specification materials

Standard Specification for

Material for Pressure Vessels

0 ASA 21.10.02 AVV 23.10.02 AD 24.10.02 ISSUED AS STANDARD SPECIFICATION Rev. Name Date Name Date Name Date Remark, kind of revision

Prepared, revised Checked Approved

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Issue: Rev. 00 , 31.08.2000

Table of Contents 1 SCOPE................................................................................................................................................... 3 1.1 Precedence ......................................................................................................................................... 3 1.2 Reference Documents ........................................................................................................................ 3 2 GENERAL REQUIREMENTS ................................................................................................................ 3 2.1 All Materials : ....................................................................................................................................... 3 2.2 Plates :................................................................................................................................................. 3 2.3 Pipes :.................................................................................................................................................. 3 2.4 Forgings : ............................................................................................................................................ 3 2.5 Boltings :.............................................................................................................................................. 4 2.6 Certified Documents :.......................................................................................................................... 4 2.7 Inspection Authority ............................................................................................................................. 4 2.8 Material Substitution ............................................................................................................................ 4 2.9 Material Marking, Identification and Certification................................................................................. 4 3 MATERIALS ........................................................................................................................................... 5 3.1 Carbon Steel Plates............................................................................................................................. 5 3.2 Cr-Mo Steel Plates .............................................................................................................................. 6 3.3 Requirement for 2-1/4Cr 1 Mo Plates.................................................................................................. 7 3.4 Clad Plates .......................................................................................................................................... 9 3.5 Stainless Steel..................................................................................................................................... 9

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1 SCOPE

This Specification, together with other listed Standards, Specifications and Engineering Data Sheets, covers general requirements for material of pressure containing vessels designed in accordance with Section VIII, Divisions 1 or 2 of the ASME Code.

1.1 Precedence When the requirements of special equipment specifications and vessel data sheets conflict with this Specification those requirements shall govern and supplement this Specification.

1.2 Reference Documents This specification shall be read in conjunction with the following project specifications: Pressure Vessels LI-ODV-STD-1001 Welding of Pressure Vessels LI-ODV-STD-1005

2 GENERAL REQUIREMENTS

2.1 All Materials :

2.1.1 All material used in equipment shall be of the type and grade specified in data sheet.

2.1.2 All material welded directly to pressure retaining parts shall be of the same material specification including impact requirements as the pressure retaining part.

2.1.3 Rimmed, semi-killed or structural quality steels shall not be used for pressure retaining parts.

2.2 Plates :

2.2.1 Tolerance on the thickness shall be on positive side only.

2.2.2 Final rolling of plates shall be length wise only. The plates shall be free from injurious defects and shall have workman like finish. Reconditioning/repair of plates by welding shall not be permitted. Surface conditions shall meet requirements of EN 10163 Class A Subclass 3.

2.2.3 No painting/coating of any kind is permitted on the steel plates.

2.2.4 Plates supplied to this specification shall confirm to specification ASTM A-20 with additional requirement mentioned herein.

2.3 Pipes :

2.3.1 All pipe material for pressure retaining parts with 14 NPS or below for CS and 8 NPS or below for SS shall be seamless.

2.4 Forgings :

2.4.1 Flanges fabricated from plate are prohibited in pressure retaining parts.

2.4.2 Self reinforced forged nozzles shall be used when shell thickness is 40 mm or over.

2.4.3 All plates and forging with a shell or flange thickness of 40 mm or greater (except ASME B 16.5 standard flanges) shall be ultrasonically examined in accordance with ASTM A435 and ASTM A388 (acceptance to ASME Section VIII, Div 2, paragraph AM-203.2).

2.4.4 Final heat treatment of forging shall be performed after rough machining which shall have no greater than 20 mm remaining on either surface.

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2.5 Boltings :

2.5.1 Low hardness bolting shall be used for pressure bearing connections being in contact with the process fluid ( such as bolting for floating head covers) when this fluid may cause stress corrosion cracking (e.g. sour gas, caustic, amine).

2.6 Certified Documents :

The supplier shall furnish 6 copies of the following certificates/documents inclusive of all tests required as per specification duly certified by the Inspecting Authority before shipment of plates. The actual values obtained shall be recorded in the test certificates/documents. Material certificates shall confirm to DIN 50049 Type 3.1B. a) Chemical Analysis. b) Mechanical Test. c) Additional Tests (if specified in the requisition). d) Data of heat treatment i.e initial temperature including heat rate soaking temperature soaking

time/cooling rate etc. e) Simulated Heat Treatment of Mechanical Test Coupons (S3 of SA-20) at indicated Heat

Treatment Cycle only. f) Ultrasonic Examination (S 12 of SA 20). g) Certification as per IBR (if specified in the requisition). h) Charpy V-notch impact tests (S5 of SA-20). i) Bend test (S14 of SA-20). j) SSC and/or HIC tests (if specified). k) Date of manufacture ( Final Rolling).

