT

ENGINEERING SPECIFICATION
FOR
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VESSELS AND HEAT EXCHANGERS

ES No.

D-202

Revision

PAGE 2 OF 8

1. GENERAL
1.1 Intent
This specification covers the minimum requirements for the procedures of inspection and
tests to be carried out by Vendor, and for the acceptance standards of Purchaser pertinent
to such procedures.
1.2 Scope
1.2.1 This specification applies to shop inspection and tests of tanks, towers, shell-and-tube
type heat exchangers, etc. (hereinafter referred to as vessels) fabricated in
accordance with Engineering Specification D-101 Pressure Vessels", D-121
"Pressure Vessels of Low Alloy Steel" and E-101Heat Exchangers" Where there are
conflicts between this Specification and D-121, there requirements in D-121 shall take
precedence.
1.2.2 Where requirements in this specification are not acceptable by Vendor, suggested
alternatives shall promptly be referred to Purchaser for approval before proceeding
with the work.
1.3 Referenced Codes and Standards
The codes and standards referred to in this specification, to the extent specified herein,
form a part of this specification. Such codes and standards shall be of the latest editions
unless otherwise specified.
1.4 Vendor's Inspection Procedure
Vendor shall submit a detailed procedure of the applicable inspection and tests required for
the individual components and weldments of each vessel for Purchaser's approval.
1.5 Inspection by Purchaser
1.5.1 Purchaser and/or his designated representative shall have the right to witness
inspection and tests to be performed by Vendor, and to review Vendor's records and
data. Witnessing by Purchaser's inspector shall be performed at intermediate and/or
final stages, depending on the design, fabrication and service of the vessels.
1.5.2 At any time during fabrication is underway, Purchasers inspector shall have free
access to any vendors shop concerned with fabrication of the vessels. Vendor shall

S-OIL ONSAN REFINERY

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ENGINEERING SPECIFICATION
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D-202

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PAGE 3 OF 8

provide all reasonable facilities necessary to satisfy Purchasers inspector that the
vessels are being furnished in accordance with the specifications.
1.5.3 Vendor shall notify Purchaser sufficiently in advance of the witnessed inspection and
test operations to permit Purchaser's inspector to arrive at Vendor's shop.
1.5.4 The term Purchaser's inspector in this specification shall also include inspectors of
customer and/or his designated representative.
1.5.5 Inspection by Purchasers inspector shall in no way relieve Vendor of his responsibility
to meet all requirements of the Purchase order.

2. INSPECTION AND TEST RECORDS

2.1 Records and Data Required
2.1.1 The complete records, as outlined in par. 2.1.2, of inspection and tests shall be
supplied for each vessel by Vendor to Purchaser after completion of all inspection and
tests.
2.1.2 The complete records shall include, but not limited to, (where applicable):
(1) As-built sketch or tabulation for identification of the materials showing the location
(2) Mill test reports, including data of impact tests and records/certificates of nondestructive examination required for the materials
(3) Records of production weld tests and welding procedure specifications
(4) Time-temperature charts of postweld heat treatment, and records of other heat
treatments
(5) Records/certificates of non-destructive examination such as radiographic,
ultrasonic magnetic-particle and liquid-penetrate examination
(6) Data/results of dimensional inspection
(7) Certificates of hydrostatic test, pneumatic test or other pressure tests
(8) Rubbing of nameplates

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ENGINEERING SPECIFICATION
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ES No.

