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1、TECHNICAL SPECIFICATION EQUIPMENT MADE OF 2.25 Cr-1 Mo STEEL IN QUENCHED AND TEMPERED CONDITION W-6-1/2/3 December 1984 DESIGN AND ENGINEERING PRACTICE USED BY COMPANIES OF THE ROYAL DUTCH/SHELL GROUP This document is confidential. Neither the whole nor any part of this document may be disclosed to
2、any third party without the prior written consent of Shell Internationale Petroleum Maatschappij B.V., The Hague, the Netherlands. The copyright of this document is vested in Shell Internationale Petroleum Maatschappij B.V., The Hague, the Netherlands. All rights reserved. Neither the whole nor any
3、part of this document may be reproduced, stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owner. PREFACE DEP (Design and Engineering Practice) publications refle
4、ct the views, at the time of publication, of: Shell International Oil Products B.V. (SIOP) 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 du
5、ring their involvement with the design, construction, operation and maintenance of processing 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
6、 of practice. The objective is to set the recommended standard for good design and engineering 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 technic
7、al and economic benefit from standardization. The information set forth in these publications 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
8、DEPs is expected to be sufficiently flexible to allow individual operating companies to adapt 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
9、of the required design and engineering standards. In particular, for those requirements not 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 Ma
10、nufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal 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 receivi
11、ng technical advice and services from SIOP, SIEP or SIC. Consequently, three categories of 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 th
12、e terms and conditions of the relevant Service Agreement. 2)Other parties who are authorized 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 pr
13、ojects, materials supplied or - generally - work performed on behalf of the said users comply 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 dama
14、ge (including injury or death) suffered by any company or person whomsoever as a result of 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 compan
15、y affiliated to these companies that may issue DEPs or require the use of DEPs. Without prejudice 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 p
16、erson whomsoever and the DEPs shall be used exclusively for the purpose for which they have 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
17、 and SIEP. Users shall arrange for DEPs to be held in safe custody and SIOP or SIEP may at 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 t
18、o DEP publications there are Standard Specifications and Draft DEPs for Development (DDDs). 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 applica
19、ble to Standard Specifications and DDDs. Standard Specifications and DDDs will gradually be replaced by DEPs. W-6-1/2/3 December 1984 Page 2 TABLE OF CONTENTS 1.INTRODUCTION.5 1.1GENERAL 5 1.2DEFINITIONS 6 2.MATERIALS 7 2.1BASE MATERIAL: PLATE.7 2.1.1Chemical composition.7 2.1.2Heat treatment.7 2.1.
20、3Mechanical properties7 2.1.4Ultrasonic testing of plate material8 2.1.5Repair welding.8 2.1.6Plate thickness.8 2.1.7Marking and certification8 2.2BASE MATERIAL: FORGINGS.9 2.2.1Non-pressure parts9 2.2.2Pressure parts.9 2.2.3Ultrasonic testing.10 2.3CLADDING AND INTERNALS11 3.FABRICATION12 3.1FORMIN
21、G AND ASSEMBLY.12 3.2WELDING 14 3.2.1General 14 3.2.2Plate welding procedure qualification14 3.2.3Overlay welding procedure qualifications15 3.3PREHEAT AND INTERPASS TEMPERATURE.17 3.3.1Base metal welds.17 3.3.2Overlay welds17 3.4POST-WELD HEAT TREATMENTS.18 3.5FABRICATION TOLERANCES.19 4.PRODUCTION
22、 TESTS AND NON-DESTRUCTIVE TESTING 20 4.1MECHANICAL TESTING OF MATERIAL AND WELDS.20 4.2RADIOGRAPHIC EXAMINATION.21 4.3ULTRASONIC EXAMINATION21 4.4MAGNETIC PARTICLE EXAMINATION.22 4.5DYE-CHECK EXAMINATION OF WELD OVERLAY22 4.6HARDNESS MEASUREMENTS.22 4.7CHEMICAL ANALYSIS23 4.7.1Base metal weld23 4.7
