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1、TECHNICAL SPECIFICATION GLASS-LINED STEEL EQUIPMENT AND PIPING DEP 30.48.70.30-Gen. July 1998 DESIGN AND ENGINEERING PRACTICE This document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of Shell International Oi
2、l Products B.V. and Shell International Exploration and Production B.V., The Hague, The Netherlands. The copyright of this document is vested in these companies. All rights reserved. Neither the whole nor any part of this document may be reproduced, stored in any retrieval system or transmitted in a
3、ny form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owners. PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of: Shell International Oil Products B.V. (SIOP)
4、 and Shell International Exploration and Production B.V. (SIEP) and Shell International Chemicals B.V. (SIC) The Hague, The Netherlands, and other Service Companies. They are based on the experience acquired during their involvement with the design, construction, operation and maintenance of process
5、ing units and facilities, and they are supplemented with the experience of Group Operating companies. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice. The objective is to set the recommended standard for good design and enginee
6、ring practice applied by Group companies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such facility, and thereby to achieve maximum technical and economic benefit from standardization. The information set forth in these publicati
7、ons is provided to users for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual operating companies to ad
8、apt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements no
9、t specifically covered, the Principal will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Pri
10、ncipal or its technical advisor. The right to use DEPs is granted by SIOP, SIEP or SIC, in most cases under Service Agreements primarily with companies of the Royal Dutch/Shell Group and other companies receiving technical advice and services from SIOP, SIEP or SIC. Consequently, three categories of
11、 users of DEPs can be distinguished: 1)Operating companies having a Service Agreement with SIOP, SIEP, SIC or other Service Company. The use of DEPs by these Operating companies is subject in all respects to the terms and conditions of the relevant Service Agreement. 2)Other parties who are authoriz
12、ed to use DEPs subject to appropriate contractual arrangements. 3)Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users com
13、ply with the relevant standards. Subject to any particular terms and conditions as may be set forth in specific agreements with users, SIOP, SIEP and SIC disclaim any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of
14、 or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof. The benefit of this disclaimer shall inure in all respects to SIOP, SIEP, SIC and/or any company affiliated to these companies that may issue DEPs or require the use of DEPs. Without pr
15、ejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of SIOP and SIEP, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they hav
16、e been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of SIOP and SIEP. The copyright of DEPs vests in SIOP and SIEP. Users shall arrange for DEPs to be held in safe custody and SIOP or SIEP may at
17、 any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative queries should be directed to the DEP Administrator in SIOP. NOTE: In addition to DEP publications there are Standard Specifications and Draft DEPs for Development (DDDs)
18、. DDDs generally introduce new procedures or techniques that will probably need updating as further experience develops during their use. The above requirements for distribution and use of DEPs are also applicable to Standard Specifications and DDDs. Standard Specifications and DDDs will gradually b
19、e replaced by DEPs. DEP 30.48.70.30-Gen. July 1998 Page 2 TABLE OF CONTENTS 1.INTRODUCTION.4 1.1SCOPE 4 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS4 1.3DEFINITIONS 4 1.4CROSS-REFERENCES4 2.MATERIALS 5 2.1BASE METAL 5 2.2GLASS LINING5 2.3GASKETS 6 3.MANUFACTURE AND PRODUCTION TESTING7
20、 3.1GENERAL 7 3.2EQUIPMENT (VESSELS, REACTORS, COLUMNS ETC.)10 3.3PIPING COMPONENTS13 3.4HYDROSTATIC TESTING14 3.5ROTATING EQUIPMENT15 4.INSPECTION BY THE PRINCIPAL16 5.PAINTING 17 6.RECORDS AND CERTIFICATION.18 7.TRANSPORT19 7.1SEALING, SUPPORTING AND PACKING.19 7.2ANTI-CORROSION PROTECTION19 7.3AR
21、RIVAL INSPECTION19 8.INSTALLATION20 8.1GENERAL 20 8.2LIFTING. 20 8.3MARKING 20 8.4STORAGE. 20 8.5LEVELLING. 20 8.6CONNECTIONS20 8.7INSPECTION.21 9.OPERATION.22 9.1START UP. 22 9.2THERMAL SHOCK22 9.3ACID SPILLS.22 9.4ELECTROSTATIC DISCHARGE22 9.5STEAM HAMMER.22 10.MAINTENANCE23 10.1VESSEL ENTRY23 10.
