Guidance On Practice For New Pressure Vessels: Document No. Applicability Date

BP DOC NUMBER - GP-46-01 REV A
Document No. GP 46-01

Applicability Group
Date 18 December 2006
Guidance on Practice for

New Pressure Vessels
GP 46-01
BP GROUP
ENGINEERING TECHNICAL PRACTICES
18 December 2006 GP 46-01
Guidance on Practice for New Pressure Vessels
Foreword
This is the first issue of Engineering Technical Practice (ETP) BP GP 46-1. This Guidance on Practice
(GP) is based on parts of heritage documents from the merged BP companies as follows:
British Petroleum
RP 24-1 Fire Protection – Onshore.
RP 24-2 Fire Protection – Offshore.
RP 42-2 Bolting for flanged joints.
RP 46-1 Unfired Pressure Vessels.
RP 5-2-2 Flanges, Gaskets and Bolting
RP 7-4-1 Bolting procedures for flanged connections.
Amoco
A FE-VE-DV1-E Fabricated Equipment—Pressure Vessels—Division 1—Engineering
Specification.
A FE-VE-DV1-G Fabricated Equipment—Pressure Vessels—Division 1—Guide.
A FE-VE-DV1-P Fabricated Equipment—Pressure Vessels—Division 1—Procurement
Specification.
A FE-VE-DV2--E Fabricated Equipment—Pressure Vessels—Division 2—Engineering
Specification.
A FE-VE-DV2-P Fabricated Equipment—Pressure Vessels—Division 2—Procurement
Specification.
A PN-PLT-GASK-E Piping—Plant—Gaskets—Selection Specification.
A PN-PLT-GASK-G Piping—Plant—Gaskets—Guide.
ARCO
Std 40-89 Pressure Vessels.
Std 42-95 General Welding: Fabrication and Inspection for General Refinery
Service.
Copyright © 2006, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organization. None of the information
contained in this document shall be disclosed outside the recipient’s own organization
without the prior written permission of BP Group, unless the terms of such agreement or
contract expressly allow.
Page 2 of 62
Table of Contents
Foreword ........................................................................................................................................ 2
1. Scope .................................................................................................................................... 7
2. Normative references............................................................................................................. 7
3. Definitions.............................................................................................................................. 9
4. Symbols and abbreviations .................................................................................................. 10
5. Introduction, codes, legislation and quality assurance.......................................................... 10
5.1. Introduction ............................................................................................................... 10
5.2. Codes ....................................................................................................................... 11
5.3. Legislation................................................................................................................. 11
5.4. Quality Assurance..................................................................................................... 12
6. Materials selection ............................................................................................................... 12
6.1. Process specific requirements .................................................................................. 12
7. Design ................................................................................................................................. 14
7.1. General..................................................................................................................... 14
7.2. Loadings ................................................................................................................... 16
7.3. Design against corrosion under insulation (CUI) ....................................................... 19
7.4. Design for non-intrusive inspection ........................................................................... 19
7.5. Plate layout and weld design .................................................................................... 20
7.6. Nozzles and manways .............................................................................................. 20
7.7. Flanges, gaskets, and bolts ...................................................................................... 21
7.8. Welds........................................................................................................................ 23
7.9. Internals.................................................................................................................... 23
7.10. Supports ................................................................................................................... 23
7.11. External attachments ................................................................................................ 26
7.12. Spheres .................................................................................................................... 27
7.13. Pig launchers and receivers...................................................................................... 28
8. Fabrication........................................................................................................................... 28
8.1. General..................................................................................................................... 28
9. Inspection and testing .......................................................................................................... 28
9.1. Preparation ............................................................................................................... 28
9.2. Surface examination of welds ................................................................................... 28
9.3. Volumetric examination of welds............................................................................... 28
9.4. Fracture mechanics assessment of weld flaws ......................................................... 28
9.5. Hydrostatic test ......................................................................................................... 29
9.6. Positive materials identification and datum thickness readings ................................. 29
10. Internal non-metallic coating or refractory lining ................................................................... 29
10.1. Non-metallic coating ................................................................................................. 29
10.2. Refractory lining ........................................................................................................ 29
Page 3 of 62
11. External coating ................................................................................................................... 30

12. Insulation ............................................................................................................................. 30
13. Packing and shipping........................................................................................................... 30
14. Documentation..................................................................................................................... 30
Annex C (Normative) Additional requirements for clad vessels ..................................................... 31
C.1 General................................................................................................................................ 31
C.7 Design ................................................................................................................................. 31
C.7.1 General..................................................................................................................... 31
C.8 Fabrication........................................................................................................................... 37
C.8.2 Welding..................................................................................................................... 37
Annex E (Normative) Additional requirements for vessels in duplex stainless steel (DSS) ............ 38
E.6 Material................................................................................................................................ 38
E.6.3 Mechanical properties............................................................................................... 38
Annex F (Normative) Additional requirements for vessels in high nickel alloys.............................. 39
F.1 General................................................................................................................................ 39
Annex G (Normative) Additional requirements for vessels in titanium ........................................... 40
G.1 General................................................................................................................................ 40
Annex Q (Normative) Requirements for bolt tightening ................................................................. 41
Q.1 Scope .................................................................................................................................. 41
Q.2 Objective.............................................................................................................................. 41
Q.3 Supplier requirements.......................................................................................................... 41
Q.3.1 Engineering information ............................................................................................ 41
Q.3.2 Data to be recorded .................................................................................................. 41
Q.4 Related documents/references ............................................................................................ 41
Q.5 Qualified technicians............................................................................................................ 41
Q.6 Joint criticality and selection of tightening method................................................................ 42
Q.6.1 General..................................................................................................................... 42
Q.6.2 Selection of tightening method and control of loading ............................................... 42
Q.7 Gasketed joints - bolt load/stress requirements.................................................................... 43
Q.8 Required torque ................................................................................................................... 46
Q.9 Compact flanges – bolt load determination .......................................................................... 46
Q.10 Clamp connectors................................................................................................................ 49
Q.11 Preparation for tightening..................................................................................................... 50
Q.11.1 Gasketed and compact flanges................................................................................. 50
Q.11.2 Clamps ..................................................................................................................... 51
Q.12 Torque tightening................................................................................................................. 52
Q 12.1 Flanges..................................................................................................................... 52
Q.12.2 Clamps ..................................................................................................................... 53
Q.13 Tightening using hydraulic bolt tensioners ........................................................................... 54
Page 4 of 62
Q.14 Prevention of yielding with low strength bolts, e.g. stainless steel ........................................ 55
Q.15 Measurement of elongation.................................................................................................. 56
Q.15.1 Ultrasonic elongation measurement.......................................................................... 56
Q.15.2 Proprietary bolts with integral load measuring........................................................... 57
Q.16 Safety .................................................................................................................................. 57
Annex AA (Normative) Requirements for vessels to the ASME Code ........................................... 58
AA.1 General................................................................................................................................ 58
AA.6 Materials .............................................................................................................................. 58
AA.7 Design ................................................................................................................................. 58
AA.7.1 General..................................................................................................................... 58
AA.7.2 Division 1 .................................................................................................................. 58
AA.7.3 Division 2 .................................................................................................................. 59
AA.8 Fabrication........................................................................................................................... 59
AA.16 Division 3 .................................................................................................................. 59
Annex BB (Normative) Requirements for vessels to PD 5500 ....................................................... 60
BB.1 General................................................................................................................................ 60
BB.6 Materials .............................................................................................................................. 60
Annex CC (Normative) Requirements for vessels to BS EN 13445............................................... 61
CC.1 General................................................................................................................................ 61
CC.6 Materials .............................................................................................................................. 61
CC.7 Design ................................................................................................................................. 61
CC.7.1 Component design ............................................................................................... 61
CC.7.2 Alternative flange design method ......................................................................... 61
CC.7.3 Pressure relief systems ........................................................................................ 61
Bibliography .................................................................................................................................. 62
List of Tables
Table 1 - Recommended gaskets for different duties .................................................................... 22

Table 2 - Recommended hardness values for RTJ gasket materials............................................. 22
Table 3 – Suggested maximum values of macro-hardness in parent plate and welds ................... 28
Table Q.1 – Selection of criticality rating for bolted joints .............................................................. 43
Table Q.2 – Selection of bolt tightening method............................................................................ 43
Table Q.3 - Bolt torque to develop a bolt stress(1) of 345 MPa (50 000 psi).................................. 46
List of Figures
Figure 1 - Typical hot box at skirt to head attachment on high temperature vessel........................ 24
Figure 2 - Slotted skirt to head attachment on high temperature vessel under cyclic temperature
loading ................................................................................................................................. 25
Figure C.1 – Legend used in the cladding figures in Annex C ....................................................... 32
Page 5 of 62
Figure C.2 - Typical clad nozzle attachment to shell ..................................................................... 32

Figure C.3 - Typical attachment of a solid nozzle to shell.............................................................. 33
Figure C.4 - Attachment of lightly loaded internals ........................................................................ 33
Figure C.4(a) - Attachment of a lightly loaded clad bar or ring to a clad vessel ............................. 33
Figure C.4(b) - Attachment of a lightly loaded solid bar to a clad vessel........................................ 34
Figure C.5 - Attachment of moderately loaded internals................................................................ 35
Figure C.5(a) - Attachment of a moderately loaded clad bar to a clad vessel ................................ 35
Figure C.5(b) - Attachment of a moderately loaded solid bar to a clad vessel ............................... 35
Figure C.6 - Acceptable method for cladding a raised face flange................................................. 36
Figure C.7 - Cladding the groove for a ring type joint (not-acceptable).......................................... 36
Figure Q.1 - Stress relaxation curves ............................................................................................ 45
Figure Q.2 - Types of compact flange ........................................................................................... 47
Figure Q.2(a) - Metal to metal flange facing .................................................................................. 47
Figure Q.2(b) - Pressure energised ring........................................................................................ 48
Figure Q.3 - Clamp ....................................................................................................................... 49
Figure Q.4 - Typical nubbin ........................................................................................................... 50
Figure Q.5 – Sample torque sequence based on 8 bolt flange...................................................... 53
Figure Q.5(a) - Marked up 8 bolt flange ........................................................................................ 53
Figure Q.5(b) - 1st, 2nd, & 3rd stage criss-cross sequence........................................................... 53
Figure Q.5(c) - 4th & final stage adjacent bolt sequence ............................................................... 53
Figure Q.6 - Dimensions for determining bolt elongation............................................................... 56
Page 6 of 62
1. Scope
This GP provides guidance on practice in the specification of new pressure vessels, spheres, and pig
launchers/receivers. Its purpose is to brief BP engineers or contractors working on behalf of BP.
2. Normative references
The following normative documents contain requirements that, through reference in this text,
constitute requirements of this technical practice. For dated references, subsequent amendments to, or
revisions of, any of these publications do not apply. However, parties to agreements based on this
technical practice are encouraged to investigate the possibility of applying the most recent editions of
the normative documents indicated below. For undated references, the latest edition of the normative
document referred to applies.
American Petroleum Institute (API)

API STD 2510 Design and Construction of LPG Installations
API RP 578 Material Verification Program for New and Existing Alloy Piping
Systems.
API RP 579 Fitness-for-Service.
American Society for Testing and Materials (ASTM)

ASTM E10 Test Method for Brinel Hardness of Metallic Materials.
American Society of Civil Engineers (ASCE)

ASCE-7 Minimum Design Loads for Buildings and Other Structures.
American Society of Mechanical Engineers (ASME)

ASME Boiler and Pressure Vessel Code 2004 edition.
Section VIII Division 1 Rules for Construction of Pressure Vessels.
Division 2 Alternative Rules.
BP
DS 46-010 Data Sheet for Pressure Vessels.
GIS 36-103 Guidance on Industry Standard for Positive Materials Identification
(PMI) for Pressure Vessels, Piping, and other Components.
GIS 46-010 Guidance on Industry Standards for New Pressure Vessels.
GIS 46-020 Guidance on Industry Standard for Pressure Vessel Details.
GIS 46-030 Guidance on Industry Standard for Commercial Vessel Purchasing
Specification.
GP 06-20 Guidance on Practice for Materials for Sour Service.
GP 06-25 Guidance on Practice for Design to Prevent Corrosion under Insulation.
GP 06-60 Guidance on Practice for Coating of Metal Surfaces and Equipment
(A CP-COAT-00-E or BP GS 106-2).
GP 06-63 Guidance on Practice for Internal Coatings.
GP 24-23 Guidance on Practice for Active Fire Protection – Offshore.
GP 24-24 Guidance on Practice for Offshore Passive Fire Protection.
GP 24-10 Guidance on Practice for Fire Protection – Onshore.
Page 7 of 62
GP 30-76 Safety Instrumented Systems – Process Requirements Specification.