D-202

Revision

PAGE 4 OF 8

(9) Manufacturer's Data Report

(10) Painting report as per Engineering Specification O-301
3. INSPECTION AND TEST ITEMS, PROCEDURES AND ACCEPTANCE STANDARDS
3.1 General
3.1.1 All inspection, examination and tests shall be in accordance with the applicable codes
and the following additional requirements unless otherwise specified.
3.1.2 Classification of vessel and welded joint category used herein are defined as shown in
Appendix 1.
3.1.3 Supplemental inspection and testing requirements that pertain to the individual
classes of vessels tabulated in Appendix 1 shall be as shown in Appendix 2.
3.1.4 Welding procedure qualifications shall be in accordance with Appendix 3
3.2 Inspection and Examination of Materials
3.2.1 Materials used for pressure-retaining parts shall be furnished with mill test reports.
3.2.2 When examination is required, minimum examination of materials shall conform to the
methods and acceptance standards outlined in Table 1.
3.2.3 Materials for primary pressure-retaining parts to be divided into two or more, shall be
so marked by a suitable method that individual pieces of materials can be related
back to the mill test reports.
3.2.4 Surfaces and edges of the materials shall be visually examined for freedom from
injurious defects, such as excessive surface flaw and lamination before the fabrication
proceeds.
3.3 Inspection of Welding
3.3.1 Beveled edges shall be smooth and uniform with dimensions conforming to the
welding procedure specifications. Edges to be welded shall be free from cracks,
laminations and other defects that may adversely affect the welds.

S-OIL ONSAN REFINERY

EXPANSION PROJECT

ENGINEERING SPECIFICATION
FOR
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VESSELS AND HEAT EXCHANGERS

ES No.

D-202

Revision

PAGE 5 OF 8

3.3.2 Prior to start of welding of butted joints, edges shall be properly fit-up and misalignment of the edge shall be within the code tolerances.
3.3.3 For double welded joints, the backside of the joints shall be cleaned to sound metal
and assured that cracks, slag inclusions or other weld defects have been removed
before backside welding is started.
3.3.4 All welds and area adjacent to the welds shall be visually inspected after completion
of the welding on accessible interior and exterior surfaces. Visual inspection shall
show that the following requirements are met:
(1) Weld reinforcement shall be as required by the applicable codes.
(2) Internal weld protrusion shall not exceed 1.5 mm in height for single butt-welded
joints.
(3) Undercutting shall not exceed 0.3 mm in depth.
(4) Welds shall be free from overlap at the toe of the welds.
(5) Spatter, slag and scale shall be removed.
(6) Crater and jig marks shall be finished smoothly.
(7) No cracks, incomplete penetration and lack of fusion shall present.
(8) The profile of fillet welds shall be uniform such that leg/throat length is regular and
the surface of welds is slightly convex.
3.3.5 Vessels subject to postweld heat treatment shall, prior to heat treatment, be carefully
inspected by visual and non-destructive methods for defects and checked for
dimensions so as to avoid welding repair after completion of the heat treatment.
3.4 Non-Destructive Examination of Welds
3.4.1 When examination is required, minimum examination of welds shall conform to the
methods and acceptance standards outlined in Table 2.
3.4.2 The degree and extent to be radiographed shall be as indicated on Purchaser's
drawings and data sheets.

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ENGINEERING SPECIFICATION
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D-202
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PAGE 6 OF 8

3.4.3 When full radiography is required, butt-welded joints in nozzles with nominal nozzle
size exceeding 10 in shall be radiographed on their entire length.
3.4.4 When spot radiography is required, each intersection of longitudinal and
circumferential welding seams in the shell and heads of the vessels shall be
radiographed.
3.5 Visual and Dimensional Inspection
3.5.1 Unless otherwise noted, tolerances for pressure vessels shall be ln accordance with
Appendix 4.
3.5.2 Unless otherwise noted, tolerances for heat exchangers shall be in accordance with
Appendix 5.
3.5.3 Thickness measurements shall be made on primary pressure-retaining parts, such as
heads and shells after forming and bending by a ultrasonic thickness meter or other
suitable instrument.
3.5.4 Main dimensions of the completed vessels and vessel parts and all connections
relating to other equipment and pipings shall be checked and measurement data shall
be recorded.
3.5.5 Vessels to be field-assembled (welded) shall be pre-assembled at shop in order to
ensure that the circumference at ends and the mis-alignment of edges are such to
allow a correct assembling.
3.5.6 Heat exchangers that are to be stacked in service shall be trial-stacked in the shop in
order to check for connection alignments of mating nozzles and supports.
3.5.7 For removal tube bundle type heat exchangers (except kettle type units) the
completed shell shall be inspected for out-of-roundness and diameter by using a
template and allow it to pass completely through the shell.
3.5.8 Location of anchor bolt holes for baseplate shall be dimensionally checked by gauge
plate which is coincident with template separately shipped from the vessels.
3.5.9 Upon completion of hydrostatic test, inspection of painting works shall be carried out
in accordance with Engineering Specification O-304.