22、2INSPECTION.23 10.3REPAIRS. 23 10.4WELDING 23 10.5CLEANING OF THE JACKET SPACE23 11.REFERENCES24 APPENDICES APPENDIX 1GLASS LINING DEFECTS.26 APPENDIX 2REPAIR METHODS.28 APPENDIX 3DIMENSIONAL TOLERANCES FOR PIPING.31 DEP 30.48.70.30-Gen. July 1998 Page 3 1.INTRODUCTION 1.1SCOPE This new DEP specifie
23、s requirements and gives recommendations for the manufacture, inspection and supply of equipment, ancillaries and piping components made of glass lined carbon steel. Installation, operation and maintenance aspects are also included in the scope of this DEP. 1.2DISTRIBUTION, INTENDED USE AND REGULATO
24、RY CONSIDERATIONS Unless otherwise authorised by SIOP and SIEP, the distribution of this DEP is confined to companies forming part of the Royal Dutch/Shell Group or managed by a Group Company, and to Contractors and Manufacturers/Suppliers nominated by them (i.e. the distribution code is “F“, as def
25、ined in DEP 00.00.05.05-Gen.). This DEP is intended for use in chemical plants and, where applicable, in oil refineries and gas plants. If national and/or local regulations exist in which some of the requirements may be more stringent than in this DEP, the Contractor shall determine by careful scrut
26、iny which of the requirements are the more stringent and which combination of requirements will be acceptable as regards safety, environmental, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to
27、 be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned with the object of obtaining agreement to follow this DEP as closely as possible. 1.3DEFINITIONS 1.3.1General definitions The Contractor is the party which carries
28、 out all or part of the design, engineering, procurement, construction and commissioning or management of the project or operation of a facility. The Principal may sometimes undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party which manufactures or supplies e
29、quipment and services to perform the duties specified by the Contractor. The Principal is the party which initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal may also include an agent or consultant,
30、 authorised to act for, and on behalf of the Principal. The word shall indicates a requirement. The word should indicates a recommendation. 1.3.2Specific definitions Glass lining-the process of producing an intimately bonded glass layer onto a base material. In industrial applications, this is also
31、known as “enamelling“ and “vitreous enamelling“. 1.4CROSS-REFERENCES Where cross-references to other parts of this DEP are made, the referenced section number is shown in brackets. Other documents referenced by this DEP are listed in (11). DEP 30.48.70.30-Gen. July 1998 Page 4 2.MATERIALS 2.1BASE ME
32、TAL 2.1.1General As glass lining properties are influenced by the chemical composition of the steel, special glass lining steel qualities have been developed in co-operation between glass lining and steel Manufacturers. Generally, fine-grained carbon steels are used. Steels having a tensile strength
33、 of more than 480 MPa should not be glass-lined due to the increased risk of stress-induced glass lining failures at highly stressed areas. 2.1.2Welding and welding materials Welded equipment items shall be fully normalised before the glass lining process, in order to remove stresses that may cause
34、deformation during the high temperature firing cycles of the glass lining process. Normal post-weld heat treatment (stress relieving) is not sufficient. 2.2GLASS LINING The glass lining shall consist of a number of subsequent layers, i.e. one or more ground coats to provide a good bond to the steel
35、substrate and various top coats to provide the required chemical or mechanical resistance. The glass lining shall be applied by the wet spraying, wet pouring or dual spray/dust method. Powder dusting shall be limited to local patch-ups only. The service life of glass linings in corrosive service is
36、mainly determined by the thickness ratio of ground coat(s) to topcoats as only the latter are the real anti-corrosion barrier. Ground coat(s) shall, therefore, not constitute more than 40% of the total thickness and shall not be more than 0.6 mm in thickness. The Principal shall indicate the type of