GP 44-70 Guidance on Practice for Overpressure Protection Systems.
GP 50-01 Guidance on Practice for the Application of Criticality Ratings (BP
RP 50-1).
GP 52-10 Guidance on Practice for Thermal Insulation (BP RP 52-1 or
A NM-I-00-E).
GP 72-00 Guidance on Practice for Design and Selection of Refractory Lining
Systems.
British Standards Institute (BSI)

BS 470 Inspection, access and entry openings for pressure vessels.
BS 7448 Fracture mechanics toughness tests
Part 1: Method for determination of KIc, critical CTOD and critical
J values of metallic materials.
Part 2: Method for determination of KIc, Critical CTOD and critical
J values of welds in metallic materials.
Part 4: Method for determination of fracture resistance curves and
initiation values for stable crack extension in metallic materials.
BS 7910 Guide on methods for assessing the acceptability of flaws in metallic
Structures.
BS EN 764 Pressure equipment
Part 5: Inspection documentation of metallic materials and compliance
with the material specification.
Part 7: Safety systems for unfired pressure equipment.
BS EN 13445 Unfired pressure vessels.
PD 5500 Unfired Fusion Welded Pressure Vessels.
The Engineering Equipment and Materials Users Association (EEMUA)

EEMUA 190 Guide for the design, construction and use of mounded horizontal
cylindrical vessels for pressurised storage of LPG at ambient
temperatures.
International Organization for Standardization (ISO)

ISO 15156 Petroleum and natural gas industries. Materials for use in H2S-containing
environments in oil and gas production
Part 1: General principles for selection of cracking-resistant materials.
Part 2: Cracking-resistant carbon and low alloy steels, and the use of cast
irons.
Part 3: Cracking-resistant CRAs (corrosion-resistant alloys) and other
alloys.
Institute of Petroleum (IP) – Energy Institute

IP Model Code of Safe Practice
Part 9 Liquefied Petroleum Gas
Volume 1: Large Bulk Pressure Storage & Refrigerated LPG.
International Code Council (ICC)

International Building Code.
Page 8 of 62
Liquid Petroleum Gas Association (LGPA)

LP Gas Association Code of Practice Bulk LPG Storage at Fixed Installations.
NACE International (NACE)

NACE MR0103 Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum
Refining Environments.
NACE RP0472 Methods and Controls to Prevent In-Service Environmental Cracking of
Carbon Steel Weldments in Corrosive Refining Petroleum Environments.
NACE RP0198-98 The Control of Corrosion under Thermal Insulation and Fireproofing – A
Systems Approach.
NACE TM0103-2003 Laboratory Test Procedure for Evaluation of SOHIC Resistance of Plate
Steels Used in Wet H2S Service.
NACE TM0177 Laboratory Testing of Metals for Resistance to Sulfide Stress Cracking in
H2S Environments.
NACE 6H 189 A State of the Art Report on Protective Coatings for Carbon Steel and
Austenitic Stainless Steel Surfaces Beneath Thermal Insulation and
Fireproofing.
Other
UK Health and Safety Executive Guidance Note GS 4, Safety in pressure testing.
UK Health and Safety Executive, Pressure test safety, Contract research report 168/1998.
Website for Upstream separator guidelines
3. Definitions
approval
acceptance by the purchaser.
ASME code
ASME Boiler and Pressure Vessel Code.
BP
BP p.l.c., an associate or subsidiary, or other organization as defined in the Conditions of Contract for
the project.
clad plate
plate that has been purchased by the supplier already clad (by roll or explosion bonding).
cladding re-instatement
the process in which small areas at nozzles and attachments, where the cladding has been removed for
welding of the base material, are re-clad by welding.
purchaser
contractor acting on behalf of BP or BP itself in the case of a direct purchase.
sour water, wet H2S or wet sour service

exposure to environments that contain H2S and can cause cracking of materials by the mechanisms
addressed in GP 06-20.
Page 9 of 62
These mechanisms are: sulphide stress corrosion cracking, soft zone cracking,
hydrogen induced cracking, stepwise cracking, or stress orientated hydrogen
induced cracking.
supplier
the organisation, purchaser or agency which is contracted to provide vessels to BP.
4. Symbols and abbreviations
ASS austenitic stainless steel
CUI corrosion under insulation
DSS duplex stainless steel
HBW Brinell hardness measured by tungsten carbide ball (also referred to as HB)
Hv10 Vickers hardness measured with a 10 kgf indenter (also referred to as HV)
LPG liquefied petroleum gases
MOP maximum operating pressure
MDMT minimum design metal temperature
NDE non-destructive examination
PED Pressure Equipment Directive (see Bibliography)
PWHT post weld heat treatment
PT liquid or dye penetrant testing
RT radiographic testing
RF raised face.
UT ultrasonic testing
RTJ ring type joint
SW spiral wound gasket
5. Introduction, codes, legislation and quality assurance
5.1. Introduction
For ease of reference, the index of GIS 46-010 generally also applies to this GP. However, if a
topic is raised that is not addressed in GIS 46-010, it is entered as an extra paragraph at the end
of the relevant section in this GP. In some cases, a complete annex has been added.
Guidance is given on standard pressure vessel details in GIS 46-020 and on the commercial
aspects of pressure vessel purchase in GIS 46-030.
Page 10 of 62
5.2. Codes
a. The vessel code shall be approved by the Engineering Authority in the BP Business Unit
for which the vessel is being bought. This should be done before order placement.
b. The code to be used depends mainly on national regulations, precedent, and cost. It may
also depend on the type of vessel being specified, the material, design, and method of
fabrication, and the familiarity of the fabricator with the code proposed. The following are
typical options:
1. A vessel may be supplied to the ASME code and stamped with either the U or U-2
stamps.
2. It may be purchased to the ASME code but not stamped.
3. It may be made to PD 5500 or BS EN 13445.
BS EN 13445 is new but considered to be technically acceptable.
4. It may be made to another internationally recognised code but this would be subject
to the approval of the Engineering Authority.
Component thicknesses to ASME VIII Division 1 are generally larger than those to
PD 5500, BS EN 13445, or ASME VIII Division 2.
The ASME code includes materials such as zirconium and some nickel alloys that
PD 5500 does not.
PD 5500 has well regarded design methods for external pressure, nozzle
compensation, and saddles. It also permits greater use of weld inspection by
ultrasonics in lieu of radiography.
BS EN 13445 is harmonised under the PED and does not therefore require approval
from a Notified Body every time it is used (in Europe). It contains advanced sections
on fatigue, flange and tubesheet design.
The definition of a pressure vessel varies from one design code to another. The
ASME code has a minimum pressure requirement of 1 bar. PD 5500 excludes
vessels in which the calculated stresses are less than 10% of the allowable design
stresses.
5.3. Legislation
5.3.1. In the US
Pressure vessels supplied to BP for use within the US shall be constructed and stamped in
accordance with the ASME code.
ASME code construction and stamping of new pressure vessels is a requirement of
the Occupational Safety and Health Administration.
5.3.2. In Europe
a. Pressure vessels supplied to BP for use within the European Economic Area (i.e. European
Union with other countries including Norway and Switzerland) must be stamped with a CE
mark and supplied with all other necessary certification including a Declaration of
Conformity.
Stamping and certification are provided by the manufacturer when the vessel in
manufactured within the European Economic Area. For vessels imported into the
European Economic Area, they may be provided by the manufacturer if he has the
necessary certification or by an agent acting on his behalf who is certified.
Page 11 of 62
b. The PED uses the term ‘maximum allowable pressure’ and the vessel design pressure must
equal or exceed maximum allowable pressure of the system in which it is to be installed.
c. For conformity assessment, the manufacturer specifies the module, but in the enquiry the
purchaser should indicate any requirements that he has regarding the module to be used.
Suppliers are required to manufacture to a conformity assessment procedure. For
pressure vessels supplied to BP, this is likely to be either Module G (purchaser
inspection) or Module H1 (full conformity assessment by the manufacturer under the
surveillance of his Notified Body).
d. A material that is specified in a harmonised standard requires no further regulatory
approval and, providing it is cost competitive, is therefore preferred. Other materials shall
be accepted using a Particular Material Appraisal (specific approval by a Notified Body
using) or, in rare cases, by a European Approval of Materials.
The aim of the PED is the removal of barriers to trade of pressure equipment (i.e.
vessels, piping, valves, etc.) within the European Economic Area. It applies to
‘placing on the market’ and ‘putting into service’ of pressure equipment. Hence
manufacturers and operators are both responsible for its implementation.
The PED defines pressure equipment as being designed for maximum allowable
pressures in excess of 0,5 barg. It requires that vendors provide operating
instructions and recommendations for the operating instructions are given in the
draft BS CEN/TS 764-6.
5.3.3. In the Rest of the World

Nothing.
Comments on any aspects of legislation in ROW on pressure vessels that could be
incorporated in this GP are requested.
5.4. Quality Assurance

BP or their contractor may allocate a criticality rating (1, 2, 3, or 4) to each vessel. Criticality 1
is for the most severe duties and Criticality 4 refers to those with least risk. See GP 50-01
(pending its publication use BP RP 50-1).
6. Materials selection
6.1. Process specific requirements
6.1.1. General
Nothing.
6.1.2. Sour water, wet H2S service or wet sour service

a. Sour water, wet H2S service, or wet sour service shall be determined from ISO 15156 for
upstream applications.
ISO 15156 is essentially identical to NACE MR0175 and the requirements are
substantially different from earlier versions of MR0175. It is sold through the
standards organisations of different countries (e.g. in UK it is BS EN ISO 15156).
b. For clad vessels, because BS EN ISO 15156-3 does not require any exceptional restriction
on the hardness of the (ferritic) base material and its welds, requirements on hardness and
compensation pads may be relaxed from those that apply to unclad vessels. See paragraph
A.13.1 of BS EN ISO 15156-3.
Page 12 of 62
This can be of benefit where the base material is a high strength carbon steel. It is
assumed that the cladding prevents corrosion and therefore formation of hydrogen,
hence the main agent for cracking of the base material is absent.
c. Sour water, wet H2S service, or wet sour service shall be determined from NACE MR0103
for refineries.
NACE TM0177 is used by the upstream business and has been used by the refineries
to some extent, though use of the new TM0103 will likely reduce its use.
NACE RP0472 is used by refineries.
NACE MR0103 has an appendix on hardness testing. ASTM E10 on Brinell testing
now requires the use of a tungsten carbide ball, so the hardness reading is referred
to as HBW.
6.1.3. Amine service

Nothing.
6.1.4. Hydrogen service

Nothing.
6.1.5. Hydrogen service with hydrogen sulphide

Nothing.
6.1.6. High temperature hydrogen sulphide

Nothing.
6.1.7. Duties containing Naphthenic acids and a design temp. above 220°C (430°F)
Nothing.
6.1.8. Caustic service (sour or non-sour)

The design of steam tracing shall be such that local hot spots cannot be formed.
6.1.9. Hydrofluoric acid

Nothing.
6.1.10. Propane and butane storage spheres

Because of potential carry over of moisture/H2S conditions, both strength and hardness should
be limited. In addition, good quality fabrication procedures shall be applied.
There have been cases of cracking of spheres caused by unexpected carry over of
moisture/H2S conditions where the conditions above did not apply.
6.1.11. Low temperature service

The additional cost for carbon steel vessels suitable for –50°C (–58°F), as opposed
to vessels in non-impact tested grades, is small. Nowadays, there is ample supply of
good quality, low temperature steel and weld consumables; suitable weld
procedures are readily available. Therefore specifying a steel that is suitable for
–50°C (–58°F) on a vessel which could experience a temperature below 0°C (32°F)
and as low as –50°C (–58°F) may be cost effective.
At temperatures below –50°C (–58°F), particularly where the stresses remain at
design level, it becomes increasingly difficult to specify carbon steel and below
–60°C (–76°F) generally an alternative material, e.g. ASS, aluminium or titanium,
Page 13 of 62
has to be used with a substantial increase in cost. Nickel steel may be suitable but is
little used for pressure vessels.
The requirements for vessels with minimum design temperatures lower than –60°C (–76°F)
shall be specified by the purchaser.
6.1.12. Wet CO2 service

Wet CO2 service is defined as that in which the aqueous phase contains dissolved CO2. Wet CO2
conditions may be handled either by C Mn steel with additional corrosion allowance, corrosion
inhibition, or material upgrading (e.g. Cr-containing steel, 304L), depending upon the specific
conditions.
Carbon dioxide is soluble in water and forms carbonic acid, which is corrosive. The
severity of corrosion depends on a number of factors, which include partial pressure
of CO2, pH, temperature, and other chemical species present.
6.1.13. Acetylene service

Acetylene service is defined as that where the process fluids contain any quantity of free
acetylene however small. Material containing more than 60% of copper shall not be used in the
construction of any parts in contact with acetylene. Material with a lower percentage of copper,
e.g. alloy 400, may be used with approval.
With more than 60% copper present in the alloy, copper acetylide may form which
is explosive.
6.1.14. Duties in which Polythionic Acid may be present during shutdown

a. Polythionic acid service exists if the process stream contains H2SXO6 (where x = 3 to 5)
which can form during equipment shutdown from the presence of sulphide, oxygen, and
moisture.
Solid ASS vessels are unlikely to be found in these conditions, since clad plate (roll
bonded or weld overlayed) is usually specified for this type of service. The issue is
more relevant to piping since solid ASS piping is used in this service.
b. Stabilised ASS is preferred where polythionic acid may be produced during shutdown i.e.
type 321 or 347 SS. Consideration should be given to obtaining the material in the
stabilised annealed condition and carrying out stabilise annealing after welding.
7. Design
7.1. General
7.1.1. Corrosion allowance