23、.2Overlay weld 23 4.8HYDROSTATIC TESTING24 5.REPAIRS. 25 6.INSPECTION.26 7.DRAWINGS AND REPORTS27 7.1PREPARATION OF MANUFACTURERS DRAWINGS.27 7.2DISTRIBUTION AND APPROVAL OF DRAWINGS.28 7.3VESSEL REPORTS AND DATA SHEETS28 8.CLEANING AND SHIPPING.29 9.GUARANTEE30 10.REFERENCES31 11.APPENDICES33 APPEN
24、DICES APPENDIX 1EXAMPLE OF SKIRT ATTACHMENT.34 W-6-1/2/3 December 1984 Page 3 APPENDIX 2POSITION OF HEAT TREATMENT PRODUCTION TEST PLATE35 APPENDIX 3POSITION OF PRODUCTION WELD TEST PLATE36 W-6-1/2/3 December 1984 Page 4 1.INTRODUCTION 1.1GENERAL This specification contains minimum requirements for
25、the material, fabrication, production tests and non-destructive testing of equipment for hydrogen service, fabricated from 2.25 Cr - 1 Mo steel with or without austenitic stainless steel cladding. It is intended for use in oil refineries, chemical plants, gas plants and, where applicable, in explora
26、tion, production and new ventures. Unless otherwise authorized by SIPM, the distribution of this specification is confined to companies belonging to or managed by the Royal Dutch/Shell Group, and to contractors and manufacturers/suppliers nominated by them. As a rule the requirements of this specifi
27、cation shall be adhered to. However, national and/or local regulations may exist in which some of the requirements are more stringent. The contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable as regar
28、ds safety, economic and legal aspects. In all cases the contractor shall inform the principal of any deviation from the requirements of this specification which is considered to be necessary, in order to comply with national and/or local regulations. The principal may then negotiate with the authori
29、ties concerned with the object of obtaining agreement to follow this specification as closely as possible. The publications referred to in this specification are mentioned in Section 10. Where cross references are made, the number of the section or sub-section referred to, is shown in brackets. W-6-
30、1/2/3 December 1984 Page 5 1.2DEFINITIONS For the purpose of this specification the following definitions shall hold: Shall and Should - The word shall is to be understood as mandatory and the word should as strongly recommended to comply with the requirements of this specification. The Principal is
31、 the party which initiates the project and ultimately pays for its design and construction. The principal wil generallyspecify the technical requirements. The Principal may also include an agent or consultant, authorized to act for the Principal. The Contractor is the party which carries out all or
32、part of the design, engineering, procurement, construction and commissioning for the project. The Principal may sometimes undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party which manufacturers or supplies equipment and services to perform the duties specifi
33、ed by the Contractor. The Purchaser is the party which buys equipment, materials and/or services for its own use or as agent for the owner. The Purchaser may be either Principal or Contractor. W-6-1/2/3 December 1984 Page 6 2.MATERIALS 2.1BASE MATERIAL: PLATE 2.1.1Chemical composition The chemical c
34、omposition of the plate material shall be in accordance with ASTM A 387 Gr. 22, with the following additional chemical requirements: Cu content:0.20% max. Ni content:0.30% max. (%Si + %Mn) x (%P + %Sn) x 104 180 Vacuum degassed, aluminium-killed steel is required. 2.1.2Heat treatment The steel shall
35、 be in the quenched and tempered condition. The aproximate heat treatment temperature ranges are: Austenitizing temperature:940-960C Tempering temperature:680-720C The cooling rate after austenitizing shall not be lower than 5C/min. 2.1.3Mechanical properties -Tensile properties The tensile properti
36、es (specimens at 1/4 and 1/2 of the plate thickness) shall meet the requirements as per ASTM A 387 Gr. 22, Class 2 . -Hardness The maximum hardness shall not exceed 248 HV 20. -Impact values (Charpy-V) The minimum individual impact values (Charpy-V) of plate material in the quenched and tempered con