37、 chemicals and the intended service of the equipment or piping ordered. The Manufacturer shall indicate and confirm the type, quality and properties of the glass linings applied for the specified service. 2.2.1Chemical resistance requirements 2.2.1.1Resistance to acids A representative sample of the
38、 glass lining shall not show any porosity and the weight loss shall not be more than 0.50 g/m2per 24 h (approximately 0.08 mm/yr) at the condensate- facing surface after having been tested in accordance with ISO 2743. The absence of porosity after the test shall be verified with a high voltage direc
39、t current spark test set at 10 kV. 2.2.1.2Resistance to alkalis A representative sample of the glass lining shall not show any porosity and the weight loss shall not be more than 2.50 g/m2per 24 h (approximately 0.4 mm/yr) after having been tested in accordance with ISO 2745. The absence of porosity
40、 after the test shall be verified with a high voltage direct current spark test set at 10 kV. 2.2.1.3Resistance to boiling water and water vapour A representative sample of the glass lining shall not show any porosity and the weight loss shall not be more than 0.30 g/m2per 24 h in the vapour phase a
41、fter having been tested in accordance with ISO 2744 The absence of porosity after the test shall be verified by a high voltage direct current spark test set at 10 kV. 2.2.1.4Resistance to high temperature corrosion Representative samples of the glass lining shall not show any porosity and the weight
42、 loss DEP 30.48.70.30-Gen. July 1998 Page 5 shall not be more than 2.25 g/m2per 24 h after having been exposed to 20%wt HCl at 40 C for 24 hours and not more than 3.00 g/m2per 24 h after having been exposed to 0.1 N NaOH at 140 C for 24 hours in accordance with DIN 51174.The absence of porosity afte
43、r the tests shall be verified by a high voltage direct current spark test set at 10 kV. 2.2.2Physical properties requirements 2.2.2.1Resistance to thermal shock Representative samples of the glass lining shall be tested in accordance with DIN 51167. The crack formation limit shall be at least 210 C.
44、 2.2.2.2Resistance to mechanical shock Representative samples of the glass lining shall be tested in accordance with DIN 51155. The absorbed energy shall be at least 70 Nm. 2.2.2.3Freedom from pores Representative samples of the glass lining shall be tested in accordance with ISO 2746 or ASTM C 537.
45、 At the set test conditions, i.e. with a dry and clean glass lining surface and at ambient temperature (not higher than 30 C) and a voltage of 20 kV, there shall be no indications of pores. 2.2.2.4Lining thickness Representative samples of the glass lining shall be tested in accordance with ISO 2808
46、 and shall comply with (3.1.4.1). 2.2.3Test requirements and results Test samples shall be made fully in accordance with the normal manufacturing processes, i.e. with the same number and thickness of ground and cover coats, and the same firing temperatures and sequences. NOTE:Firing temperatures and
47、 sequences may need adaptation to suit the metal mass. Samples used in any of the above tests (2.2.1, 2.2.2) shall be visually inspected before being tested. They shall show a homogeneous glass lining structure and be free from inclusions (chamotte and iron oxide) or any defects. 2.2.4.Exceptions Gl
48、ass lining types solely intended for prevention of product build-up and/or product contamination shall be clearly distinguished by type indications (code numbers). For such types, the Principal may consider an adapted test programme and/or less stringent test results. For particular services (erosiv
49、e, mechanical or thermal shock) and odd-shaped items, the use of semi-crystalline glass may be considered. The Manufacturer shall indicate his intentions to apply this and an adapted test programme shall be agreed between the Principal and the Manufacturer. 2.3GASKETS Gaskets shall be 100% bi-axially expanded PTFE with ultra-high molecular weight fine powder resin, without binders or fillers. DEP 30.48.70.30-Gen. July 1998 Page 6 3.MANUFACTURE AND PRODUCTION TESTING Production testing is the testing of glass-lined items on a specific order. Depending on the type, number, intended service a
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