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ENGINEERING SPECIFICATION
FOR
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D-202

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PAGE 7 OF 8

3.6 Hydrostatic Test

3.6.1 All shop fabricated vessels shall normally be hydrostatically tested with clean water.
3.6.2 Pneumatic tests in lieu of hydrostatic tests are permitted provided Purchaser's
approval is obtained.
3.6.3 The hydrostatic test pressure shall be as indicated on Purchaser's drawings or Local
Regulation, whichever is stringent.
3.6.4 The hydrostatic test pressure shall be held for at least 30 minutes.
3.6.5 The water temperature shall be determined with consideration to brittle fracture.
3.6.6 When austenitic stainless steel materials (including clad and lining materials) will be
exposed to the test water, only water having less than 30 ppm chloride content shall
be used for hydrostatic test. Such vessels shall be drained and dried immediately
after the hydrostatic tests.
3.6.7 The jacketed vessels shall be hydrostatically tested before mounting the jackets, if the
construction permits.
3.6.8 For heat exchangers, girth flanged joints that have been taken apart after a
hydrostatic test shall be re-assembled and then re-tested for tightness.
3.7 Other Leak Test
3.7.1 Reinforcing pads and similar attachments shall be leak-tested with air before
hydrostatic test.
3.7.2 Sleeve type liners for nozzles shall be leak-tested with air between the sleeve and
base metal.
3.7.3 For heat exchangers, tube-to-tube sheet joints shall be tested for tightness with air in
the shell side. Unless otherwise specified, the test pressure shall be the design
pressure of shell side or 6 kgf/G (0.588 MPa [gauge]) whichever is less.
3.7.4 Stacked type heat exchangers having interconnecting nozzles shall be pneumatically
leak-tested to check for tightness of nozzle connections in the stacked conditions.

ES No.

ENGINEERING SPECIFICATION
FOR
INSPECTION & TESTS OF
VESSELS AND HEAT EXCHANGERS

S-OIL ONSAN REFINERY

EXPANSION PROJECT

D-202

Revision

PAGE 8 OF 8

3.8 Charpy Impact Test

The Charpy impact tests, where required in this specification shall be performed in
accordance with ASME Code Sec. VIII .Div. 1, par. UG-84 or ASME Code Sec. VIII Div. 2,
AM-204 and AM-210.
Table 1 Non-Destructive Examination of Materials

Product Form

Type of Examination

Standards and Specifications

Notes

Solid Plates

Ultrasonic (UT)

ASTM A 435

Stainless clad
Plates

Ultrasonic (UT)

ASTM A 578

(1)

Forgings

Ultrasonic (UT)

ASTM A 388 or
Vendors equivalent

(2)

Heat exchanger
tubes

Ultrasonic (UT)

ASTM A 450

Eddy Current (ET)

ASTM A 450

Notes : (1) Acceptance standards (quality of bond) shall be in accordance with A578
Acceptance Level S6.
(2) Vendor shall submit his quality control specification, including acceptance
standards and rejection standards for Purchaser's approval.
Table 2 Non-Destructive Examination of Welds
Standards and Specifications
Type of Examination

ASME Code
Section VIII, Div. 1

ASME Code
Section VIII, Div.2

Par. UW-51 Note (1)

Article I -5

Ultrasonic (UT)

Appendix 12

Article 9-3

Magnetic-Particle (MT)

Appendix 6

Article 9-1

Liquid-Penetrant (PT)

Appendix 8

Article 9-2

Radiographic (RT)

Note : (1) Acceptance standards for spot radiography shall always be in accordance with par.
UW-51. In any case, acceptance standards according to par. UW-52 shall not be
permitted.