Corrosion allowance shall be zero on removable internals made of ASS, DSS, other high alloy
steels, or nonferrous metals.
7.1.2. Hydraulic testing

If part of a vessel is not self-venting during operation or hydrotest, means of venting, e.g. by a
vent pipe or a vent nozzle, shall be specified by the purchaser.
7.1.3. Design by analysis

Nothing.
Page 14 of 62
7.1.4. Experimental design verification

This provides a means for verifying components for which the design rules given in
the codes are not applicable. See commentary in GIS 46-010.
7.1.5. Cyclic service

a. A full statement of the design fatigue life of the vessel, i.e. the number and size of the load
cycles which are to be used for design against fatigue, shall be provided to the vessel
supplier by the purchaser.
The load cycles may be cycles of pressure, in which case all the components in the
vessel should be checked. They might refer to a local temperature change or to the
cyclic application of a force or moment, in which case only that component need be
checked. Purchasers should appreciate that life extension beyond the original
design life may be very limited and that it is advisable to regularly inspect the vessel
during its life.
b. Repair shall not be considered as a safe or economic means for compensating for poor
design or inadequate specification of the number of cycles to be expected.
The scope for repairing a vessel that is showing fatigue cracks is very limited.
Indeed, the detection of a fatigue crack due to pressure cycling probably indicates
that the life of that component is exhausted.
Fatigue crack growth is generally not linear but logarithmic. Once a detectable
crack is present, its propagation through the remaining thickness of the component
may be very rapid.
c. Full volumetric inspection of the welds by UT or RT and surface inspection by PT or MT
should be made on vessels in cyclic service. The acceptance standard should be
appropriate to the duty.
A basis for the NDE standard may be the fabrication codes. However, an allowable size of
initial defect may be calculated by fracture mechanics, see BS 7910 or API 579 and this
may give an indication of the acceptance standard for NDE.
A permissible final size of flaw is assumed and the allowable initial size determined
from it by calculating the extent of the crack propagation from the initial size to the
final during the design number of cycles.
Welds are a likely source of fatigue failure (because of minute defects present in the
toes of all welds). There is no benefit to fatigue life from PWHT.
d. To minimise the effect of thermal stress cycling, on insulated vessels, insulation shall be
designed to minimize temperature differentials. Therefore, the shell and nozzles shall be
fully insulated and the vessel skirt or vessel supports shall be insulated where they attach to
the shell.
Internally insulated vessels can result in lower metal temperatures and hence lower thermal
stresses than externally insulated vessels.
e. It is advisable to indicate when specifying the maximum time before the first internal
inspection of the vessel. It may be given as a percentage of the vessel fatigue life, say 20%.
Some codes, e.g. BS EN 13445, recommend that inspection be carried out within a
certain percentage of the vessel fatigue life.
7.1.6. Requirements specific to different process duties
7.1.6.1. Two and three phase separators

Process design of two and three phase separators for the separation of oil/water and gas from
production wells involves the consideration of multiple aspects including:
Page 15 of 62
1. Residence time requirements.

2. Control volumes.
3. Upstream pipework.
4. Inlet and outlet nozzle diameters.
5. Internals: inlet device, coalescing packs, baffles, solids removal, flow distribution,
vane packs, mesh pads, and cyclones.
The Upstream Separator Guidelines provide detailed information on each of these
aspects. These design guidelines can be found on the EPT website:
These design guidelines are maintained by Exploration and Production Technology
Group.
7.1.6.2. LPG Installations

a. Above ground pressure storage vessels for LPG shall meet the requirements of the
following or equivalent specifications:
1. IP Model Code of Safe Practice, Part 9.
2. LP Gas Association Code of Practice 1 Bulk LPG Storage at Fixed Installations
Part 1: Design, Installation and Operation of Vessels Located above Ground.
3. API STD 2510.
b. Mounded vessels shall be in compliance with EEMUA 190.
7.1.7. Minimum heat loss

Internal insulation on a vessel may result in lower energy transmission than external. However,
it is prone to trapping contaminants between the vessel and the insulation, and can be difficult to
gas free.
Externally insulated vessels are easier to gas free for maintenance and inspection. It is usually
easier and more economical to insulate externally. Therefore, external insulation is usually
preferred for liquid treating service or in gas applications where heavy ends exist.
7.1.8. Pressure relief systems

Pressure relief systems shall be in accordance with GP 44-70.
7.2. Loadings
7.2.1. Static
7.2.1.1. Maximum operating pressure

MOP is the highest pressure at which vessel will be operated in a specified process condition.
7.2.1.2. Design pressure

Design pressure shall be 1,1 MOP or MOP + 1 bar (15 psi), whichever is greater, except as
noted below:
a. Above 70 barg. (1 000 psig), design pressure shall be specified by the purchaser;
b. For full or partial vacuum service, the design pressure shall be full vacuum;
c. If a pilot operated relief valve is used, design pressure shall be the greater of 1,05 MOP or
MOP + 1 barg, (15 psi.).
Page 16 of 62
7.2.1.3. Maximum design temperature

a. For vessels with maximum operating temperature at or below 425°C (800°F), the
maximum design temperature shall be taken as maximum operating temperature plus a
margin of at least 30°C (50°F), unless specified otherwise. For vessels with higher
maximum operating temperature, the margin shall be specified by the purchaser.
b. Vessels subjected to a gradient in the temperature of the fluid contents may be separated
into zones with different maximum design temperatures. For example, if a vessel is
exposed to fluids before quenching or flashing occurs, the design metal temperature for
vessel parts (such as the inlet and adjacent area) shall be the temperature of the fluid
(before quenching or flashing) or the design metal temperature of the vessel, whichever is
higher.
c. For internally insulated vessel parts, the design metal temperature shall be based on
thermal calculations using the maximum operating fluid temperature, no wind, and the 2%
summer dry-bulb temperature.
d. Gaskets and bolting shall not determine maximum design temperature unless approval is
obtained from the purchaser.
7.2.1.4. Minimum design temperature

a. The minimum design temperature shall be the lesser of minimum design temperature
(operating) and minimum design temperature (ambient):
1. The minimum design temperature (operating) shall be the minimum operating
temperature. (For specification of MDMT as used in the ASME code, see AA.2.1).
2. If the site ambient temperature could affect material selection, a review should be
made of:
a) The metal temperatures likely to occur from ambient effects.
b) The incidence of brittle fracture at the site due to ambient effects with
comparable materials.
Following this review a minimum design temperature (ambient) shall be determined.
b. On vessel components that are insulated externally, the minimum design temperature shall
be taken to be the minimum temperature of the contents of the vessel at the appropriate
loading condition. In the case of components not thermally insulated, the minimum
temperature shall be determined from the operating conditions and also the site ambient
conditions during shutdown.
c. If autorefrigeration leads to low metal temperature at low pressure:
1. Process modelling may be use to accurately predict the variation with time of pressure
and temperature. In such cases, the design minimum temperature shall be 10°C (18°F)
lower than the minimum calculated temperature.
2. This modelling, combined with the methods given in the codes for accepting ferritic
materials at low stress and exceptionally low temperature, may provide a means for
determining the acceptability of the design without changing the materials.
7.2.1.5. Vessel design conditions

a. All feasible coincident design pressures and design temperatures (maximum and
minimum) shall be specified by the purchaser. All phases of normal operation and transient
conditions such as start-up, shutdown, upset, pressure surge, and pump or compressor shut-
off shall be considered.
b. BP requirements for overpressure protection practice, including the use of safety relief
valves and bursting discs, shall be as required by:
Page 17 of 62
1. The vessel code.

2. GP 44-70.
3. GP 30-76.
7.2.2. Dynamic
a. Vessels or vessel components shall be checked for vibration if there is any likelihood of
flow induced vibration occurring.
Dynamic analysis depends on determining the natural frequency (or frequencies) of
the vessel or component and the frequency of the applied loading. If the two are
close to each other, resonance may occur leading to large amplitude vibration with
a high probability of failure. (It is very easy for a large number of cycles to occur in
a short time, and hence fatigue damage to accumulate quickly).
The solution lies in one of the following:
• Change the natural frequency of the component. It may be possible to alter the
support of a pipe or the mass of a vessel to alter the natural frequency
sufficiently to stop the vibration.
• Change the nature of the loading. With wind induced vibration of distillation
columns, the platforms, ladders, and vertical piping all act as spoilers for the
wind flow. Therefore, by distributing these at different orientations at different
elevations, it may be possible to break up the vortex shedding sufficiently to stop
the vibration. Pressure dampers similarly alter the loading being applied, in this
case the internal flow, so that the effect of the resonance becomes minimal.
• Take the energy out of the resonance, thereby rendering it harmless. This is the
principle behind a snubber or damper on a piping system. However, these can
be expensive and may be impossible to apply with the large energies involved in
pressure vessel vibration.
b. Vessels shall be checked for dynamic effects if the process is likely to apply shock loading
to the vessel.
Because the natural period of most vessel components is long compared with the
duration of the shock wave, a simple, conservative solution is to design the
component for twice the applied pressure of the impulse. However this may not be
economic in some cases and a more detailed analysis may be necessary. The
fundamentals of such design are discussed in UK Health and Safety Executive,
Pressure test safety, Contract research report 168/1998.
7.2.3. Environmental
7.2.3.1. Wind loading

Unless otherwise specified:
a. For US sites, wind load shall conform to ASCE-7; importance factor shall be Category III;
velocity pressure exposure coefficient and gust response factors shall be Exposure C for
inland and coastal and Exposure D for offshore installation.
b. In UK, BS 6399:Part 2 shall be used for wind loading and Enquiry Case 5500/127 in
BSI PD 5500 provides the method for calculating the load.
7.2.3.2. Earthquake loading

a. Earthquake design shall conform to the International Building Code.
b. Pressure vessels shall normally be designed as follows:
Page 18 of 62
1. The allowable stress design method shall be used. When the pressure vessel is
designed using the allowable stress method and the supporting structure or foundation
bolts are designed using the strength design method a check shall be made that there
is no inconsistency between the two design methods.
The strength design or load and resistance factor design method is not normally
used for pressure vessel design but is frequently used for civil engineering design.
2. The equivalent static method design method shall be used. Dynamic analysis shall not
be used unless authorised by BP. If the dynamic analysis method is used, the
competence of the designer should be verified.
The additional effort and complexity of performing a dynamic analysis for pressure
vessels is not normally justified. The equivalent static method is normally slightly
more conservative but is less prone to error.
3. The basic load combinations associated with the allowable stress design method shall
be used.
The load combination factors for the allowable stress and the strength design or
load and resistance factor design are different.
4. Vertical columns may be considered as “cantilevered column systems” provided they
are anchored to a foundation at grade.
Flexibility of the supporting structure may alter the response of a heavy vessel.
5. Seismic design need only be considered for operating conditions. Hydrotest
conditions do not need to be considered.
6. Parameters such as seismic user group and site class shall be defined for each site.
Site class shall be consistent with the factors used for the civil engineering design.
In accordance with table 1604.5 in the International Building Code, process plant is
normally considered as category II, except for facilities that are required for post-
earthquake recovery (e.g. fire fighting facilities) which are considered as
category IV.
7.2.3.3. Snow loading

Unless otherwise specified:
a. For US sites, snow load shall conform to ASCE-7.
b. Elsewhere snow load shall conform to local standards.
7.3. Design against corrosion under insulation (CUI)

The purchaser shall indicate whether the vessel is susceptible to CUI. If so, GP 06-25 shall be
applied.
The following references may assist when specifying vessels for minimum CUI:
NACE publications 6H 189 and RP0198 and BP Corrosion and Materials
Guidelines 2001: Corrosion under Insulation A Guide to the Prevention and
Detection of Corrosion Beneath Insulation.
7.4. Design for non-intrusive inspection

a. The purchaser shall state if the vessel is to be designed for non-intrusive inspection.
b. The purchaser shall review the requirements resulting from non-intrusive inspection fully
reviewed with the selected fabricator and, preferably, before an order is placed. The
requirements may affect: materials selection, design, inspection during fabrication, and
inspection during service. A considerable amount of advance engineering of the vessel,
Page 19 of 62
perhaps leading to preparation of a full set of fabrication drawings, may be needed before
materials are ordered. The contract shall be set-up accordingly.
A requirement to design a vessel for non-intrusive inspection may considerably alter
the materials required and the design (mainly to permit external ultrasonic
inspection). Details of the vessel should therefore be agreed with the vendor at a
very early stage.
7.5. Plate layout and weld design