37、dition in transverse direction for specimens at 1/4 and 1/2 of the plate thickness and at a temperature of -40C shall not be less than 55 J. A step cool treatment test as specified in (3.2.2) shall be carried out for each heat of plate material. After this treatment, impact properties (Charpy-V at 1
38、/4 and 1/2 of the plate thickness) shall meet the following requirement: T55+ 3 T55 1800 mm, open at either one end or both ends, shall have test specimens removed from full-size prolongations of the open end. (If open at both ends, test specimens shall be removed from full-size prolongations of bot
39、h ends.) Sufficient material shall be provided for the production tests on the base material as specified in (4.1.2). The specimens governing acceptance of the forging shall be removed from the diagonal corners of an axial plane, as described in paragraph 8.2 of ASTM A 336. Vessel shells with integr
40、ally forged bottom heads shall have the head-end test specimen removed from a prolongation of the head-end and the specimen shall be located as if it were being removed from a prolongation of the shell. The specimen location shall be approved by the purchaser. 2.2.3Ultrasonic testing All forgings sh
41、all be 100% ultrasonically tested in accordance with ASTM A 388 with longitudinal and shear wave techniques. Rejection levels shall be as specified in paragraph AM 203 of Section VIII Div. 2, of the ASME Boiler and Pressure Vessel Code. W-6-1/2/3 December 1984 Page 10 2.3CLADDING AND INTERNALS The c
42、hemical composition of cladding and internals shall be as specified in the requisition sheet. All shell components shall be integrally clad by means of roll-bond cladding or explosion cladding. Where this is not possible, overlay welding may be considered and applied after the purchasers approval. I
43、f overlay welding is applied, a two-layer system shall be used. The clad plates shall conform to ASTM A 264, including the shear-strength test. Cladding shall be examined on disbonding over 100% of the surface area according to ASTM A 578 with acceptance level S6. In addition the following requireme
44、nts must be fulfilled: -The total of the unbonded areas between 625 mm2surface and those which can be encompassed by a 76 mm diameter circle shall not exceed 0.025 m2per 1 m2area of plate (areas less than 625 mm2shall be ignored). -Any cut edge shall be 100% tested over a band-width not less than 75
45、 mm wide and in this band no defects are acceptable. Cladding repair welding shall be performed by ASME IX qualified welders and welding procedures. Procedures shall be approved by the principal. Internal grid support rings (e.g. for catalyst beds) shall be deposit-welded on the bare base material w
46、ith 2.25 Cr-1Mo steel weld metal, and be machined. Thereafter, these deposit-welded rings shall be overlay-welded with at least 2 layers of the required weld metal, and machined to the final dimensions. Internal flanges (such as for quench decks) shall be made from forged material. W-6-1/2/3 Decembe
47、r 1984 Page 11 3.FABRICATION 3.1FORMING AND ASSEMBLY The internal diameter of heads and shell shall be identical. The manufacturer shall take all precautions to minimize plate damage due to scale formation during heating, see (2.1.6). Any such damage shall be repaired after approval from the princip
48、al. If hot forming is applied, austenitizing, quenching and tempering shall be carried out after hot forming. If the longitudinal welds are electro-slag welded, austenitizing, quenching and tempering shall be carried out after electro-slag welding. The preparation of plate edges for welding shall be
49、 effected by machining or by flame cutting. In the case of flame cutting pre-heating shall be applied and heat-affected zones shall be removed by grinding. Each shell section shall be completely welded longitudinally and corrected for out-of- roundness and peaking of the weld seam prior to assembly. Corrections shall not be made until the welds have received a post-weld heat treatment, see (3.4). Likewise, all re-rolling or forming of the shell sections shall be completed prior to radiographic and ultrasonic examination. Nozzles shall be flush a
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