2.7 Inspection Authority

2.7.1 Unless otherwise stated in requisition, no third party inspection is required. Material test certificate duly certified by Mills quality assurance/quality control department is acceptable.

2.7.2 However, if third party inspection is specified in requisition, all test certificates and documents shall be duly certified by the third party.

2.8 Material Substitution Substitution of material may be made only upon written approval of the PURCHASER and provided there is no increase in cost. Approval must be given prior to commencement of work.

2.9 Material Marking, Identification and Certification

2.9.1 All materials shall be identifiable by means of certified legible markings relating to available, authentic material certificates during all stages of manufacture.

2.9.2 When metal stamping is done it shall preferably be on the long edge of each component as it leaves the mill. Plate rolling direction shall be indicated by suitable marking.

2.9.3 Stockist certification will not be accepted. Certification for pressure retaining parts, including bolting is to be 3.1B minimum as per DIN EN 10 204. All certificates shall be originals or verified true copies of the original.

2.9.4 The VENDOR shall maintain a system of material identification such that all materials used in the fabrication of pressure parts may be traced to the appropriate certification.

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2.9.5 Where the material identification mark is unavoidably removed, transfer of the identification mark to pressure retaining parts shall be witnessed and documented by the third party inspector.

2.9.6 Identification marking shall be made by purpose made low stress stamps (conventional stamps not acceptable) or vibro-etching. The identification mark shall be ringed by white paint. Additionally, when vibro-etching is used, the identification mark shall also be protected by a clear paint laquer.

3 MATERIALS

All the material shall satisfy requirement of ASME SEC II. In addition to code requirements, following additional requirements shall be followed.

3.1 Carbon Steel Plates

3.1.1 Plates supplied to this specification shall confirm to specification SA-20 with additional requirements covered in this specification.

3.1.2 Surface conditions shall meet requirements of EN 10163 Class A Subclass 3.

3.1.3 SA36, SA 283 and other structural steel plates shall not be used for pressure parts.

3.1.4 All carbon steels over 40 mm in thickness shall be in the normalised condition.

3.1.5 All carbon steels 40 mm and below in thickness shall be in the normalised condition unless it is in the as hot rolled condition and the austenitic grain size number is over 5 (five) according to ASTM E 112.

3.1.6 Quenched & tempered steel is limited to a maximum tensile strength of 100,000 PSI and actual yield to tensile ratio < 0.85.

3.1.7 One product analysis of each heat shall be carried out and reported. Chemical analysis shall be as per applicable specification.

a) Maximum carbon content shall not exceed 0.23%.

b) Additionally one of the following conditions for carbon equivalent based on heat analysis shall be met with.

i) CE = C+Mn/6 0.42

ii) CE=C+1/6Mn+ 1/5(Cr+Mo+V)+1/15(Cu+Ni) 0.43

However if base material is C & Mn only condition (i) shall be observed Equation (ii) shall be used when applicable material specification specifies the above elements or restricted chemical requirements are specified or supplementary requirements S19 & S21 of SA20 are specified.

3.1.8 One product analysis of each heat shall be carried out and reported for C-Mn-Si for Storage tanks. Chemical analysis shall be as per applicable specification.

Maximum permissible alloy contents shall be as per API 650 (Section 2 materials).However carbon content shall not exceed 0.24%.Moreover carbon equivalent shall not exceed 0.47 % based on the eqution.

CE=C+1/6Mn+ 1/5(Cr+Mo+V)+1/15(Cu+Ni) 0.47

3.1.9 Quenched and Tempered carbon steels shall be as per code requirements.

3.1.10 Ultrasonic examination shall be carried out for plates as under.

For plates having thickness 16 mm to 50 mm (both inclusive), as per SA 435. For plates having thickness more than 50 mm, as per SA 578 with acceptance standard of level B, if not specified elsewhere. For quenched and tempered plates, U.T. examination shall be carried out after the heat treatment.

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3.1.11 Simulated Heat Treatment of Test Coupons

The following heat treatment shall be conducted on the test coupons representative of heat treated plates before the specified mechanical testing like tensile, bend, impact tests, etc. These details shall also be recorded on the test certificates.

For plates above 16mm thickness One normalizing * + one stress Intended for hot rolling / hot forming relieving as per UCS-56 of ASME Sec.VIII Div.1.

