Chevron PVM-EG-5019

HYDROPROCESSING REACTORS FOR HIGH ACID FEED

SPECIFICATION PVM-EG-5019
HYDROPROCESSING REACTORS FOR HIGH ACID FEEDS

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HYDROPROCESSING REACTORS FOR HIGH ACID FEED

CONTENTS

1.0 SCOPE .................................................................................................................................... 4

2.0 GENERAL .............................................................................................................................. 4

2.1 Code Conformance ..................................................................................................................4
2.2 Bid Preparation ........................................................................................................................4
2.3 Conflicts ..................................................................................................................................4
2.4 Purchaser’s Inspectors & Code Inspectors ................................................................................5
2.5 Production Flow Chart..............................................................................................................5
3.0 DESIGN .................................................................................................................................. 5
3.1 Design Conditions.....................................................................................................................5
3.2 Welded Joints...........................................................................................................................5
3.3 Openings & Reinforcement.......................................................................................................5
3.4 Nozzles & Manways ................................................................................................................6
3.5 Support Skirt & Attachments ....................................................................................................6
3.6 Internals ..................................................................................................................................6
4.0 MATERIALS.......................................................................................................................... 7
4.1 General....................................................................................................................................7
4.2 Positive Materials Identification PMI .........................................................................................7
4.3 Shell, Heads, and Nozzles .........................................................................................................7
4.4 Tensile Test Requirements........................................................................................................9
4.5 Charpy V-notch (Cv) Impact Testing..........................................................................................9
4.6 Inspection ................................................................................................................................9
4.7 Weld Repairs .........................................................................................................................10
4.8 Temper Embrittlement Screening.............................................................................................10
4.9 Internals ................................................................................................................................11
4.10 Support Skirt ..........................................................................................................................11
5.0 WELDING ............................................................................................................................ 12
5.1 General..................................................................................................................................12
5.2 Methods of Welding ...............................................................................................................12
5.3 Cr - Mo Weld Joints ...............................................................................................................12
5.4 Weld Overlay Cladding...........................................................................................................16
5.5 Internal Attachment Welds & Gasket Ring Grooves .................................................................17
6.0 INSPECTION ....................................................................................................................... 18
6.1 General..................................................................................................................................18
6.2 Radiographic Examination (RT)...............................................................................................18
6.3 Ultrasonic Examination (UT)...................................................................................................18
6.4 Magnetic Particle Examination (MT) .......................................................................................18
6.5 Weld Overlay Cladding...........................................................................................................19
6.6 Repair Procedures..................................................................................................................19
7.0 HYDROSTATIC TESTING................................................................................................. 19

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8.0 NAMEPLATE ...................................................................................................................... 20

9.0 PREPARATION FOR SHIPMENT..................................................................................... 20

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1.0 SCOPE

1.1 This Specification covers the design and fabrication of Chevron’s proprietary hydroprocessing
reactors from Cr-Mo low-alloy steel, both with and without an internal austenitic stainless steel (SS)
weld overlay. The attached mechanical design drawings for the reactor(s) are a part of this
specification.
1.2 Only Manufacturers that have been prequalified by Chevron are authorized to use this specification
for the design and fabrication of Chevron’s proprietary hydroprocessing reactors.
1.3 Purchaser refers to Chevron or other organizations authorized by Chevron to use this specification
for the procurement of Chevron’s proprietary hydroprocessing reactors.

2.0 GENERAL

2.1 Code Conformance

Design and manufacture shall conform to ASME Boiler and Pressure Vessel Code, Section
VIII, Division 2 (hereafter referred to as Code Division 2). The latest edition including addenda
effective through the date of the purchase agreement shall be used.
2.2 Bid Preparation

2.2.1 Chevron has determined that the design, materials, fabrication, and inspection
requirements of this specification and the attached drawings are satisfactory for
operation under the proprietary hydroprocessing conditions for which the mechanical
design drawings have been prepared.

2.2.2 The manufacturer shall submit a bid for the design and manufacture of the reactor(s)
that meets all of the requirements of this specification and the attached drawings. All
proposed deviations from (or requests for clarification of) these requirements must be
clearly identified as such and submitted with the bid.