Nothing.
7.6. Nozzles and manways
7.6.1. Construction details

a. The location and projection of internally projecting nozzles shall not unduly restrict
product flow nor hamper placement and removal of internals.
b. Nozzles in a service where coke may be found and those handling fluid catalyst, catalyst
slurry, or viscous fluids shall have an inside diameter of not less than 25 mm (1 in.)
7.6.2. Reinforcing pads

Nothing.
7.6.3. Allowable nozzle loads

Nothing.
7.6.4. Manways
a. Manways on towers, regenerators, reactors, fractionators, strippers and vessels where there
are substantial quantities of internals shall be DN 600 (NPS 24).
b. If the tower diameter precludes this, one flanged head is required.
c. Manways shall have a minimum inside diameter of 457 mm (18 in), measured from the
inside surface of the overlay or refractory. Thus, unless the pressure is exceptionally high
or the nozzle is internally clad, it shall be DN 500 (NPS 20).
d. Horizontal drums larger than 70 m3 (2 400 ft3) shall have one manway at each end. Drums
70 m3 (2 400 ft3) and smaller shall have one manway in one end and one DN 150 (NPS 6)
vent, minimum, in shell top at opposite end.
e. Vertical vessels without trays shall have one manway located in bottom section, with one
DN 150 (NPS 6) vent, minimum, in top head of vessel.
f. Fractionating columns shall be provided with manways as follows:
1. One in the base section as low down in the shell as practicable.
2. One above the top tray.
3. One at each reflux tray.
4. One at each feed section.
5. One at each other section that contains internal equipment, other than trays, that is
likely to require inspection or maintenance, e.g. mist eliminator pads or trap-out trays.
6. One spaced at not more than 1 every 6 trays, except that for valve and sieve trays this
may be increased to 10.
g. Access through tray manways both up and down the tower is preferred.
Page 20 of 62
h. In vessels where quantities of coke or other material may be expected to collect at the
bottom, manways shall be provided at the base of the shell to give ready access for
cleaning.
i. A manway shall be provided in any large division plate to permit access to all parts of the
interior of the vessel. If this is not possible, additional manways shall be provided in the
vessel shell.
j. If access to the interior of a vessel cannot be via manways, a minimum of one DN 150
(NPS 6) or larger inspection opening shall be provided. If approved by BP, a piping nozzle
may be used as an inspection opening if piping can be removed. Inspection openings
should be located such that representative shell joints and critical parts of the interior of the
vessel can be inspected.
k. Manways or inspection openings shall satisfy the statutory requirements at the point of
usage. In the absence of such directions, BS 470 may be followed.
l. Adequate nozzles and/or manways shall be provided to meet venting requirements for gas
freeing vessels and ventilation for mechanical work such as welding.
7.6.5. Instrument nozzles

a. Unless otherwise specified, connections for internal-displacement liquid level devices shall
be DN 100 (NPS 4), with ASME PN 50 (Class 300) flanges minimum.
b. Unless otherwise specified, connections for external-displacement liquid level devices
shall be DN 50 (NPS 2), with ASME PN 50 (Class 300) flanges minimum.
7.7. Flanges, gaskets, and bolts
7.7.1. Flanges
a. Nozzles NPS 1-1/4, 2-1/2, 3-1/2, 5, and 9 shall not be used. Class 400 shall not be used.
b. The use of compact flanges shall be subject to approval.
7.7.2. Gaskets
7.7.2.1. Gasket selection - general

The suitability of a particular gasket or joint ring should be established from consideration of
the whole flange assembly, i.e.:
a. Flange type and material,
b. Flange facing and finish,
c. Quantity and type of bolting,
d. Service conditions,
e. Specific requirements on leak tightness for reasons of Health, Safety, or Environment,
f. Limitations on gasket materials e.g., use of asbestos substitutes,
g. Intended bolting up procedure.
Incorrect gasket selection, incorrect tightening procedure, bolts of the wrong
strength (too strong or too weak) relative to the flange, or an incorrectly
proportioned flange ring may lead to leakage.
7.7.2.2. Gasket selection – for specific duties

a. General guidance on the selection of gaskets for different services is provided in Table 1.
Page 21 of 62
Table 1 - Recommended gaskets for different duties
Flange design conditions

Service Max. Max. Flange Gasket selection Comments
Temp. coincident facing
pressure
General hydrocarbon 350°C 40 barg RF Metal jacketed or Tanged
660°F 600 psig graphite sheet
Steam/condensate/ boiler 450°C 250 barg. RF SW with graphite filler
feed water 840°F 3 600 psig
500°C SW with non-graphite filler
930°F
General utilities 250°C 40 barg RF Nitrile rubber based Min. temp.
480°F 600 psig reinforced sheet –40°C (–40°F)
Hydrocarbon/ 500°C 250 barg RF SW with graphite or
Steam/condensate/boiler 930°F 3 600 psig Kammprofile
feed water
High pressure hydrocarbon/ 450°C 150 barg RTJ RTJ Gaskets only made in
steam/boiler feed water 850°F 2 200 psig sizes for piping
Hydrogen 500°C 250 barg RF SW with graphite
930°F 3 600 psig RTJ RTJ Gaskets only made in
sizes for piping
Chemical oxidisers: 180°C 10 barg RF Virgin PTFE
Sulphuric acid 350°F 600 psig
Nitric acid 200°C PTFE envelope
Phosphoric acid/ 400°F
Hydrofluoric acid
260°C PTFE reinforced
500°F
260°C 80 barg SW with PTFE filler
500°F 1 200 psig
Notes:
1. The standard of SW gaskets can vary considerably between manufacturers. Gaskets shall only be obtained from reputable
suppliers.
2. Non-asbestos fibre gaskets should be specified as oil resistant and have a chloride content of less than 100 ppm unless agreed
otherwise.
3. Hardness of RTJ should be less than flange hardness and a minimum difference of 15 HB is recommended. See Table 2 for
hardness values. Consideration should be given to the specification of zinc plated soft iron or carbon steel rings that offer
improved corrosion protection whilst in storage and enhanced protection from external corrosion due to weather. Cadmium
plating is considered to be toxic and should not be specified.
Table 2 - Recommended hardness values for RTJ gasket materials
Flange Material Gasket Material Maximum Brinell Hardness

Carbon steel Soft iron 90
Low carbon steel 120
Low alloy (≤ 5Cr) 5Cr-1/2Mo 130
Low alloy (9Cr) 9Cr 130
Carbon steel
Low alloy (≤ 5Cr)
AISI Types 304, 316, 347 160
Low alloy (9Cr)
AISI Types 304, 316, 321, 347
Alloy 400 Alloy 400 130
b. For flat gaskets, flange faces should be machined to a surface roughness between 3,2 and
12,5 μm (125 – 500 μin) Ra, except where the manufacturer of a selected proprietary
gasket advises otherwise.
Page 22 of 62
c. Flange facings used with SW gaskets should be machined a surface roughness between 3,2
and 6,3 μm (125 – 250 μin).
7.7.3. Bolts
7.7.3.1. Bolt general

a. If austenitic bolting is used with ferritic flanges operating above 204°C (400°F), the
flanges shall not be insulated.
b. Bolt selection where the flanges are in two different materials shall be subject to approval.
c. Electrical insulation may be required at a flange connection (e.g. on material combinations
such as titanium/ duplex, and on cathodically protected systems). The joint assembly shall
be designed to use a central insulating gasket, insulating bolt sleeves and washers, and
steel bolt back-up washers. It shall be subject to approval.
7.7.3.2. Bolt coatings

Nothing.
7.7.3.3. Bolt tightening

Annex Q gives guidance on bolt tensioning.
7.8. Welds
Unless otherwise approved by BP, vessels shall be designed and fabricated with a minimum of
spot radiographic examination.
7.9. Internals
Subject to the agreement of the purchaser, manways in vertical vessels shall be supplemented
with rungs attached to the inside of the vessel shell when other internal fixtures do not afford
suitable safe footing and handholds for persons entering or leaving the vessel.
Guidance on manway rungs is given in GIS 46-020.
7.10. Supports
7.10.1. Skirts
a. Skirts on vessels 2 m (6 ft) or less in diameter shall have at least one access opening. On
vessels with diameters over 2 m (10 ft) and skirt heights over 2,5 m (8 ft), two access
openings may be provided in the skirt.
This allows improved access and ventilation on larger diameter vessels.
b. The minimum access opening shall be 600 mm (24 in) diameter, or 450 mm (18 in) x
900 mm (36 in) obround.
c. Skirts are preferred over lugs.
Skirts provide a more uniform distribution of load to the shell.
d. In essentially non-cyclic service, where the design temperature is in excess of 350°C
(650°F), a hot box shall be provided as shown in Figure 1.
e. In cyclic high temperature services, i.e. where highest temperature in the cycle is greater
than 343°C (650°F), such as coke drums, slots may be used in the vessel skirts to
accommodate thermal expansion. See Figure 2.
Slots relieve some of the thermal stress in the skirt as they permit some flexing.
Page 23 of 62
1. Stress in portions of the skirt between slots may be analysed by assuming the portions
to be flat plates loaded with a uniform load in the plane of the plate.
There are designs without slots.
Figure 1 - Typical hot box at skirt to head attachment on high temperature vessel
H = 20 x SKIRT THICKNESS,
BUT NO MORE THAN 1/2
SUPPORT CLIPS ON
SKIRT HEIGHT
457mm (18 in) CENTRES
OMIT CLIPS W HEN S <
305m m (12 in)
5mm (3/16 in) FILLET W ELD
(BO TH SIDES)
(CLIPS BY VESSEL VENDOR)
6mm (1/4 in)

SKIRT IT
SU
76 TO
(3 m m
in )
S
H/2 BUT NOT LESS
THAN 152mm (6 in)
6mm (1/4 in) SUPPORT RING. TO SUIT (i.e. TO LEAVE A

W IDTH SAM E AS SPECIFIED SMALL GAP 10m m (3/8 in) IN
INSULATION THICKNESS OPERATION)
ELEVATION DETAIL OF CLIP
45
7 229mm
(1 8 m m
in ) (9 in)
HOT BOX DETAIL
PLAN VIEW
Page 24 of 62
Figure 2 - Slotted skirt to head attachment

on high temperature vessel under cyclic temperature loading
TOP OF SKIRT
51mm
(2 in)
R=(1/2)t A
16t
3mm (1/8 in) SLOTS BLEND SMOOTH SKIRT
EQUALLY SPACED ATTACHMENT WELD
AT 15° INTERVALS
RADIALLY AROUND R 5mm A
SKIRT (3/16 in)
m
R 6m n)
4 i
(1/
MIN. 1.6mm (1/16 in)

CHAMFER BOTH SIDES
BLEND WITH RADIUS
AT KEY HOLE
R 6m
(1/4 m
in )
SECTION A-A
7.10.2. Legs or column supports

The use of legs on cylindrical vessels should be limited to vessels less than 1,5 m (5 ft) in
diameter having a height to diameter ratio of 3 or less.
7.10.3. Saddles
Horizontal vessels shall be supported on two saddles only. Slots shall be provided in one saddle
to allow for expansion
Page 25 of 62
7.10.4. Lug supports

Lug supports are preferred for vessels that are supported by structural steelwork.
Lugs are inexpensive and provide easy levelling and shimming of the vessel in the
field. However, due to the eccentricity of the support and the local concentration of
the load, large compressive, tensile, and shear stresses are induced in the wall of the
vessel. The forces and moments cause flexural stresses that combine with the
pressure stresses.
Lug supports are more appropriate for thick-walled vessels because they are
capable of absorbing the flexural stresses due to the eccentricity of the loads. For
thin-walled vessels, a skirt may be more economical.
7.11. External attachments
7.11.1. Insulation supports and details

Nothing.
7.11.2. Fireproofing
a. Directions on fireproofing are given in GP 24-10 for Onshore and GP 24-23 and GP 24-24
for Offshore.
b. Exterior surfaces of skirts supporting towers or vertical vessels containing hydrocarbons
and located within a fire exposed envelope of sufficient duration and intensity shall be
fireproofed.
Details of fireproofing of skirts are given in GIS 46-020.
c. Skirt interior surfaces shall be fireproofed if there are flanges or valves within the skirt or
if there are manway openings greater than 600 mm (24 in) diameter. Skirts of vessels less
d. than 760 mm (30 in) diameter need not be protected on the inside.
e. Pipe penetrations and other small openings shall be plugged if possible. Manways in skirts
shall be left clear and, if necessary, additional reinforcement should be provided around the
periphery of the manway. Vent holes at or near the top of vessel skirt shall be kept clear.
f. Anchor bolts shall be fireproofed unless otherwise specified. Particular attention shall be
paid to the detailing around bolts anchored in epoxy resin, if there is a danger of conducted
heat affecting the anchorage.
g. Brackets or lugs used to attach vertical reboilers or heat exchangers to towers or tower
skirts should be fireproofed. The earthing (grounding) lug should be kept clear of the fire
protection.
h. Elevated exposed legs supporting vessels shall be fireproofed to their full load bearing
height.
i. Steel saddles supporting horizontal vessels that have a diameter of 760 mm (30 in) or
greater, and which have a vertical distance between the concrete pier and the shell
exceeding 460 mm (18 in), shall be fireproofed if within a significant fire envelope.
j. The protection of vessel saddles that have provision for sliding on a bedplate should
include covering the bolts in protective paste or tape or equivalent and keeping the
elongated holes free of concrete. It is important to check before commissioning and
periodically thereafter that the appropriate supports are free to slide.
k. The paint system shall be compatible with the fireproofing system. See NACE publications
6H 189 and RP0198 for further information on the prevention of corrosion under
fireproofing.
Page 26 of 62
l. For vessels up to approximately 2 m (6 ft), a cover may be fitted over the access way to
prevent human entry and ingress of flames. In this case, the inside of the skirt may not
need to be fire proofed.
7.11.3. Nameplates
Nothing.
7.11.4. Manway davits