Attachment #1 1/2
CLASSIFICATION AND CATEGORY
1. Classification of Vessel
Vessels or vessel parts are classified as shown in Table 1-1
Table 1-1 Classification of Vessel
Materials and Services

Class

Low-alloy steel for high temp. service

C - 0.5 Mo, Cr-Mo,

Mn-Mo, Mn-Mo-Ni

A1

Carbon steel for high and intermediate

temp. service (Design temp. -10C)

C, C-Si, C-Si-Mn

B1

Carbon steel for low temp. Service

(Design temp. < -10C)

Fine grained killed steel

C1

Low-alloy steel for low temp. service

2.5 Ni, 3.5 Ni

Austenitic stainless steel

Type 304, 316, 321

and 347

Clad steel and overlay deposit

SC

Remarks: 1. A vessel shall be classified using any combination of the classes provided vessel
parts having different materials and/or design conditions.
2. For heat exchangers, classification shall be made separately to shell side and tube
side.
2. Welded Joint Category
The categories of welded joints are illustrated in Figure 1-1 for solid wall vessels.
3. Term of Thickness
3.1 Nominal thickness includes corrosion allowance.
3.2 Nominal thickness for forgings (forged nozzles or forged girth flanges) is defined as
"t1"or"t2", whichever is thicker, in the following figure.

3.3 Shell thickness is defined as the nominal thickness, including corrosion allowance, of
cylindrical parts for the vessels.

Attachment #1 2/2
Figure 1-1 Welded Joint Categories (Solid Wall Vessels)

A, B, C & D : According to ASME Code Sec. VIII Div. 1, par. UW-3 or Div. 2, AD-400
(See Note (1))
E : Attachment welds (welded directly to pressure-retaining parts)
(See Note (2))
T: Tube-to-tubesheet welds (strength welded joints)
Notes: (1) Butted type welded joints of nozzle neck-to-flanges, shell-to-girth flanges or shell-to
tubesheet connections shall be considered to be equivalent to Category B in this
specification.
(2) Attachment welds include structural support, tray support and skirt attachment welds.

Attachment #2 1/5
SUPPLEMENTAL INSPECTION AND TESTING REQUIREMENTS
1. General Requirements
1.1 Liquid-penetrant examination may be substituted for magnetic-particle examination when
the required magnetic-particle examination is considered impracticable.
1.2 Unless otherwise noted, the required weld examination by the magnetic particle or liquidpenetrant method shall be performed after postweld heat treatment. When the vessel wall
thickness (shell thickness) is 50 mm and over, such examination shall be performed before
postweld heat treatment and after hydrostatic test.
1.3 When magnetic-particle or liquid-penetrant examination is required, such examination shall
be performed on all accessible interior and exterior surfaces of the intended welds unless
otherwise noted.
1.4 When ultrasonic examination is specified for Welded Joint Category D, it shall be applied
to full penetration type welds, without added separate reinforcing pads, where nominal
nozzle size exceeding 6 in.
1.5 The following requirements are in addition to the specific requirements given in the
individual Vessel Class.
(1) All area where temporary lugs or attachments have been removed shall be examined by
either the magnetic-particle or liquid-penetrant method.
(2) Fillet welds on intermediate heads shall be examined by either the magnetic-particle or
liquid-penetrant method after hydrostatic test.
(3) Welds joining dissimilar materials shall be examined by either the magnetic-particle or
liquid-penetrant method.
(4) Welds in metal linings shall be examined fully by the liquid-penetrant method.
(5) For heat exchangers, Welded Joint Category T welds shall be examined by either the
magnetic-particle or liquid-penetrant method.
2. Supplemental Inspection and Testing Requirements
Supplemental inspection and testing requirements for the individual Vessel Class are listed as
follows:

Attachment #2 2/5
Inspection & Testing Requirements

Applicable
Paragraphs

Notes

Vessel Class A1
(1) UT of all plates 50 mm and over in nominal thickness

3.2.2

(2) UT of all forgings (except for standard nozzle flanges)

100 mm and over in nominal thickness

3.2.2

(3) Charpy impact tests of plates and forgings used in main

components when shell thickness 100 mm and over

3.8

(1)
(2)

(4) MT or PT for welding edges of base materials when shell

thickness 50 mm and over

3.3.1
3.4.1

(4)

(5) MT or PT for backside of double welded joints after being

prepared for welding when shell thickness 25 mm and over

3.3.3
3.4.1

(4)

(6) MT of weld surfaces for :

3.4.1

(5)

3.4.1

(4),(7)

(a) P-No.3 materials: Welded Joint Category A & B

(when shell thickness 25 mm and over)
and Welded Joint Category D & E
(b) P-No.4 & P-No.5 materials : Welded Joint Category A,
B, D & E
(7) UT of Welded Joint Category A, B & D when shell
thickness 50 mm and over
Vessel Class B1
(1) UT of all plates (raw material) 75 mm and over in nominal
thickness

3.2.2

(2) UT of all forgings (except for standard nozzle flanges)

100 mm and over in nominal thickness

3.2.2

(3) Charpy impact tests of plates and forgings used in main

components when shell thickness 100 mm and over

3.8

(1)
(2)

(4) MT or PT for welding edges of base materials when shell

thickness 75 mm and over.

3.3.1
3.4.1

(4)

(5) MT or PT for backside of double welded joints after being

prepared for welding when shell thickness 50 mm and over

3.3.3
3.4.1

(4)

(6) MT of weld surfaces for;

3.4.1

(6)

(a) Welded Joint Category A & B when shell thickness 38 mm

and over
(b) Welded Joint Category C & D when full RT Required

Attachment #2 3/5
(C) Welded Joint Category E when shell thickness 50 mm
and over
(7) UT of Welded Joint Category A, B & D when shell
thickness 75 mm and over

3.4.1

(4),(7)

Vessel Class C1
(1) UT of all plates 50 mm and over in nominal thickness

3.2.2

(2) UT of all forgings (except for standard nozzle flanges)

100 mm and over in nominal thickness

3.2.2

(3) Charpy impact tests of materials

3.8

(3)

(4) MT or PT for welding edges of base materials when shell

shell thickness 50 mm and over

3.3.1
3.4.1

(4)

(5) MT or PT for backside of double welded joints after being

prepared for welding when shell thickness 25 mm and over

3.3.3
3.4.1

(4)

(6) MT of weld surfaces for:

3.4.1

(5)

3.4.1

(4),(7)

3.8

(8)

(a) Welded Joint Category A & B when shell thickness

25 mm and over
(b) Welded Joint Category C , D & E
(7) UT of Welded Joint Category A, B & D when shell
thickness 50 mm and over
(8) Vessel production impact tests

Vessel Class D
(1) UT of all plates 38 mm and over in nominal thickness

3.2.2

(2) UT of all forgings (except for standard nozzle flanges)

100 mm and over in nominal thickness

3.2.2

(3) MT or PT for welding edges of base materials when

shell thickness 38 mm and over

3.3.1
3.4.1

(4)

(4) MT or PT for backside of double welded joints after being

prepared for welding

3.3.3.
3.4.1

(4)

(5) MT of weld surfaces for Welded Joint Category A,

B, C, D & E

3.4.1

(6) UT of Welded Joint Category A, B & D when shell

thickness 38 mm and over

3.4.1

(4),(7)

(1) PT for backside of double welded joints after being prepared

for welding when shell thickness 25 mm and over

3.3.3
3.4.1

(4)

(2) PT of weld surfaces for:

3.4.1

Vessel Class S

(a) Welded Joint Category A, B, C, D & E in contact with fluids

(See Note (9))

(9)

Attachment #2 4/5
(b) Welded Joint Category A, B, C, D & E when shell
thickness 19 mm and over
(c) Welded Joint Category C & D when full RT Required
(10)

Vessel Class SC (See Note (10).)