Any other special requirement specified elsewhere.

* Recommended normalising cycle:

i) Soaking temperature: 900C to 1000C

ii) Holding time one hour per 25 mm thickness but not less than half an hour

iii) Cooling in still air

3.1.12 If equipment is coming under purview of IBR code, plates shall meet the requirements of Indian Boiler Regulations (IBR).

3.1.13 Additional requirements for high thickness plates

Plates of thickness 50 mm and above shall meet following additional requirements:

3.1.14 Vacuum Degassing treatment as per the supplementary requirement S1 of specification SA-20.

3.1.15 Charpy V-notch impact test as per the supplementary requirement S5 of specification SA-20.

i) Material meant to be used for design temperature warmer than 0C, impact test shall be carried out at (-) 29C and acceptance criteria for energy absorption shall be as per Table A2.15 of SA-20.

ii) Acceptance criteria and test temperature for impact testing of non listed material of Table A2.15 of SA-20 shall be as specified in material requisition.

3.1.16 Bend test as per the supplementary requirement S14 of specification SA-20.

3.1.17 Simulated heat treatment of test coupons for all plates as per Clause 1.1.1.8 mentioned above.

3.2 Cr-Mo Steel Plates

3.2.1 Requirement for 1-1/4Cr Mo Plates



3.2.4 SA387 Gr.11 Cl.1 Plates shall be supplied in annealed and tempered.

3.2.5 All plate & forging materials shall be ultrasonically tested as per ASME SEC II A SA435, SA 578/A578M or SA 388/A 388 M as the case may be.

3.2.6 Simulated Heat Treatment on Test Coupons Test Coupon shall be taken from heat treated plates. Following heat treatment shall be conducted on the tests coupons before the specified mechanical testing like tensile, bend, impact etc. The details of heat treatment cycle shall also be recorded on the Test certificates. Heat Treatment Cycle One annealing + One Stress relieving

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Recommended Annealing Cycle - Soaking Temperature : 950-975 C - Holding Time : 1 Hour per 25 mm thickness but not less than half an hour. - Cooling in furnace. Recommended Stress Relieving Cycle - Soaking Temperature : 680 20 C - Holding Time : 1 hour per 25 mm thickness but not less than half an hour. - Rate of Heating/Cooling : As per ASME Sec. VIII Div. 1 Cl. UCS-56

3.2.7 Hardness of plates shall not exceed 190 BHN.

3.2.8 Additional requirements for high thickness plates

Plates of thickness 50 mm and above shall meet following additional requirements:

Vacuum Degassing treatment as per the supplementary requirement S1 of specification SA-20.

One product analysisof each heat shall be carried out and reported. Chemical analysis shall be as per applicable specifications.

Bend test as per the supplementary requirement S14 of specification SA-20.

3.3 Requirement for 2-1/4Cr 1 Mo Plates



3.3.3 SA387 Gr.22 Cl.2 Plates shall be supplied in quenched and tempered condition.

3.3.4 The steel shall be manufactured by basic electric furnace process, vacuum degassed and aluminium killed.

3.3.5 Chemical analysis shall be carried out on heat as well as on product. In addition to chemical composition as per material specification, the following additional requirements shall also be met. These requirements shall be fulfilled on heat as well as on product analysis. C < 0.15% (Max) Ni < 0.20% (Max) Cu < 0.20% (Max) S < 0.007% (Max) P < 0.009% (Max) Sn < 0.01% (Max) As < 0.01% (Max) Sb < 0.003% (Max) H2 < 1PPM J = (Si + Mn)* (P + Sn)* 10E4 < 120 (Si, Mn, P, Sn as %) X = (10P + 5Sb + 4Sn + As) < 15 (Element Concentration in PPM) Material shall have grain size number 4 or finer as determined by the method of ASTM E 112.

3.3.6 All plate & forging materials shall be ultrasonically tested after specified heat treatment as per SA 578.

3.3.7 Simulated Heat Treatment on Test Coupons.

3.3.8 All test specimens shall be subjected to simulated heat treatment including two repairs (one at shop and one at site/future). Following heat treatment shall be conducted on the tests coupons before the specified mechanical testing like tensile, bend, impact etc. The details of heat treatment cycle shall also be recorded on the Test certificates. The test coupons shall be drawn from one final heat treated plated (in each thickness) per heat.