If practical, stops shall be provided to prevent damage to vessel insulation.
7.11.5. Lifting lugs and trunnions

Removal of lifting lugs after installation eliminates a potential site for corrosion.
a. For vessels in cyclic service or for vessels with a process fluid such that local cooling of
the vessel wall may induce acid dew point corrosion, lifting lugs and stiffeners shall be
removed after installation of the vessel.
b. For vessels in any other service, lifting lugs need not be removed.
c. For an insulated vessel operating at or below 340°C (650°F), the insulation juncture at the
lifting lugs shall be weatherproofed. For an insulated vessel operating above 340°C
(650°F), the lifting lugs shall be covered with a minimum of 25 mm (1 in) thick insulation.
d. In some cases, it may be possible to lift the vessel in by means of the top nozzle.
Calculations of the stresses which apply shall be submitted for approval.
This avoids the need for lifting lugs.
7.11.6. Other fittings

a. Approval to use external stiffeners on vessels subject to thermal cycling, such as coke
drums, shall be obtained from purchaser by the supplier.
External stiffeners in vessels subject to large thermal gradients may lead to cracking
of the shell due to the restraint.
b. Unless otherwise specified by the purchaser, the requirements for vessel auxiliary
structures for maintenance and operation (platforms, walkways, and ladders) shall be in
accordance with GIS 46-020.
c. The location and orientation of vessel appurtenances shall be such that clear access is
provided to permit the use of mobile equipment for the removal and subsequent
reinstallation of vessel internals. Unless otherwise notified, designs should be based on use
of mobile equipment for heights up to 25 m (80 ft).
d. Packed towers, reactors, or driers that require periodic replacement of the packing or
catalyst shall be designed to be serviced by mobile equipment for dumping and loading.
Minimum elevations of dump connections shall provide adequate clearance for dumping
devices or trucks.
7.12. Spheres
a. The design calculations for the sphere should be reviewed by the purchaser.
The design of the legs of spheres is outside code rules and mainly proprietary to the
suppliers. The calculations for this in particular should be requested and reviewed.
b. If the sphere is to be subject to PWHT, a full check on the design for PWHT shall be
carried out.
Spheres have successfully been subject to PWHT.
Page 27 of 62
c. For spherical storage vessels, one manway with a davit shall be provided at the top of the
sphere and one with a hinge at the bottom.
7.13. Pig launchers and receivers

a. It is strongly recommended that pig launchers or receivers should be designed to pressure
vessel rules rather than pipeline rules. There are three main reasons for this:
1. They have developed in complexity and designs, materials, and fabrication
requirements tend to closely resemble those for vessels and not pipelines.
2. They may be subject to significant fatigue loading.
3. They involve human intervention.
b. Interface with the design rules for pipeline shall be addressed by means of an individual
specification prepared by the purchaser.
8. Fabrication
8.1. General
a. When environmental attack is not a concern and PWHT is not required, hardness need not
be checked.
b. Suggested maximum values of macro-hardness in parent plate and welds of ferrous
materials in non-sour service are given in Table 3 for information. They apply to vessels
with and without PWHT and are subject to confirmation by the supplier.
Table 3 – Suggested maximum values of macro-hardness in parent plate and welds
Suggested maximum values of macro-hardness for base material and weld metal
C Mn steels 1 ¼ Cr ½ Mo Other Ferrous Materials
Without PWHT 225HBW (Hv10 238) 225HBW 241HBW
With PWHT 200HBW 215HBW 235HBW
For most vessel fabrications, hardness values are not required for non-sour
applications. However, typical values are provided here for those cases in which
hardness is of significance.
9. Inspection and testing
9.1. Preparation
Nothing.
9.2. Surface examination of welds

Nothing.
9.3. Volumetric examination of welds

X-ray gives a resolution that detects meaningful defects in pressure vessels up to
50 mm (2 in) thick. Gamma radiography only detects gross defects and is not
suitable for pressure vessels.
9.4. Fracture mechanics assessment of weld flaws

a. If specified by the purchaser, samples should be ordered at the time of vessel fabrication so
that fracture mechanics tests can be made. The purchaser should specify the number and
location of the samples.
Page 28 of 62
If a crack-like flaw assessment is likely to be required during the life of the vessel,
samples should be made available during manufacture of the vessel from which
fracture mechanics data may be obtained. Accurate fracture toughness and other
data greatly improve the accuracy of flaw assessment calculations. The tests can be
made either during fabrication or at a later date during operation (perhaps when a
flaw assessment is required).
b. Fracture mechanics tests on either welded or unwelded samples should be made to
BS 7448 Parts 1 – 4 or an equivalent standard.
c. Flaw assessment calculations should be made to either BS 7190 or API 579.
Flaw assessment may be made on both actual defects and on postulated ones. With
the latter, it is possible to use the technique to determine allowable flaw sizes and
therefore set levels for NDE. Conversely, given a known accuracy of NDE, it is
possible to determine whether PWHT is or is not needed. (PWHT greatly reduces
the level of residual stress and allows a much larger permissible flaw).
9.5. Hydrostatic test

a. Procedures for pressure testing field fabricated vessels shall be subject to approval prior to
testing. Such procedures shall describe the locations and types of pressure gauges, the
method to be used to heat the water (if necessary), and safety precautions that will be taken
during the testing.
b. If there is uncertainty over the safety precautions to be taken in pressure testing, whether
for routine applications or for research into explosions, reference shall be made to Pressure
test safety, UK Health and Safety Executive, Contract research report 168/1998 and the
related HSE Guidance Note GS 4, Safety in pressure testing.
9.6. Positive materials identification and datum thickness readings
9.6.1. PMI
PMI shall be specified to be in accordance with GIS 36-103.
Background information on PMI for piping systems is given in API RP 578.
9.6.2. Datum (baseline) thickness readings

Nothing.
10. Internal non-metallic coating or refractory lining
10.1. Non-metallic coating

Internal coating of vessels shall conform to GP 06-63.
10.2. Refractory lining

a. Refractory lining shall not be used to decrease the metal temperature for vessels in
hydrogen service to satisfy the temperature limitation specified in API Publication 941.
b. Refractory linings used to decrease vessel wall metal temperature may be in accordance
with GP 72-00.
c. If a refractory lining is required, details for the design of the shroud or other internal
components shall be specified on the drawings and/or data sheet.
Page 29 of 62
11. External coating
External coating of vessels for corrosion protection shall generally conform to conform to
GP 06-60.
12. Insulation
Thermal insulation of vessels for temperature conservation, personal protection, sound insulation, or
fireproofing shall conform to either GP 52-10.
13. Packing and shipping
Nothing.
14. Documentation
Basic design information and options selected shall be documented on a data form such as
DS 46-010.
Information on inspection documentation for metallic materials is given in
BS EN 764-5.
Page 30 of 62
Annex C
(Normative)
Additional requirements for clad vessels
C.1 General
a. Suppliers should be questioned on their choice of supply route in particular in relation to:
1. Method of cladding.
Large, low pressure clad vessels are generally made from roll clad plate. The
disadvantage of this is that it takes time, early in the contract, to clad the plate and
there is always a risk of disbonding during fabrication. For vessels in which the
base material is above 25 mm (1 in) thick, there are major advantages in cost and
delivery time in cladding the vessel by applying weld overlay to the manufactured
cylinders and heads. Explosion cladding is expensive but is used for materials that
cannot be clad by other means, e.g. titanium onto steel, or for flat plates such as
tubesheets that would distort with weld overlay.
2. Depth of cladding, number of layers, and dilution.
3. Thermal stresses during operation.
4. The need for and feasibility of stress relief.
5. Likely service performance of the cladding material.
6. Risk of disbonding.
7. The need for buffer layers; compatibility of cladding with substrate material.
8. Details of cladding re-instatement.
b. Layered vessels may be considered when a corrosion resistant liner is required in a vessel
designed for such a pressure that it is either impossible or uneconomic to make the vessel
in a conventional way by cladding base plate.
Rules for layered vessels are given only in ASME VIII Divisions 1 and 2. There are
numerous additional points in both manufacture and operation to be considered
when specifying layered vessels.
C.7 Design
C.7.1 General
a. The purchaser shall specify which cladding details are acceptable and which are not.
The way a vessel should be clad depends on: the nature of the cladding material, the
likelihood of significant thermal stress in operation and the methods of NDE that
can be applied to the clad vessel when it is new and when it is in service.
The method of cladding nozzles, particularly small bore nozzles, is an important
detail. Loose liners are generally unsatisfactory because, however well machined
the base material and the liner are, settlement occurs that may crack the welds. The
only exception to this is titanium, in which there is little alternative to a machined
shrunk fit liner and, carefully executed, it may provide a satisfactory cladding.
Note: The legend shown in Figure 1 applies in all the figures in

Annex C.
Page 31 of 62
Figure C.1 – Legend used in the cladding figures in Annex C
UNALLOYED WELD IN ALLOY CLIP ALLOY WELD

MATERIAL UNALLOYED OR LINER
MATERIAL
b. For all cladding materials other than titanium, nozzles shall be made as follows:
1. By weld overlay cladding. See Figure C.2 for the attachment of the nozzle to the
vessel.
2. From roll clad plate. This applies to large nozzles (larger than DN 200 (NPS 8)). See
also Figure C.2 for the attachment of the nozzle to the vessel
3. From solid corrosion resistant material, see Figure C.3. A check should be made of
any thermal stresses that could result from the presence of a solid nozzle in a clad
vessel.
Figure C.2 - Typical clad nozzle attachment to shell
NOZZLE MADE FROM

CLAD PLATE OR WELD
OVERLAID PIPE OR
FORGING
3mm (1/8 in) MINIMUM

THICKNESS
Page 32 of 62
Figure C.3 - Typical attachment of a solid nozzle to shell
SOLID ALLOY
NOZZLE
c. Lightly loaded supports may be considered to be those where the average shear stress
across the section does not exceed 25 MPa (3 625 psi). Moderately loaded are those where
it lies between 25 MPa (3 625 psi) and 50 MPa (7 250 psi), and heavily loaded where it
exceeds 50 MPa (7 250 psi). These stress values are approximate and, where custom and
practice indicates otherwise, designs shall follow satisfactory precedent.
d. The design of attachments shall be as follows:
1. Lightly and moderately loaded internal supports may be welded directly to clad plate
where the plate has been clad by weld overlay.
2. Lightly loaded internal supports may be made by welding directly to clad plate as
shown in figures C.4(a), and C.4(b).
Figure C.4 - Attachment of lightly loaded internals
Figure C.4(a) - Attachment of a lightly loaded clad bar or ring to a clad vessel
CLAD PLATE
CLAD STRIP
Page 33 of 62
Figure C.4(b) - Attachment of a lightly loaded solid bar to a clad vessel
CLAD PLATE OR
WELD OVERLAID
SOLID STRIP
e. The design of moderately loaded attachments shall be as follows:

If thermal stress is negligible, moderately loaded attachments may be made by cutting back
the cladding and welding to the base material. See Figures C.5(a) and 5(b). Cladding re-
instatement shall be made over any remaining unlined areas.
Page 34 of 62
Figure C.5 - Attachment of moderately loaded internals
Figure C.5(a) - Attachment of a moderately loaded clad bar to a clad vessel
CLAD PLATE
CLAD STRIP
Figure C.5(b) - Attachment of a moderately loaded solid bar to a clad vessel
SOLID ALLOY CLIP
STRIP, SHEET OR
WELD OVERLAY
Page 35 of 62
f. Heavily loaded internals where thermal stress is present shall be integral with the shell.
g. Clad flanges shall be raised face as shown in Figure C.6. Clad ring type joints made as
shown in Figure C.7 are not acceptable because these are vulnerable to cracking at the root
of the groove, particularly if thermal stresses are large.
Figure C.6 - Acceptable method for cladding a raised face flange

THICKNESS AFTER
(1/4 in)
6mm
MACHINING
GRIND FLUSH
BORE LINING
Figure C.7 - Cladding the groove for a ring type joint (not-acceptable)