(1) Shear tests of integrally clad (rolled or explosive clad)
materials

(11)

(2) UT of all integrally clad (rolled or explosive clad) materials

3.2.2

(12)

(3) PT of clad welds and overlay deposits

3.4.1

(13)

Notes: (1) Main components shall cover such parts as shell, heads, girth flanges, forged nozzles,
tubesheets, channels and channel covers.
(2) The test temperature shall be the minimum design temperature or 0, whichever is
lower.
(3) Charpy impact test requirements shall be as specified on Purchaser's drawings or by the
Code
(4) This requirement shall apply to the pressure-retaining welds (Welded Joint Category A, B
& D) in the shell and heads.
(5) Welded Joint Category A & B in nozzles that are not subject to RT shall additionally be
examined by MT.
(6) When full RT required, Welded Joint Category A & B in nozzles that are not subject to RT
shall additionally examined by MT.
(7) UT shall be performed after postweld heat treatment.
(8) Vessel production impact tests shall be performed for minimum design temperature
below -10. Impact tests shall be made both in the weld metal and heat affected zones.

(9) PT shall apply to the interior surfaces of the welds in regardless of thickness.
(10) Base materials, and welds in base material sections shall comply with the inspection
and testing requirements given in the applicable Vessel Class for base materials used.
(11) UT shall be performed to check for quality of the bond between cladding metal and base
materials.
(12) Shear tests shall be performed in accordance with ASTM A 263 or A 264, whichever is
applicable.

Attachment #2 5/5
(13) PT shall be made on clad welds and overlay deposits in the following steps.
Where weld overlays are to be machined, such examination shall be performed after
machining.
Step 1

: PT after first, layer

Step 2

: PT on the completed surfaces

Attachment #3 1/1
WELDING PROCEDURE QUALIFICATIONS
1. Welding procedure qualifications shall conform to the requirements of the applicable codes
and to the requirements of this specification.
2. Procedure qualification tests shall be completed prior to starting fabrication. All welding
procedure specifications (WPS) and procedure qualification records (PQR) to be used shall
be submitted to Purchaser for approval prior to the start of production welding. Welding
procedure qualification records (PQR) shall include the results of additional tests when these
tests are specified by the applicable codes and other related specifications.
3. For low temperature service (minimum design temperature below -10), procedure
qualifications for ferritic materials shall include impact tests of both the weld metal and heat
affected zones.
4. When the thickness of cylindrical parts of the vessel (shell thickness) is 100 mm and over,
welding procedure qualification tests shall include impact tests of both the weld metal and
heat affected zones. The test temperature shall be the minimum design temperature or 0,
whichever is lower.
5. Procedure qualification tests for welding steels classified low-alloy (P-3, P-4 and P-5
materials) shall include hardness tests of the weld metal and heat affected zones after post
weld heat treatment. Hardness values shall not exceed the limits given below.

P-No.

Materials

Maximum Brinell (BHN)

Hardness Number

C-0.5 Mo, Mn-Mo, Mn-Mo-Ni

225

Cr 0.5% Max.

225

Cr 0.5% to 2.25%

225

Cr 3% to 9%

236

4,5
5

Attachment #4 1/2
TOLERENCES FOR PRESSURE VESSELS

[SHELLS AND HEADS]

Tolerances for shape of formed heads and out-of-roundness of
shells shall be as specified in the applicable codes.
1. Overall length between T.L. :
13 or 1.5 per 1000, whichever is greater, but not
exceed the following value
(Unit: mm)
Length, (L)

Tolerances

30000
> 30000

25
40

L
L

2a. Inside diameter as determined by circumferential by

circumferential measurements :
(Unit: mm)
Nominal I.D., (D)

1200
2100
4000
6000
8000
10000

<
<
<
<
<
<

D
D
D
D
D
D
D

1200
2100
4000
6000
8000
10000

Tolerances
3
5
6
7
8
10
15

2b. Inside diameter of vessels with internal trays

(by direct measurements) :
0.5% X Nominal I.D.
3.