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Heat Treatment Cycle One quenching and Tempering + Three stress relieving a) Recommended Quenching Cycle

- Soaking Temperature : 930-950 C - Holding Time : 1 Hour per 25 mm thickness but not less than half an hour.

b) Recommended Tempering Cycle - Soaking Temperature : 680-720 C - Holding Time : 1 hour per 25 mm thickness but not less than half an hour.

c) Recommended Stress Relieving Cycle - Soaking Temperature : 680 10 C - Holding Time : 1 hour per 25 mm thickness but not less than half an hour. - Rate of Heating/Cooling : As per ASME Sec. VIII Div. 1 Cl. UCS-56

Note: Tempering temperature shall be minimum 20 C higher than the final stress relieving temperature.

3.3.9 Impact tests (Charpy V Notch) shall be carried out at minus 30C with 55J average value for three specimen and with no single specimen below 48J. The orientation of test specimen shall be transverse to the direction of final rolling.

3.3.10 Step Cooling Treatment Test a) Step cool tests shall be performed on fully heat treated (including simulated heat treatments) sample

from each heat of plate. b) Step cooling shall be in accordance with the following temperatures, holding times and cooling rates,

to the next lower temperature: Temperature Holding time Cooling rate to the next temperature Deg. C/hr. 593 1 5.6 538 15 5.6 524 24 5.6 496 60 2.8 468 100 27.8 315 % air cooling

3.3.11 Impact energy versus temperature (transition) curves shall be developed for each heat of plate. Impact tests of each step cooled test samples shall be performed and transition curve developed as follows: a) A minimum of eight sets of three impact tests of fully heat treated material shall be performed.

Sample location of the three specimen shall be as ASME code. b) The eight sets of impact test shall be performed at different temperature but shall include minus

30 C. The generated transition curve shall clearly define the transition zone and the upper shelf. The maximum test temperature shall correspond to the upper shelf energy level.

c) Acceptance criteria for materials shall be in accordance with the following: vTr 55+ 3.0 x vTr 55 10 C

Where vTr 55= Charpy V notch 55J impact energy transition temperature of completely heat treated specimens.

VTr 55 = The shift in charpy V notch 55J impact energy transition temperature after step cooling tests.

3.3.12 Hardness of plates shall not exceed 225 BHN.

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3.3.13 Additional tests Following additional tests shall be applicable, if specified in Material Requisition: a) High temperature tension test for each heat as per S7 of SA-20 at temperature specified in

Material Requisition. Yield point at the specified temperature shall be as per material specification. Other parameters like tensile strength, percentage elongation etc. shall be furnished for record.

b) Through-thickness tension test for plates 25 mm and above in thickness shall be conducted with frequency and test procedure as per SA 770 and determination of reduction of area as per SA-370. Minimum reduction area shall not be less than 35%.

3.4 Clad Plates

3.4.1 Plates supplied to this specification shall confirm to specification SA-263 or SA-264 or SA-265, SA-20 & SA578 with additional requirements covered in this specification.

3.4.2 Outside surface conditions of base metal shall meet requirements of EN 10163 Class A Subclass 3. The inside surface of alloy cladding shall have no.1 finish as per SA-480.

3.4.3 All cladding material of all thickness shall be U.T tested as per ASTM A 578 level S6.

3.4.4 Base metal satisfy the requirement of the code. In addition to the requirement of the code, the base metal shall satisfy requirement specified in 3.1, 3.2 & 3.3 as the case may be. Parent metal used for lining shall satisfy the requirement of 3.5 or corresponding requirement of ASME Sec II in case of non ferrous metals.

3.4.5 Clad plate formed into dished ends shall always be ultrasonically tested for soundness of bonding after forming.

3.4.6 Integrally clad plate may be supplied in the normalised or quenched and tempered condition. The tempering temperature shall exceed the stress relief temperature range by a minimum of 30C.

3.5 Stainless Steel


3.5.2 Plates shall have finish no.1 on both sides as per SA-480.

3.5.3 All plates shall be supplied in hot rolled, annealed and pickled conditions.

3.5.4 Plate representative of each heat shall be subjected to intergranular corrosion tests as per ASTM A-262 Practice B for all the 300 series materials with acceptance criteria or corrosion rate equal to 48 mils/year.

3.5.5 Ultrasonic Examination

3.5.6 Plate having thickness 16 mm to 50 min (both inclusive) shall be examined ultrasonically as per SA 435.

3.5.7 For thickness above 50 mm ultrasonic examination shall be carried out as per SA-578 and shall have acceptance standard of level-B.

3.5.8 All Mandatory tests as per material specification shall be carried out. However tension test specimen shall be from finished material and shall be selected in transverse direction.

3.5.9 Plates are not to be painted / coated but shall be covered with plastic foils or paper or by other means for careful protection and shall be packed against any damage during transit and sea-weather conditions.