2.2.3 The manufacturer may submit alternative bids that deviate from the requirements of
this specification and the attached drawings providing that:

2.2.3.1 Prior approval is obtained from the Purchaser.

2.2.3.2 Technical documentation is submitted to validate the deviations.

2.2.3.3 The benefits of the proposed alternatives (re cost, delivery, transportation,
erection, etc.) are clearly documented.

2.3 Conflicts
In cases of conflict between this specification and the attached drawings (or any other
documents including Code Division 2), the Manufacturer shall request clarification and
resolution from the Purchaser.

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2.4 Purchaser’s Inspectors & Code Inspectors

The Purchaser’s inspectors shall have free entry to the manufacturer’s facilities (including all
subcontractors and suppliers) at all times while work on the reactor(s) is being performed.
Inspections made by the Purchaser’s inspectors or ASME Code authorized inspectors shall not
relieve the Manufacturer of its responsibility for complying with all of the requirements of this
specification and the attached drawings, or the requirements of Code Division 2.
2.5 Production Flow Chart
The Manufacturer shall prepare a production flow chart for each reactor that shows all major
fabrication, welding, heat treatment, and nondestructive examination steps.

3.0 DESIGN

3.1 Design Conditions

3.1.1 Design pressure and temperature shall be as shown on the attached drawings for the
reactor(s).

3.1.2 Design for seismic and wind loading shall be in accordance with Chevron’s Civil and
Structural Manual, Section 100 (or an acceptable alternative approved by the
Purchaser), and the allowable stresses shall comply with Code Division 2.

3.1.3 The minimum thickness of internal austenitic SS weld overlays shall be as shown on the
attached drawings, and shall not be included in the calculations for the pressure design
of the shell.

3.2 Welded Joints

3.2.1 All Category A, B, C, and D welded joints shall be full penetration, double welded butt
joints (Type 1), or an acceptable equivalent agreed to by the Purchaser in writing.

3.2.2 Category C welded joints with corner welds are not permitted.

3.2.3 All Category A, B, C, and D welded joints shall be designed to be inspected by both
radiographic (RT) and ultrasonic (UT) nondestructive examination.

3.2.4 All welded joints including internal and external attachment welds shall be designed and
located to provide access for the nondestructive examinations during fabrication by the
RT, UT, and liquid penetrant (PT) methods that are required by this specification.

3.2.5 All Category A, B, C, and D welded joints shall be located to provide access for
nondestructive examination during in-service inspections by UT methods, and all
internal and external attachments by PT methods.

3.3 Openings & Reinforcement

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3.3.1 All openings shall be provided with full reinforcement according to the requirements of
Code Division 2, and the additional requirements of the attached drawings.

3.3.2 Unreinforced openings may be used for thermowell penetrations through the shell when
they are shown in the attached drawings and comply with Code Division 2, Section
AD-510.

3.3.3 All openings shall be located a minimum of 2.5 (Rt)1/2 from locations where the local
membrane plus primary bending stress intensity (Pl + Pb) exceeds 1.1 Sm. Exceptions,
when necessary, shall be submitted to the Purchaser for written approval of the design.

3.4 Nozzles & Manways

3.4.1 Nozzles and manways with their full reinforcement shall be manufactured from integral
forgings, that are forged as close as practicable to finished size and shape to produce
metal flow in the direction most favorable to resisting the stresses that are encountered
in service.

3.4.2 Flange ratings shall not limit either the design pressure or the hydrostatic test pressure.

3.4.3 Bolt holes shall straddle centerlines, unless otherwise noted on the attached drawings.

3.4.4 Flange facings and gasket types shall be as shown on the attached drawings.

3.5 Support Skirt & Attachments

3.5.1 Attachment of the support skirt shall be similar to Code Division 2, Figure AD-912.1
(k).

3.5.2 A weld pad deposit on the head that is machined to a suitable contour for skirt
attachment may be substituted for an integral forging, when approved by the
Purchaser.