Straightness (deviation of shell external surface from

a straight line)
(1) Max. 6 in any 6000mm length
(2) As measured in the total length (from bottom to
top T.L.) :
(Unit: mm)

L
L

Length, (L)

Tolerances

>

Max. 19
Max. 25

30000
30000

[NOZZLES, MANHOLES AND OTHER ATTACHMENTS]

(Unit: mm)
4a. Location of nozzle from T.L.
4b. Orientation of nozzle from reference centerline
4c. Nozzle flange face from shell external surface
4d. Alignment of nozzle flange face
4e. Rotational orientation of bolt hole at bolt circle
4f. Top (or bottom) flange face from adjacent T.L.
4g. Location of nozzle on top head from center of
head
4h. Flange face of bottom draw-off nozzles from
reference centerline
5a. Location of manhole from T.L.
5b. Orientation of manhole from reference centerline
5c. Manhole flange face face from shell external
surface
5d. Alignment of manhole flange face
6. Location of nozzle and manhole (related to
trays) from tray support ring as shown on
Vessel Drawing

: 6
: 6
: 5
: 1/2
: Max.1.5
: 10
: 6
: 10
: 10
: 10
: 10
: 1
: 3

Attachment #4 2/2
7. Any pair of nozzles (i.e. nozzles for liquid level gauge and
connected to reboiler)
(Unit: mm)
7a. Difference in nozzle length
7b. Distance between nozzles
7c. Difference in orientation
7d. Alignment of flange face

: Max. 1
: 2
: Max. 2
: 1/4

[TRAY SUPPORTS]
13a. Location of tray support ring from bottom T.L. (Unit: mm) : 10
13b. Tray support ring out-of-level (difference between max. and.
min. distances from T.L. to tray support ring) : (Unit: mm)
Nominal I.D., (D)

8. Clips or other similar structural attachments for platform,

ladder or pipe support
(Unit: mm)
8a. Location rom T.L.
8b. Orientation from reference centerline
8c. Distance between any pair of clips

: 10
: 10
: 3

[SUPPORTS (SKIRT, LUGS, LEGS AND SADDLES)]

9a. Distance from T.L. to bottom of baseplate
(height of skirt or leg):
(Unit: mm)

1500
2500
4000
6000
8000
10000

<
<
<
<
<
<

D
D
D
D
D
D
D

1500
2500
4000
6000
8000
10000

Tolerances
Max. 2
Max. 3
Max. 4
Max. 6
Max. 8
Max. 10
Max. 13

14. Distance between adjacent tray support rings : (Unit: mm)

Nominal I.D., (D)

Tolerances

D 2100
D > 2100

6
9

Distance,(S)
S
S

9b. Out-of-level of baseplate (difference between max. and min.

distances from T.L. to bottom of baseplate):
(Unit: mm)
Nominal I.D., (D)

2100
4000
6000
8000
10000

<
<
<
<
<

D
D
D
D
D
D

Tolerances

2100
4000
6000
8000
10000

3
4

15. Height of downcomer support bar above tray support : 1.5

ring (Unit: mm)
16. Bottom of downcomer support bar above tray support : 3
ring (Unit: mm)
17. Distance between bolt holes of downcomer support bar : 7
(Unit: mm)

Max. 3
Max. 6
Max. 7
Max. 8
Max. 10
Max. 15

10. Distance from T.L. to support lug (Unit: mm)

300
> 300

Tolerances

18. Distance from reference centerline to downcomer

support bar (Unit: mm)