THICKNESS AFTER
MACHINING STANDARD RING
(1/4 in)
6mm
TYPE
GROOVE
GRIND FLUSH
BORE LINING
Page 36 of 62
C.8 Fabrication
C.8.2 Welding
C.8.2.3 Weld procedure and welder qualification

Corrosion testing is rarely required on weld procedure tests other than on duplex
stainless steel (see E.8.2.3.h. in GIS 46-010). For some specific duties, it may be
relevant to material selection and the test to ASTM G48 may be applied.
C.8.2.5 PWHT
The temperature for PWHT of vessels clad with austenitic stainless steel shall be decided taking
into account:
(a) The effect of thermal stresses on the dissimilar joint, e.g. dimensional stability, buckling,
disbonding of cladding.
(b) The importance of maintaining the required strength of the base metal and corrosion
resistance of the cladding.
(c) The importance of minimising the development of undesirable metallic phases, e.g. sigma
phase or precipitation of intergranular chromium carbide (weld decay).
Page 37 of 62
Annex E
(Normative)
Additional requirements for vessels in duplex stainless steel (DSS)
E.6 Material
E.6.3 Mechanical properties

DSS have only moderate elevated temperature capability and their range of use is
much restricted compared with ASS.
A typical limit for 22%Cr duplex is 316°C (600°F) but the limit for any particular application
should be checked with the applicable code.
Page 38 of 62
Annex F
(Normative)
Additional requirements for vessels in high nickel alloys
F.1 General
a. In services where Type 304H SS is required (e.g. on Fluid Catalytic Cracking service) it is
recommended that the carbon content be controlled between 0,04 – 0,08% C.
b. In oxygen service, only Alloy 400 shall be used.
This is because with all other readily available materials, particles striking them
may cause sparks.
Page 39 of 62
Annex G
(Normative)
Additional requirements for vessels in titanium
G.1 General
Titanium shall not be used where methanol could be present in the process. It shall not be used
in conjunction with cupro-nickel or any other material with which it is not galvanically
compatible.
Page 40 of 62
Annex Q
(Normative)
Requirements for bolt tightening
Q.1 Scope
This annex sets down the requirements to ensure joint integrity assurance is achieved and
maintained throughout the life of the equipment being purchased. The requirements apply to all
joints on new pressure vessels.
Q.2 Objective
BP is committed to protecting the environment, assets, and employees.

This commitment requires that bolted joints be tightened in a safe manner using
procedures that reflect best practice to achieve first time leak free tests and
production.
Q.3 Supplier requirements
Q.3.1 Engineering information

Supplier shall provide details of the torque or tension pressures used during the making of the
joints on the pressure vessel during fabrication together with any other related details that may
provide guidance during the service life of the vessel.
Q.3.2 Data to be recorded

The following shall be recorded:
a. Bolt loads, torque values, and/or tensioner type and pressures used to tighten each joint
including any remedial work undertaken as a result of leakage whilst under test.
b. Any special requirements to be observed if it becomes necessary to re-machine one or
more of the flange faces.
Q.4 Related documents/references
ASME PCC-1-2000 Guidelines for Pressure Boundary Bolted Flange Joint Assembly. ISBN
0-7918-2676-7.
NORSOK Standard L-005 – Compact flanged connections. www.norsok.no
UKOOA/IP. Guidelines for the Management of Bolted Pipe Joints. ISBN 1 903003 14 8
Q.5 Qualified technicians
If specified by the purchaser, only operatives trained and examined by a competent instructor in
the use of bolt tightening tools shall carry out the controlled tightening of bolted joints. BP may
require proof of competency.
Guidance for the standards required for skilled performance can be obtained from
the Engineering Construction Training Board (ECITB) in the UK. The ECITB can
also advise on locations of approved training and assessment centres.
Page 41 of 62
Q.6 Joint criticality and selection of tightening method
Q.6.1 General
Before tightening a bolted joint, criticality assessments should be performed.
Allocation of a criticality rating to a joint defines the controls, reviews, and checks
required to minimise the risk of a leak during test, start up, and in service. These are
required to ensure that appropriate levels of resource and materials are allocated to
a joint on the basis of its criticality.
Q.6.2 Selection of tightening method and control of loading

a. After full consideration of the risks involved from potential leakage in service, the joint
tightening method shall be selected taking account of design and service conditions,
mechanical criteria, and past experience.
b. Table Q.1 shall be used to determine a criticality rating based on design, service, and
mechanical criteria. The highest applicable rating should be selected.
c. Table Q.2 shall then be used to select the method for bolting and to determine whether or
not elongation measurement should be considered.
d. In bolt tightening methods, control of the applied load shall be in one of three forms:
1. Manual torque – using calibrated hand wrenches.
2. Hydraulic torque wrenches.
3. Hydraulic bolt tensioners.
e. There are only two acceptable methods for measuring bolt elongation. These are by
ultrasonic measurement of bolt length or by a proprietary bolt with internal measuring
device.
Table Q.2 does not conflict with the more stringent requirements in 7.7.1.e of
GIS 46-010 for flanges that must be designed for bolt tensioning. The flange may be
designed to be suitable for bolt tensioning, but the method used on site is decided
later by others.
f. The use of slug/hand wrenches and impact guns is discouraged.
These methods cannot be controlled and the resultant bolt load can vary
considerably increasing the risk of bolt or flange damage. Further, both methods
have a high incidence record of causing short term and long term injuries to the
user. It is advisable that any impact wrench that exposes the user over an eight hour
period to a vibration magnitude of 2,8 m/sec/sec (9,2 ft/sec/sec) be risk assessed and
ways sought to reduce exposure.
Page 42 of 62
Table Q.1 – Selection of criticality rating for bolted joints
Criteria Rating
Design Temp < 400 F 1
400 F > Temp < 800 F 2
Temp > 800 F 3
Pressure > 750 psig 2
Service Hydrogen or Hydrogen rich 2
Hydrofluoric acid 2
Category D Fluid XX 1
Category M Fluid XX 3
History of leakage 3
Insulated flanges 2
Mechanical Flange diameter ≥ 48” 2
Compact flanges⑴ 3
Clamps 2
Notes:
1. For compact flanges with bolt stress ≥ 70% bolt yield, tightening method shall be
verified.
2. For any body flange where the bolt is larger than 50 mm (2 in), during hydrotesting,
the use of hardened steel washers shall be considered to protect the back of the
flanges from damage.
Table Q.2 – Selection of bolt tightening method
Criticality Tightening method

rating
Bolt Dia ≤ 65 mm (2 ½ in) Bolt Dia > 65 mm (2 ½ in) or Non-
strain hardened austenitic SS bolts
1 Torque tighten Bolt tension only
2(1) Controlled torque or bolt tension Bolt tension only
3 Ultrasonic Elongation with Ultrasonic Elongation with bolt
controlled torque or bolt tensioners tensioners
Note. (1) If controlled torque or tension is unavailable, bolt load shall be verified using ultrasonics.
Q.7 Gasketed joints - bolt load/stress requirements
The objective in tightening bolted gasketed joints is to uniformly compress the gasket to the
correct loading, without rotating the flanges or yielding the bolts. To this end:
a. The supplier shall have responsibility for calculating the correct bolt load for each joint.
Bolt stress relaxation due to temperature can cause the bolts to relax to a load that
results in leakage.
b. The bolt load shall be sufficient to seal both test and design conditions. If appropriate, the
bolt load shall take account of stress relaxation due to the design temperature. In the
absence of alternative data, the following shall be used to estimate the effect of relaxation:
1. The bolt load for operating conditions (i.e. Wm1 in the ASME Code, Section VIII
Division 1, Appendix 2 and PD 5500; Wop in EN 13345 clause 11) shall be calculated
for the design pressure and temperature.
2. An estimate of the initial load required to provide this after stress relaxation shall be
read from Figure Q.1.
Page 43 of 62
3. The value from Step 2 shall be compared with the bolt load for the ambient test
condition and the higher value used for bolt tightening.
c. For guidance, the target bolt stress for SA-193 B7 and B16 bolts for use on flanges
designed per the Taylor Forge method (i.e. ASME Code, Section VIII Division 1,
Appendix 2, PD 5500 or EN 13345 clause 11) shall not exceed 345 MPa (50 000 psi).
d. Target bolt stresses for other bolting materials shall be determined by the formula given
below:
Where:
Sb – target bolt stress, MPa (psi)
W – larger of the minimum required bolt load for:
- the operating conditions (i.e. Wm1 in the ASME Code, Section VIII Division 1, Appendix 2 and
PD 5500; Wop in EN 13345 clause 11). The larger value of the calculated load for design and
test conditions will be used. N (lbs).
- gasket seating (i.e. Wm2 in the ASME Code, Section VIII Division 1, Appendix 2 and
PD 5500; WA in EN 13345 clause 11) N (lbs).
N – number of bolts.
AR – root area of one bolt, mm2 (in2)
Page 44 of 62
Figure Q.1 - Stress relaxation curves
Stress relaxation behavior of various bolting materials showing percentageof initial stress retained at 1000 hours
over a temerature range 0°C to 800°C
Temperature °F
212 392 572 752 932 1112 1292 1472
100
90
80
Residual Stress (% of initial stress)
70
60
50
40
30
20
10
0
0 100 200 300 400 500 600 700 800
Temperature °C
Carbon Steel B7 B16 B8M B8 B17B B80A
With acknowledgement to British Standards Institution: figure taken from BS 4882:1973
Page 45 of 62
Q.8 Required torque
a. It is often possible to identify the coefficient of friction. It is preferred that the value is
identified and a torque value calculated from the known friction factor and required bolt
load.
The coefficient of friction can be a large variable when using torque wrenches.
Lubricant and tightening tool suppliers should provide the data for the coefficient of
friction. BP may wish to specify lubricants (noting the relevant flange and bolt
materials and the design conditions) and state the friction value. Alternatively, the
tightening tool supplier should use lubricant from a manufacturer who has
conducted friction tests to ASTM D271.
b. Unless friction conditions are known accurately, there is no benefit in assuming a complex
relationship between torque and bolt tension.
c. Simplified formulae have been used to generate the predicted torque levels for 345 MPa
(50 000 psi) bolt stress (see Q.6.1.c) shown in Table Q.3. The table tends to be
conservative. Many unknowns including the amount and type of lubrication affect the
torque required to attain a given bolt stress. If bolt elongation measurements indicate that
torque loads given in Table Q.1 are higher or lower than necessary to achieve 345 MPa
(50 000 psi) bolt stress, adjustment should be made.
d. For bolting materials other than SA 193 B7 and B16, final torque values shall be subject to
approval.
Table Q.3 - Bolt torque to develop a bolt stress(1) of 345 MPa (50 000 psi)
Normal bolt Torque kg-m (ft-lbs)

Dia (in) Initial Increment Final (2)
½ 2 (15) 2 (15) 8 (60)
5/8 3 (20) 5 (33) 17 (120)
¾ 5 (35) 8 (55) 28 (200)
7/8 7 (50) 12 (90) 44 (320)
1 11 (80) 18 (130) 65 (470)
1 1/8 14 (100) 26 (190) 93 (670)
1 1/4 16 (120) 36 (260) 125 (900)
1 3/8 21 (150) 48 (350) 165 (1200)
1 1/2 22 (160) 66 (480) 220 (1600)
1 5/8 25 (180) 88 (640) 290 (2100)
1 3/4 25 (180) 115 (840) 370 (2700)
1 7/8 25 (180) 145 (1040) 450 (3300)
2 35 (250) 175 (1250) 550 (4000)
(1) Table assumes bolts are lubricated with an oil-graphite mixture.
(2) Final torque based on 3 equal increments after initial tightening.
Q.9 Compact flanges – bolt load determination
a. Proprietary compact flanges are similar in shape to conventional flanges but designed to be
smaller and lighter for a given set of design conditions. Compact flanges achieve their
compactness by either metal-to-metal flange facing or a pressure energized sealing ring.
See Figure Q.2.
Page 46 of 62
Figure Q.2 - Types of compact flange
Figure Q.2(a) - Metal to metal flange facing
Page 47 of 62
Figure Q.2(b) - Pressure energised ring
Note: the left hand side shows the flanges before tightening; the right hand side shows the tightened flanges with contact at the
outside edge.
b. Both types of flange shall be tightened using the procedures laid down in this annex.
c. Mating surfaces should be protected until immediately before inserting the seal rings and
flange closure.
d. Alignment of flange faces shall be within the manufacturer’s specification, particularly
with large flanges as permissible misalignment tolerances tend to zero.
Compact flanges are less robust than conventional ASME/ANSI flanges. The flange
surfaces affecting the seal need to be maintained and protected. Surface scuff marks
or worse, indentations, almost certainly lead to leaks.
e. Before tightening it is necessary to verify that the bolt load will be achieved.
Pressure energized flanges require moderate bolt stress typically 200 MPa
(30 000 psi) to seal successfully. As the internal pressure increases the gasket
sealing load increases thereby maintaining the seal.
Metal-to-metal faced flanges require high bolt stresses typically 500 MPa
(70 000 psi) to retain a seal on the gasket. The high load reflects the use of smaller
bolting on a reduced pitch circle diameter. Achieving the high bolt stress is crucial
to a successful seal.
Page 48 of 62
d. The requirements for bolt tightening are:

1. Verify the required bolt load/stress from the flange manufacturer.
2. If the required bolt stress is greater than 65% of the nominal yield strength of the bolt
material, the method chosen for tightening the flange shall be verified to ensure that
the correct bolt load can be achieved without risk of yielding the bolts.
3. Bolt tightening vendor shall submit a procedure for approval.
It is very important to ensure that the specified bolt load is achieved. Unlike most
ASME/ANSI flanges, the margin of safety between specified and minimum bolt load
to seal can be less than 1,25, i.e. within the margin of error of some tightening
methods.
Q.10 Clamp connectors
Torque values shall follow the clamp manufacturer’s recommendation. Clamp

connectors are selected (generally for piping connections) because of their low
weight and simplicity. Each of the pipe ends is terminated with a welded hub and a
seal ring is inserted between the hub faces. Closure is achieved by bolting together
two half shells, always by a four bolt arrangement. See Figure Q.3.
Once closure is complete, the clamp is self sealing due to the geometry of the hub
ends and shell faces. Because of this, only a moderate bolt stress is required to close
the clamp up, typically of the order of 200 MPa (30 000 psi). Clamp design does not
vary greatly between manufacturers but recommendations should be obtained from
each specific manufacturer and complied with.
Figure Q.3 - Clamp
Page 49 of 62
Q.11 Preparation for tightening
Q.11.1 Gasketed and compact flanges

Before tightening, the following checks shall be made.
1. Flange faces and bolt holes shall be clean and completely free from rust, burrs, and paint.
2. Gasket surfaces on flange faces shall be machined as per specification. Scratches or
indications shall be removed by methods subject to approval. Grooves for ring joints, in
particular, shall be defect free. Nubbins (see Figure Q.4) shall be machined to the drawing.
Figure Q.4 - Typical nubbin
3. Bolts shall conform to specification and be of correct material, size, and length. They shall
be clean and without burrs. Nuts shall be free running on the bolts.
4. The surface of the flanges where contact is made with the nuts shall be clean, flat, parallel
with the gasket face and completely free from rust or burrs.
This is essential with compact flanges.
5. Gaskets shall conform to specification and be of the correct size. They shall be clean and
metal gaskets shall have grease, rust, and burrs completely removed. Gaskets shall be fitted
against each flange gasket-seating surface to check alignment with the surface.
6. If nuts are to be torqued, only the specified lubricant shall be used and applied evenly to
both the underside nut face (and washers where fitted) and the threads in the portion where
the nut rotates when tightened.
Using the specified and approved lubricant greatly contributes to the accuracy of
the final bolt load achieved.
7. Two bolts shall be installed diametrically opposite each other at 12 and 6 o’clock positions.
A third bolt shall be inserted at a 9 o’clock position midway between the two installed
bolts for retaining the gasket. The nuts shall then be engaged.
8. The gasket shall be inserted, and centred between the flanges. Nuts shall be hand tightened
to hold the gasket in place. If flanged joints are in the vertical plane, gaskets without
centring devices such as ring joint gaskets shall be lowered to the bolts for retention and
then raised into position.
9. Gaskets shall not be held in place with tape during flange alignment. A heavy grease or
gasket cement may be used, if necessary.
Page 50 of 62
10. Alignment tolerances for flange faces prior to bolt-up shall be checked and conform to
suppliers’ requirements.
This is essential with compact flanges.
11. Flanged joints shall be drawn up squarely so that the entire flange face bears uniformly on
the gasket. Four pointing and eight pointing procedures are acceptable for the initial
alignment of joints, provided torque values less than 1/3rd of the final torque value are
used.
12. If the bolts are to be torqued at least two full threads shall protrude above the upper nut
face. If bolts are to be tensioned at least on full diameter of thread length shall protrude
above the upper nut face. Bolts for tensioning shall be arranged to ensure the tools fit.
13. Measurements of the gap between flanges shall be taken around the circumference to
assure that the flanges are being brought evenly together.
14. When assembling large vessels and exchangers, removable covers, channels, or flanges
shall be adequately supported. The pressure bolting shall not be used for this purpose. It
shall be possible to close up the cover or flange unhindered.
Q.11.2 Clamps
Before tightening, the following checks shall be made.
1. Sealing surfaces of the hubs shall be perfectly clean and completely free from scratches,
rust, burrs, corrosion, and other damage before assembly. Scratches or indications shall be
removed by methods subject to approval.
Clamp connectors are particularly sensitive to cleanliness.
2. The seal ring shall be new and conform to specification. All seal ring surfaces shall be
clean and free of defects.
3. A visual inspection shall be made of the seal ring to confirm it has been manufactured by
the same company as the hub parts.
Seal rings from other manufacturers should never be substituted for the original
design as seal rings are not always interchangeable.
4. Before assembly the seal ring shall be placed in the mating hub seat to check the specified
stand off between the ring rib and hub face has been achieved. If no stand off is present the
hub measurement shall be measured. Any deviation shall be rectified after consultation
with the manufacturer.
5. Bolts shall conform to specification and be of correct material, diameter, and length. They
shall be clean and without burrs. Nuts shall be free running on the bolts.
6. Seal rings shall be cleaned before installation using a non-abrasive material. Lubrication
shall be in accordance with the manufacturer’s instructions.
Most seal rings have a coating or plating (cadmium, PTFE or MoS2) which acts as a
lubricant during make up. In some applications where uncoated or unplated seal
rings are used, a light film of clean lubricant will be recommended.
7. The hubs shall be aligned to allow engagement of the seal ring to the hub sealing faces to
ensure correct engagement of the hub and clamp segments.
a. Any misalignment shall be removed by applying external loads to the mating
pipework only after consultation and approval.
b. Removal of misalignment shall not be attempted through use of the clamping force.
c. If external jacks or lifting equipment are used to correct misalignment they shall not
be removed before the clamp is fully assembled and tightened.
Page 51 of 62
8. Only the specified lubricant shall be used and applied evenly to both the underside nut face
and the threads in the portion where the nut rotates when tightened.
Using the specified and approved lubricant greatly contributes to the accuracy of
the final bolt load achieved.
9. Insert the bolts into the clamp lugs. Thread the nuts on ensuring the spherical face of each
nut is located in the spherical seating provided in the lug face.
10. Two full threads shall protrude above each upper nut face.
Q.12 Torque tightening
Q 12.1 Flanges
The sequence for tightening shall follow the criss-cross tightening sequence irrespective of the
torque tool being used. This sequence is described below.
1. The use of hand torque wrenches is approved for torque values of 1 000 N-m (600 ft-lb),
and less. One inch diameter bolts and smaller should be hand torqued whenever possible.
2. The manual or hydraulic torque wrench and pump unit (in particular the gauge) shall each
have a valid calibration certificate for the date of the task. If any of the certificates are
invalid, the wrench or pump unit shall be either be re-calibrated or exchanged.
3. If the joint is to be tightened using controlled torque, tightening shall not begin before a
final torque value is known.
4. If using hydraulic torque wrenches, the size of cassette or square drive shall be suitable for
the required final torque. The selection of the reaction points shall be chosen to prevent
damage to the flange or any local accessories.
5. The correct tightening sequence shall be marked on the studs in a clockwise direction with
chalk or other safe marker according to the number of bolts in the flange. For reference,
this is shown for an eight bolt flange in Figure Q.5(a). Correct numbering of bolts results
in odd numbered bolts around one side of the flange and even numbered bolts around the
other side.
4 Bolt Flange 1-3-2-4
8 Bolt Flange 1-5-3-7-2-6-4-8
12 Bolt Flange 1-5-9-3-7-11-2-6-10-4-8-12
16 Bolt Flange 1-9-5-13-3-11-7-15-2-10-6-14-4-12-8-16
20 Bolt Flange 1-13-5-17-9-3-15-7-19-11-2-14-6-18-10-4-16-8-20-12
28 Bolt Flange 1-13-21-5-17-9-25-3-15-23-7-19-11-27-2-14-22-6-18-10-26-4-16-24-8-
20-12-28
32 Bolt Flange 1-17-9-25-5-21-13-25-3-19-11-31-7-29-15-27-2-18-10-30-6-22-14-26-4-
20-12-32- 8-24-16-28
Page 52 of 62
Figure Q.5 – Sample torque sequence based on 8 bolt flange
Figure Q.5(a) - Figure Q.5(b) - Figure Q.5(c) -

Marked up 1st, 2nd, & 3rd stage 4th & final stage
8 bolt flange criss-cross sequence adjacent bolt sequence
6. Bolts shall be first torqued to 1/3rd the final torque value, using the tightening sequence
specified above. This includes the bolts that were tightened initially in the pre-assembly
procedure. Stud bolts of 5/8 inch and 3/4 inch diameter shall be torqued to 1/2 of the final
torque values on the first pass.
7. The flanges shall never be drawn up tight on one or two bolts only.
This causes local gasket crushing or pinching, which results in leaks.
Flanges shall always be tightened up gradually, using the “criss-cross” pattern shown in
Figure Q.5(b). After each round of tightening, the alignment may be checked, by
measuring the distance between the flange faces.
8. For the second or intermediate pass tightening, all bolts, except 5/8 inch and 3/4 inch bolts
shall be torqued to 2/3rds the final torqued value using the sequence specified.
9. For final pass tightening, two passes shall be made at the final torque setting for all bolts.
This is the 2nd and 3rd pass for bolts 5/8 inch and 3/4 inch in diameter and the 3rd and 4th
pass for larger bolts.
10. Additional passes may be required to ensure the final torque value is achieved in all bolts.
These passes can be made by tightening adjacent bolts in a rotary sequence. See
Figure Q.5(c).
Several passes may be required particularly if an RTJ gasket is fitted.
Q.12.2 Clamps
The sequence for tightening shall follow the criss-cross sequence, see Figure Q.5(b),
irrespective of the torque tool being used.
1. The use of hand torque wrenches is approved for torque values 1 000 N-m (600 ft-lb) and
less. One inch diameter bolts and smaller should be hand torqued whenever possible.
2. The manual or hydraulic torque wrench and pump unit (in particular the gauge) shall each
have a valid calibration certificate for the date of the task. If any of the certificates are
invalid the wrench or pump unit shall be either be re-calibrated or exchanged.
3. If the joint is to be tightened using controlled torque, tightening shall not begin before a
final torque value is known.
This value is usually provided by the manufacturer.
Page 53 of 62
4. If using hydraulic torque wrenches, the size of cassette or square drive shall be suitable for
the required final torque. The selection of the reaction points shall be chosen to prevent
any damage to the clamp or hubs.
5. The bolts shall be tightened in a criss-cross manner using the final torque value. The
position of the clamp segments shall be monitored to ensure that the segments are pulled
up evenly until the final torque value has been applied.
6. The clamp shall be jarred using a soft faced hammer by administering a blow to the back
of each clamp segment. Each bolt should be re-torqued and the process repeated until
applying the final torque load does not rotate any of the nuts further.
7. The hub faces shall be checked to ensure the faces are flush against the seal ring rib and
the gaps between both of the clamp lugs are equal on both sides.
This check confirms the clamp has been correctly installed and that any excess bolt
load has not damaged any of the clamp components.
Q.13 Tightening using hydraulic bolt tensioners
Bolt tensioners hydraulically stretch a bolt to a pre-defined strain, allowing the nut to be
manually rotated onto the flange face. The pressure is then released retaining a known and
calculable bolt load.
a. The contractor used for the work and procedures and pump pressures shall be subject to
approval.
b. The bolts shall be specified to ensure a minimum engagement of at least 80% thread
length. This requires the bolts to be at least one diameter longer than the equivalent bolts if
torque is used.
c. The hydraulic pump unit (in particular the gauge) shall have a valid calibration certificate
for the date of the task. If the certificates are invalid the pump unit shall be either be re-
calibrated or exchanged.
d. The tensioners shall be hydraulically connected together and pressurised using one pump.
1. Ideally, all bolts in the flange shall be tensioned simultaneously.
2. The next alternative is to tension half the bolts in the flange at one time. This is
usually the most commercially acceptable option often referred to as ‘50%
tensioning’. The procedure outlined below is based on this option.
3. In no case shall less than four tensioners be used simultaneously.
4. Whatever the quantity of tensioners used they shall always be equally spaced around
the flange.
e. Unless all the bolts are to be tensioned simultaneously, two different pressure settings are
required.
1. The first pass is generally performed at a pressure (often known as ‘Pressure A’)
designed to over-tension the bolts in recognition that some further bolt load is lost as
adjacent bolts are tensioned.
2. Subsequent passes are conducted at a lower pressure (often referred to as
‘Pressure B’), calculated to produce the required minimum residual bolt stress when
the joint is tight.
3. Additional passes should be performed at this lower pressure until the nuts remain
tight when this pressure is applied to the tensioning equipment.
Specialist contractors may provide further guidance in order to minimise the
number of passes required.
Page 54 of 62
f. The tensioner shall be attached in the following manner. Dependent on the orientation,
additional support or lifting equipment may be required to attach the tools safely.
Several variants of tensioner exist. The procedure outlined below is based on the
most common variant which is usually available for hire as well as purchase.
1. The tensioner socket is positioned over the nut.
2. The tensioner body and bridge are lowered over the stud and nut assembly.
3. Lower the tensioner until the base rests squarely on the flange surface.
4. The puller bar is threaded onto the stud bolt until it “bottoms out” on the tensioner
piston.
5. The above is repeated until all the tensioners have been attached.
g. The hydraulic harness is connected so that each tensioner is included and a ring main is
formed which in turn is connected to a hydraulic pump.
h. The bolts are then tensioned in the following manner:
1. Pressurise the tensioners to the higher pressure (Pressure A).
Throughout this and all pressurisations care should be taken to ensure the maximum
stroke of any of the tensioners is not exceeded.
2. Whilst retaining the pressure in the harness, all the sockets are rotated using a tommy
bar until all the nuts are seated on the flange face. The pressure is released.
3. The pressurisation is repeated twice more. Each time the nuts should rotate a little
further.
This ensures most of the nut flange face embedment losses are removed.
4. The tensioners are removed and attached to the next set of bolts, hydraulically
connected to the pump and pressurised using the lower pressure (Pressure B).
5. Whilst retaining the pressure in the harness, all the sockets are rotated using a tommy
bar until all the nuts are seated on the flange face. The pressure is released.
6. The pressurisation and nut rotation are repeated twice more. The tensioners are
removed.
i. Each bolt has now been tensioned, but bolt load has been lost in the first set of bolts
tensioned as a result of tensioning the second set.
1. To check that sufficient load has been retained a tensioner is attached to one of the
bolts tensioned in item h.1. and the tool pressurised until the nut can be rotated off the
flange face. If the pressure recorded is below the ‘Pressure B’ value then both sets of
bolts shall be re-tensioned using the ‘Pressure B’ value and a further pressure load
check carried out.
The number of tool passes required reflects the gasket fitted. Hard gaskets, e.g.
SWG with rings fitted, tension with few passes while soft gaskets, such as RTJs, can
require several passes. Maximising the safe differential between the two pressures
also reduces the number of passes.
2. This process shall continue until the pressure load check gives a pressure equal to or
in excess of ‘Pressure B’. Once this is satisfied the joint is complete.
Q.14 Prevention of yielding with low strength bolts, e.g. stainless steel
Most equipment requires a bolt stress of c. 25 000 psi (i.e. 83% yield.) so the risk of
yielding if not using controlled bolt tightening is high. If a leak develops, the natural
Page 55 of 62
tendency is to increase the bolt load and at this point that the bolts may be taken
into yield. Suggestions to avoid the bolt yielding are:
• Always specify Class 2 bolting - this gives a benefit up to 1 ½ on bolts.
• Consider using slave bolting (BP have done this in the past.) In this procedure
lubricated B7 bolts are used to tighten the joint, usually with bolt tensioners.
Thereafter each bolt is removed, one at a time, and the B8 bolt torqued in to
replace it. The torque value used is determined using the torque setting required
to break each B7 bolt out.
• Calibrate the tightening method - in a similar way to that recommended in Q.9.d
for compact flanges.
• For large bolts consider using ASTM A453 Grade 660B.
Q.15 Measurement of elongation
Q.15.1 Ultrasonic elongation measurement