3.5.3 The Manufacturer shall perform a thermal analysis to design a hot-box at the
attachment of the support skirt to the reactor(s). The design shall comply with the
provisions for exemption from a detailed fatigue analysis according to Code Division 2,
Section AD-160.2, Condition A, and with the following additional requirements:

3.5.3.1 Temperature difference in any part inside the hot box shall not exceed 50ºF
(28ºC).

3.5.3.2 Primary + secondary + peak stresses <3 Sm.

3.5.4 External attachments are not permitted, unless approved by the Purchaser in writing.

3.5.5 All locations of temporary attachments shall be ground flush and smooth after removal.

3.6 Internals

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3.6.1 Internals have been designed by Chevron, as detailed on the attached drawings, to
permit the manufacturer to prepare shop fabrication drawings that will comply with
Chevron’s design. The Manufacturer is responsible for requesting clarification of any
issue during preparation of the fabrication drawings.

3.6.2 The Manufacturer shall be solely responsible for the effects of the internals upon the
pressure containing components of the reactor.

4.0 MATERIALS

4.1 General

The materials of construction for all pressure containing shell components, internals, support
skirt, and miscellaneous attachments shall comply with those shown on the attached drawings.
All materials used for pressure containing and non-pressure containing components shall
comply with the requirements of ASME Code, Section II. The Manufacturer may make
substitutions only with the approval of the Purchaser in writing in accordance with Section
2.2.2.

4.2 Positive Materials Identification PMI

Manufacturer shall submit for Purchaser approval the plans for positive material identification
(PMI) of all pressure containing as well as internal components.

4.3 Shell, Heads, and Nozzles

The materials of construction shown on the attached drawings shall be used by the
Manufacturer for design and fabrication according to the following:

2 1/4 Cr - 1 Mo Code Division 2

2 1/4 Cr - 1Mo -1/4V Code Division 2
3 Cr - 1Mo - 1/4V-Ti-B Code Division 2
3 Cr - 1Mo - 1/4V-Cb-Ca Code Case 2151

4.3.1 Shell and head may be either forging or plate materials.

4.3.2 Nozzles must be manufactured from forgings.

4.3.3 All forging and plate materials must be accelerated cooled (or quenched) from the
austenitizing temperature and tempered to develop a microstructure consisting of a
minimum of 90% bainite.

4.3.4 Procedures for sampling of forgings and plate materials, and the heat treatment of test
coupons to represent the reactor(s) as fabricated shall be submitted to the Purchaser
for approval.

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4.3.5 Alternative materials to those shown on the attached drawings proposed by the
Manufacturer in accordance with Section 2.2.2 must be according to the list in Section
4.3.

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4.4 Tensile Test Requirements

4.4.1 Tensile testing of forgings and plates shall comply with Code Division 2, Section AM-
201.1 and the requirements of this specification.

4.4.2 Test coupons shall be taken from 1/2t of the material’s thickness.

4.4.3 Test coupons shall be heat treated to represent the maximum postweld heat treatment
(PWHT) that the reactor(s) are expected to receive during fabrication (including
repair), plus one additional cycle to allow for one in-service repair.

4.4.4 Tensile properties at room temperature shall meet the minimum requirements of ASME
Code, Section 2 or the applicable Code Case.

4.4.5 Tensile properties at 850oF (454oC) shall be as follows:

2 1/4Cr - 1Mo 59.5 ksi min.
2 1/4Cr -1Mo-1/4 V 66.8 ksi min.
3 Cr-1Mo-1/4V-Ti-B 64.9 ksi min
3 Cr-1Mo-1/4V-Cb-Ca 64.9 ksi min.

4.5 Charpy V-notch (Cv) Impact Testing

4.5.1 Cv -impact testing of forgings and plates shall comply with Code Division 2, Section
AM-204.1, and with the requirements of this specification.

4.5.2 Test coupons shall be taken from 1/2t of the material’s thickness.

4.5.3 Test coupons from forgings shall be oriented transverse to the major direction of metal
flow.

4.5.4 Test coupons shall be heat treated to represent the minimum (PWHT) that the
reactor(s) are expected to receive during fabrication.

4.5.5 The minimum Cv -impact energy shall be 40 ft-lbf (54 J) average, 35 ft-lbf (47 J) min
@ 0oF(-18ºC).

4.5.6 A minimum of three test coupons shall be tested at each of a sufficient number of
temperatures (minimum 6 temperatures) to establish a Cv -impact toughness transition
temperature curve. The curve should clearly define the transition as well as the lower
and upper shelves.