: 3

: 6

11. Bolt circle diameter and pitch between bolt holes:

(Unit: mm)
Nominal I.D., (D)

Tolerances

D 2100
D > 2100

3
6

12. Horizontal vessels (Unit: mm)

12a. Distance from reference centerline to bottom : 6
of support saddle
12b. Distance from T.L. to bolt hole center of
support saddle

: 6

12c. Distance between bolt holes of support saddle:

Nominal I.D., (D)

Tolerances

D 2100
D > 2100

3
6

REMARKS :
1. Unless otherwise stated, all dimensions and tolerances are
7. Tolerances as shown in 2a, 2b and 3 are not applied to
given in ( mm ).
distortion caused by welding for attaching parts, such as
2. T.L.: Tangent Line
nozzles, support rings, lugs and other fittings to shells and
3. Tolerances are not cumulative.
heads. Measurements shall be made to the surface of the
4. Tolerances indicated on Vessel Drawing shall govern.
parent plate and not to a weld, fitting or other raised parts.
5. Tolerances shown herein are intended to apply to both vertical
and horizontal vessels.
8. Even if the distance to flange face of nozzles (or manholes)
6. For vessels fabricated from pipes diameter tolerances shall be
from centerline of vessel is specified on Vessel Drawing,
in accordance with the relevant pipe
measurements shall be made as shown in 4c (or 5c).

Attachment #5 1/2
TOLERENCES FOR HEAT EXCHANGERS
[EXTERNAL DIMENSIONS, NOZZLE AND SUPPORT LOCATIONS]
Standard tolerances for the external dimensions of heat exchangers and for nozzle and support locations are shown in Figure
5-1.
All dimensions to flange faces are to the gasket surface.
Figure 5-1

NOTES TO FIGURE, 5-1

1. Tolerances given in parenthesis (
) shall apply only to heat
exchangers with inside diameters exceeding 1500 mm.
2. For heat exchangers with inside diameters not exceeding
1500mm, this figure gives the same tolerances as TEMA
Standards (Sixth Edition).
3. Tolerances of the inside diameters shall be as follows:
(1) Pipe Shells:
This inside diameter of pipe shells shall be in accordance
with the applicable pipe specifications.
(2) Plate Shells:
This inside diameter of any plate shell shall not exceed
the design inside diameter by more than 3mm
(4mm : See Note 1) as determined by circumferential
measurement.

4. For any pair of nozzles or liquid level gauge,

additional tolerances shall be applied as follows:
a. Difference in nozzle length
b. Distance between nozzles
c. Difference in location from
reference centerline
d. Alignment of flange face

(Unit : mm)

: Max. 1
: 2
: Max. 2
: 1/4

Attachment #5 2/2
[TUBESHEETS, PARTITIONS, COVERS, AND FLANGES]
The standard clearances and tolerances applying to tubesheets, partitions, and flanges are shown in Figure 5-2.

Figure 5-2

(Unit: mm)
DIMENSIONS

TOLERANCES

+6,

D1, D2, D3, D4, D5, D6

0.8

1.5

(R1 = 5)

+0,

(R2 = 6, R3 = 1.5)

+0.8,

(R4 = 5)

-0.8 (Note 1.)

W1, W2, W3

0.8

-3

- 0.8
-0

REMARKS :
1. Unless otherwise stated, all dimensions and tolerances are given in (mm)
2. Tolerances are not cumulative.
3. Tolerances indicated on Vessel Drawing shall govern.
4. This appendix shall be used in conjunction with TEMA Standards.

NOTES TO FIGURE 5-2

1. This figure is not intended to prohibit unmachined tubesheet faces and flat cover faces.
Therefore no plus tolerance is shown on "R4".
2. Negative tolerances shall not be construed to
mean that final dimensions can be less than
that required by design calculations.
3. For peripheral gaskets, "Confined" means
"Confined on the O.D."
4. Details are typical and do not preclude the
use of other details which are functionally
equivalent.