a. The amount of elongation of the stud required to achieve the desired tension in the stud
should be determined by use of the following formula:
Where:
D = Elongation of the stud
E = Modulus of elasticity
σ = Target Bolt Stress
LE = Effective bolt length
Figure Q.6 - Dimensions for determining bolt elongation
b. To calculate LE, determine lengths L and H as shown in Figure Q.6. Then, LE = L + 2/3 x
H.
c. Elongation is determined by measuring the length of the stud before and after the tensile
load is applied to the stud.
d. A log of measurements taken for initial lengths and any subsequent elongations shall be
recorded and provided to the purchaser.
e. For the second to last torquing/ tensioning setting, elongation shall be checked to
determine if the final torque or tension setting is appropriate. Adjustments to the final
setting may be required depending on the elongations measured.
Page 56 of 62
f. A minimum of 25% of the bolts shall be checked after final loading for each joint that is to
be ultrasonically controlled. If only a sampling (25%) of the bolts is measured, sample
bolts shall be chosen from the same quadrant on the flange.
g. The acceptance criteria for final elongation measurements shall be ± 15% of the targeted
elongation, unless otherwise specified. If the average measured value is close to the
targeted value but the scatter is not within the ±15% limit, additional passes are required at
the same load setting.
h. Measurements from the bolt gauge shall be repeatable. A number of readings shall be
taken showing consistent values before entering them on to the Data Sheet. Bolt gauges
shall be calibrated before each new application by an experienced operator.
Q.15.2 Proprietary bolts with integral load measuring

Bolts with integral load measuring devices shall be used if specified by the purchaser.
Bolts with integral load measuring devices are used in BP plants and give sufficient
accuracy to control the loading of flanges where leakage is a concern.
Q.16 Safety
a. Risk Assessments shall be undertaken according to approved supplier procedures.

b. Assessment of all potential hazards shall be made and identification of suitable measures to
mitigate the hazard. Supplier shall reduce risk in line with the ALARP principle of “As
low as reasonably practicable”.
c. A risk assessment shall be required for each tool type and each activity if the activities
differ.
d. Confirmation shall be given that all operatives have been informed and understand the
measures to be implemented.
Powered bolt tightening tools and manual slug wrenches generate large forces so a
safe system of work must be devised and used at all times.
Page 57 of 62
Annex AA
(Normative)
Requirements for vessels to the ASME Code
AA.1 General
The ASME U and U-2 stamps are quality assurance schemes comparable to ISO 9000. The
supplier is regularly audited and, providing his systems pass the audit, he is permitted to
manufacture without the attendance of an outside inspector. Some countries, states, or operating
sites require the system to be applied on major vessels but otherwise it is optional.
The ASME code is not harmonised and for compliance to the PED, a Notified Body
must confirm that it meets the Essential Requirements of the PED.
AA.6 Materials
a. MDMT shall be the lowest expected metal temperature at the operating location.
1. In determining MDMT, start-up, shutdown, and upset temperatures shall be taken into
account. If these conditions apply, the operating manual for the unit shall specifically
address these procedures.
2. Typically, the MDMT can be set at a temperature so that the coincident pressure
during the start-up and shut-down conditions is equal to or less than 25% of the
design pressure.
b. The MDMT can be determined by computation or by measurement from equipment in
service under equivalent operating conditions.
c. If controlled start-up and shut-down procedures do not determine MDMT and the process
design conditions do not result in special coding effects, the MDMT shall be set to the
lowest expected metal temperature for the site.
d. When specifying MDMT, the pressure coincident with the MDMT shall be specified.
UCS-65 through UCS-68 of ASME BPVC, Section VIII, Division 1, shall be used to
determine the coincident MDMT at pressure.
e. For vessels constructed to Division 1, the MDMT stamped on the vessel nameplate shall be
established as the minimum permissible value based upon the selected material
specification and furnished thickness. The ratio of required thickness to furnished
thickness less corrosion allowance as given in paragraph UCS-66(b) of this Code shall be
1,0 for the design condition that governs the vessel wall thickness calculation.
AA.7 Design
AA.7.1 General
Maximum allowable working pressure (MAWP) shall be calculated by the supplier and shown
on the drawings.
AA.7.2 Division 1
Intermediate heads shall be installed with 3 mm (1/8 in) additional corrosion allowance for fillet
seal weld per paragraph UW-13(b). Liquid service for this type vessel shall be avoided and shall
be used only if approved by BP. Intermediate heads, attached by fillet welds, shall have the
welds magnetic particle or liquid penetrant examined.
Page 58 of 62
AA.7.3 Division 2
Whether or not fatigue calculations have to be made is determined by rules given in AD-160.
AA.8 Fabrication
AA.16 Division 3
a. Division 3 applies to vessels designed for 70 MPa (10 000 psi) or above. It is limited to
certain materials and therefore the purchaser shall thoroughly review proposed materials.
b. Design by analysis predominates. Advanced methods of design and design methods based
on fracture mechanics are included. The results of such analyses shall be critically
reviewed by the purchaser. Article KD-3 contains an extensive fatigue design method.
Page 59 of 62
Annex BB
(Normative)
Requirements for vessels to PD 5500
BB.1 General
PD 5500 is not a harmonised standard and a Notified Body must confirm that it meets the
Essential Requirements of the PED. Guidance on where PD 5500 conforms to the PED is given
in Annex Z of PD 5500.
BB.6 Materials
a. The method in Annex D for autorefrigeration provides different allowable minimum

temperatures when the membrane stress is:
1. Equal to or greater than 2/3 of the nominal design stress,
2. Less than 2/3 of the nominal design stress but greater than 50 MPa,
3. Less than 50 MPa.
b. A graph may be plotted showing the envelope of acceptable pressure and temperature, and
the design shall lie within this envelope.
Page 60 of 62
Annex CC
(Normative)
Requirements for vessels to BS EN 13445
CC.1 General
BS EN 13445 is a harmonised standard and presumed to have conformity with the PED, without
particular approval by a Notified Body.
CC.6 Materials
The method in Annex D for autorefrigeration provides allowable minimum temperatures for
stress levels of F, 2/3F, and 50 MPa. Therefore a graph may be plotted showing the envelope of
acceptable pressure and temperature. The design shall lie within this envelope.
CC.7 Design
CC.7.1 Component design

BS EN 13445 introduces the useful terms ‘calculation pressure’ and ‘calculation
temperature’ for the design of individual components.
CC.7.2 Alternative flange design method

The flange method in Annex J is novel and permits thinner flanges when an accurate
bolt tensioning method such as hydraulic bolt tensioning is used.
CC.7.3 Pressure relief systems

BS EN 764-7 shall be considered for the design of pressure relief systems.
Page 61 of 62
Bibliography
[1] BP Corrosion and Materials Guidelines 2001: Report No. S/UTG/309/01, Corrosion Under Insulation,
A Guide to the Prevention and Detection of Corrosion Beneath Thermal Insulation.
[2] BS DD CEN/TS 764:2004 Pressure equipment Part 6: Structure and content of operating instructions
(draft).
[3] Directive 97/23/EC Pressure Equipment.
[4] Pressure Equipment Directive, Presentation by R. McFarlane and E. Smith, BP EPTG.
[5] ASTM D271, Standard Test Method for Calibration and Operation of a block-on-ring testing machine.
Page 62 of 62

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BP DOC NUMBER - GP-46-01 REV A

Document No. GP 46-01

Guidance on Practice for

11. External coating ................................................................................................................... 30

Table 1 - Recommended gaskets for different duties .................................................................... 22

Figure C.2 - Typical clad nozzle attachment to shell ..................................................................... 32

American Petroleum Institute (API)

American Society for Testing and Materials (ASTM)

American Society of Civil Engineers (ASCE)

American Society of Mechanical Engineers (ASME)

GP 30-76 Safety Instrumented Systems – Process Requirements Specification.

British Standards Institute (BSI)

The Engineering Equipment and Materials Users Association (EEMUA)

International Organization for Standardization (ISO)

Institute of Petroleum (IP) – Energy Institute

International Code Council (ICC)

Liquid Petroleum Gas Association (LGPA)

NACE International (NACE)

sour water, wet H2S or wet sour service

4. Symbols and abbreviations

ASS austenitic stainless steel

CUI corrosion under insulation

DSS duplex stainless steel

LPG liquefied petroleum gases

MOP maximum operating pressure

MDMT minimum design metal temperature

NDE non-destructive examination

PED Pressure Equipment Directive (see Bibliography)

PWHT post weld heat treatment

PT liquid or dye penetrant testing

RTJ ring type joint

SW spiral wound gasket

5. Introduction, codes, legislation and quality assurance

5.3.3. In the Rest of the World

5.4. Quality Assurance

6.1. Process specific requirements

6.1.2. Sour water, wet H2S service or wet sour service

6.1.3. Amine service

6.1.4. Hydrogen service

6.1.5. Hydrogen service with hydrogen sulphide

6.1.6. High temperature hydrogen sulphide

6.1.8. Caustic service (sour or non-sour)

6.1.9. Hydrofluoric acid

6.1.10. Propane and butane storage spheres

6.1.11. Low temperature service

6.1.12. Wet CO2 service

6.1.13. Acetylene service

6.1.14. Duties in which Polythionic Acid may be present during shutdown

7.1.1. Corrosion allowance

7.1.2. Hydraulic testing

7.1.3. Design by analysis

7.1.4. Experimental design verification

7.1.5. Cyclic service

7.1.6. Requirements specific to different process duties

7.1.6.1. Two and three phase separators

1. Residence time requirements.

7.1.6.2. LPG Installations

7.1.7. Minimum heat loss

7.1.8. Pressure relief systems