4.6 Inspection

4.6.1 All plate materials 2-inch (51 mm) thick and greater shall be UT according to the
requirements of Code Division 2, Section AM-203.1 (a).

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4.6.2 Prior to welding, all plate materials shall be UT, according to Supplementary
Requirement S1 of SA-435, within 2t of the material’s thickness from welded joints.
The maximum acceptable indication shall be 50% loss of back reflection within a 1/2-
inch (13 mm) diameter circle.

4.63 All forging materials 2-inch (13 mm) thick and greater shall be UT according to the
requirements of Code Division 2, Section AM-203.2.

4.6.4 Prior to welding, all forging materials shall be UT, according to SA-388, within 2t of the
materials thickness of all welded joints. The maximum acceptable indication shall be
50% loss of back reflection within a 1/2-inch (13 mm) diameter circle.

4.6.5 All forging materials shall be magnetic particle examined (MT) according to the
requirements of Code Division 2, Appendix 9, Article 9-1 over 100% of their finished
machined surfaces. The Manufacturer may suggest an alternative to PT testing for
Purchaser approval.

4.7 Weld Repairs

4.7.1 Weld repairs of defects in plate and forging materials in accordance with Code Division
2, Section AF-750 are acceptable provided they meet the requirements in this
specification.

4.7.2 All repairs must be made by the Manufacturer or by the materials supplier under the
supervision of the Manufacturer.

4.7.3 The Manufacturer has sole responsibility for the acceptability of the repairs according
to the requirements of Code Division 2.

4.7.4 The repair welding procedures and welders must be qualified according to the
requirements of ASME Code, Section IX.

4.7.5 The repair welding procedures must be approved in writing by the Purchaser.

4.7.6 The Manufacturer must advise the Purchaser, and obtain approval in writing, for all
repairs that exceed either 1-inch (25 mm) in depth or 1/4t of the material’s thickness.

4.8 Temper Embrittlement Screening

4.8.1 Each lot (heat) of forging and plate material shall be screened for susceptibility to
temper embrittlement in accordance with the requirements in this specification.

4.8.2 Cv-impact test coupons shall be taken, heat treated, and tested as in Section 4.5.

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4.8.3 The test coupons shall be step aged as follows:

Heat to 1,100°F (593ºC) from 600°F (315ºC) @ 100oF (56ºC)/hr

Hold @ 1,100°F (593ºC) for 1 hr Cool @ 10°F (6ºC)/hr max to next

temperature

Hold @1,000°F 538ºC) for 15 hrs Cool @ 10°F (6ºC)/hr max to next
temperature

Hold @ 975°F (524ºC) for 24 hrs Cool @ 10°F (6ºC)/hr max to next
temperature

Hold @ 925°F (496ºC) for 60 hrs Cool @ 5°F (3ºC)/hr max to next temperature

Hold @ 875°F (468ºC) for 100 Cool @ 50° F (28ºC)/hr max to 600oF(315ºC).
hrs

4.8.4 The impact properties shall meet the following requirement:

CvTr40 + 2.5 ∆CvTr40 < 50°F (10ºC)

4.8.5 The Manufacturer may propose reducing the number of lots (heats) of material tested
based upon past experience with similar production materials from the same suppliers.
The Manufacturer’s supporting data shall be submitted to the Purchaser for approval in
writing.

4.9 Internals

4.9.1 The internals have been designed by Chevron for 317L SS.

4.9.2 All 317L SS materials shall be solution annealed.

4.9.3 Heat treatment of 317L SS components for dimensional stability or other purposes at
temperatures from 1100ºF (590ºC) to 1890ºF (1032ºC) is not permitted

4.10 Support Skirt

4.10.1 The support skirt shall be fabricated from Code Division 2 acceptable plate materials.
4.10.2 2¼ Cr -1 Mo plate material is required from the point of attachment to the reactor(s) to
the location where the thermal calculations show the design temperature can be
reduced to 450ºF (232ºC). In no case shall the 2¼ Cr -1 Mo material be terminated
less than 6-inch (152 mm) below the hot box.

4.10.3 SA-516, Gr. 65 or 70 carbon steel plate is required where the temperature does not
exceed 450°F (232ºC).

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4.10.4 The Manufacturer shall determine by thermal analysis the point below the hot-box at
which the design temperature can be decreased to 450°F (232ºC).

5.0 WELDING

5.1 General

5.1.1 All welding on Cr-Mo components shall be completed prior to final PWHT.

5.1.2 SS attachment welds for internals components shall be completed after final PWHT
when shown on the attached drawings.

5.1.3 All completed welds shall be sufficiently contoured and smooth to permit all of the
nondestructive examinations required by Code Division 2 and Section 6.0 of this
specification.

5.2 Methods of Welding

5.2.1 Acceptable methods of welding for pressure containing welds are shielded metal arc
(SMAW), and submerged arc (SAW).

5.2.2 Gas metal arc welding (GMAW) is permitted for root passes in double welded butt
joints only when it is completely removed by back gouging.

5.2.3 Gas tungsten arc welding (GTAW) is permitted for root passes in single welded joints
only if the nondestructive examinations required for Type No.1 welds by Code Division
2 and Section 6.0 can be satisfactorily performed, and for the welding of nonpressure
containing internals components.

5.2.4 The Manufacturer must obtain approval from the Purchaser in writing to use other
welding methods.

5.3 Cr - Mo We ld Joints

5.3.1 Cr - Mo Consumables

5.3.1.1 Selection of the consumables is the responsibility of the Manufacturer and

must be submitted to the Purchaser for approval prior to the start of
fabrication.

5.3.1.2 The deposited weld metal for Cr-Mo pressure-containing welds shall match the
nominal chemical composition of the plate and forging base materials, and shall
comply with the requirements of any applicable ASME Code Cases according
to Section 4.2, and shall meet X < 15, where:

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10 P + 5Sb + 4Sn + As
Χ=
100

The copper content in the deposited metal should be limited to 0.20 % max and
the nickel content should be limited to 0.30 % max.

5.3.1.3 All welding consumables shall be of a low-hydrogen type that are certified to
result in a maximum of 10 ml of diffusible hydrogen in 100 gm of deposited
weld metal per AWS A4.3

5.3.1.4 Each lot of electrodes and each combination of wire and flux shall be screened
by step cooling in accordance with the requirements in Section 4.8.

5.3.2 Qualification of Welding Procedures

5.3.2.1 All welding procedures for Cr - Mo welds shall be qualified according to

ASME Code, Section IX, and with the requirements in this specification.

5.3.2.2 Vicker’s hardness traverses shall be made 1 to 2 mm below both surfaces and
at 1/2t of the thickness to include weld metal, heat-affected zones (HAZs), and
base metals. Maximum hardness shall be 235H v10 for the minimum (PWHT)
that the reactor(s) are expected to receive during fabrication.

5.3.2.3 Cv-impact testing of the weld metal and HAZs shall be performed according
to Sections 4.5.4, 4.5.5, and 4.5.6.

5.3.2.4 Tensile tests of transverse weld coupons shall be performed according to

Section 4.4.

5.3.2.5 Temper embrittlement screening tests of weld metals shall be performed

according to Section 4.8.

5.3.2.6 All Welding Procedure Specifications (WPSs) and Welding Procedure

Qualification Records (PQRs) shall be submitted to the Purchaser for review
and approval in writing before welding begins.

5.3.3 Cr-Mo Preheat

5.3.3.1 The minimum preheat for 2¼ Cr-1Mo-1/4V, 3Cr-1Mo-1/4V-Ti-B and 3Cr-

1Mo-1/4V-Cb-Ca shall be 350ºF (177ºC). The minimum preheat for
conventional 2¼ Cr-1Mo welds shall be 300ºF (150ºC). The Manufacturer
shall submit detailed procedures for preheating each category of welded joint to
the Purchaser for review and approval before welding begins.

5.3.3.2 Preheat shall extend for a minimum of 1t of the thickness of the welded joint
on each side of the weld. The heating band need not extend more than 4
inches (100 mm) in any direction from the edges to be welded.

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5.3.3.3 The Manufacturer shall provide sufficient temperature monitoring to assure

that the minimum preheat is maintained to the satisfaction of the Purchaser’s
inspector.

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5.3.4 Cr-Mo Postweld Heat Treatment (PWHT)

5.3.4.1 PWHT is required for all Cr - Mo weld joints complying with the minimum
requirements of Code Division 2 and applicable Code Cases according to
Section 4.2. PWHT should be performed as a whole in an enclosed furnace.
If, due to size, PWHT cannot be done as a whole, it may be performed locally
or in sections according to AF-410 of the Code. The Manufacturer shall submit
detailed heat treating procedures to the Purchaser for approval in writing,
showing the location of thermocouples attached to the reactor(s) for
temperature control and monitoring.

5.3.4.2 The preheat shall be maintained until PWHT, or until an intermediate stress
relief (ISR) soak in the furnace is performed at >1100°F (593ºC) for 1hr per
inch (25 mm) of thickness (2-hours minimum) of the weld joint for conventional
2-1/4Cr-1Mo. For vanadium modified Cr-Mo steels an intermediate stress
relief (ISR) soak in the furnace shall be performed at >1200°F (649ºC) for 1hr
per inch (25 mm) of thickness (2-hours minimum) of the weld joint.
or

5.3.4.3 The Manufacturer may request approval from the Purchaser in writing to use
a low-temperature dehydrogenation heat treatment (DHT) in lieu of an
intermediate stress relief (ISR) for conventional 2-1/4Cr-1Mo steels. DHT is
not permitted for any nozzle welds or for vanadium modified Cr-Mo steels. The
Manufacturer’s request shall include detailed information and data concerning
hydrogen controls for procurement and handling of consumables, hydrogen
content of weld metals and HAZs after DHT, and nondestructive examinations
of weld joints. The Manufacturer will be required to demonstrate that a high
sensitivity UT procedure is used that will detect 1/4 X 1/2-inch (6 X 13 mm)
planar flaws at both the near and far surfaces of the welded joint.

5.3.4.4 The Purchaser will require qualification of the Manufacturer’s fabrication

shop with regard to consumable procurement, storage, and shop floor handling
prior to approving the use of DHT.

5.3.5 Cr-Mo PWHT Furnace & Temperature Controls

5.3.5.1 PWHT should be performed for a completed reactor in an enclosed furnace

whenever possible. PWHT of separate sections followed by a local PWHT of
closing weld joints complying with Code Division 2, Section AF-410 is
permitted, if the completed reactor is too large to enclose in a furnace.

5.3.5.2 Sufficient thermocouples must be installed to assure controlling the PWHT

temperature to +/-25°F (14°C).

5.3.5.3 The Manufacturer is responsible for maintaining temperature gradients during

heating and cooling, and for local PWHT that are not harmful to the reactor(s).

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5.3.5.4 Continuous time-temperature records shall be obtained for all thermocouples

during PWHT to comply with the requirements of Code Division 2, Section
AF-415.

5.3.6 Cr-Mo Production Test Plates

5.3.6.1 Test plates shall be prepared during production welding of Category A, B, C, &
D joints complying with Code Division 2 and the following additional
requirements:

5.3.6.2 Hardness traverses shall be made according to Section 5.3.2.2.

5.3.6.3 Cv-impact testing shall be performed for weld metals and HAZs according to
Section 4.5.

5.3.6.4 Tensile tests of transverse weld coupons shall be performed according to

Section 4.4

5.3.6.5 Temper embrittlement screening tests of weld metals shall be performed

according to Section 4.8.

5.3.6.6 The Manufacturer shall submit to Purchaser for approval the number of test
plates that will be made.

5.4 Weld Overlay Cladding

5.4.1 Weld Overlay Material

5.4.1.1 A two-layer 309L/317L SS weld overlay shall be applied to the inside

surface of the reactor(s) as shown on the attached drawings. Use of a single-
layer 317L SS overlay requires both the Manufacturer to submit evidence to
the satisfaction of the Purchaser of the suitability of the process and written
approval from the Purchaser.

5.4.1.2 The minimum required undiluted thickness of the weld overlay shall be as
shown on the attached drawings.

5.4.1.3 The chemical composition of the finished weld overla y deposit for the minimum
required undiluted thickness shown on the attached drawings shall be that
required for 317L SS in ASME Specification SFA-5.4.

5.4.1.4 The ferrite content of deposited weld metal shall be between 3 and 10 FN as
determined by a magnetic instrument calibrated according to AWS A4.2.

5.4.1.5 The weld overlay shall be deposited on a Cr-Mo base metal surface that has
been machined, ground, or blast cleaned to a SSPC SP-10 near white metal
finish.

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5.4.2 Weld Overlay Procedure Qualification

5.4.2.1 The welding procedure for the weld overlay cladding shall be qualified
according to ASME Code, Section IX and Code Division 2, Section AF-520
and according to the requirements in this specification.

5.4.2.2 The plate or forging Cr-Mo base material specified on the attached drawings
shall be used.

5.4.2.3 The same type and brand of flux and wire (or strip) that will be used for
production welding shall be used.

5.4.2.4 The test plate shall be heat treated to represent the maximum (PWHT) that the
reactor(s) are expected to receive during fabrication (including repair), plus one
additional cycle to allow for one in-service repair.

5.4.2.5 Chemical analyses shall be performed to demonstrate that the chemical

composition of the deposited weld overlay meets that required for 317L SS in
ASME Specification SFA-5.4 from the surface to the depth of the required
minimum undiluted thickness.

5.4.2.6 Microhardness testing shall be according to Section 5.3.2.2.

5.4.2.7 The Manufacturer shall demonstrate the resistance of the weld overlay to
hydrogen induced disbonding by autoclave tests that simulate service
temperature, hydrogen pressure, and cooling rate conditions.

5.4.2.8 Welding Procedure Specifications (WPSs) and Welding Procedure

Qualification Records (PQRs) shall be submitted to the Purchaser for approval
in writing before welding begins.

5.4.3 Weld Overlay Preheat

The minimum preheat for the first layer of weld overlay cladding on the Cr - Mo base
metal shall be 220°F (104ºC).

5.4.4 Weld Overlay PWHT

All weld overlay cladding shall be deposited before the final PWHT required by Code
Division 2 and Section 5.3.4, with the exceptions in Section 5.5.

5.5 Internal Attachment Welds & Gasket Ring Grooves

5.5.1 Weld deposits of 317L SS for internal attachment welds and nozzle ring grooves shall
be deposited after final PWHT on a first layer of 309LSS weld overlay that covers the
Cr - Mo base metal, as shown on the attached drawings.

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5.5.2 The weld procedure qualification shall include Vicker’s hardness traverses to
demonstrate that maximum hardness in the HAZs does not exceed 235H v10.

6.0 INSPECTION

6.1 General

The Manufacturer is responsible for details of design and fabrication that will facilitate all of
the nondestructive examinations required by Code Division 2 and this specification. All
nondestructive examination procedures shall be submitted to the Purchaser for approval in
writing before fabrication begins.

6.2 Radiographic Examination (RT)

6.2.1 RT shall be performed in accordance with Code Division 2, Article I-5.

6.2.2 All Category A, B, C, and D welded joints shall be RT before final PWHT.

6.2.3 When RT is not practical for nozzle welds and skirt attachment welds, UT can be
applied in place of RT, with the prior approval of the Purchaser.

6.2.4 The acceptance standard shall comply with Code Division 2, Appendix 8.

6.3 Ultrasonic Examination (UT)

6.4.1 UT shall be performed in accordance with Code Division 2, Article 9-3 and Section
5.3.4.3.

6.4.2 All Category A, B, C, and D welded joints shall be UT after final PWHT.

6.4.3 All weld pad build-ups for the attachment of internal or external components shall be
UT.

6.4.4 The support skirt attachment weld shall be UT.

6.4.5 The acceptance standard shall comply with Code Division 2, Article 9-3, Section 9-320,
except as modified by Section 5.3.4.

6.4 Magnetic Particle Examination (MT)

6.4.1 MT shall be performed in accordance with Code Division 2, Appendix 9, Article 9-1.
Examinations shall be made by the wet fluorescent technique. All prod burns shall be
removed by grinding.

6.4.2 All weld bevels for Category A, B, C, and D welds shall receive a (MT) before
welding.

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6.4.3 All accessible surfaces of Category A, B, C and D welds shall receive a (MT) after
hydrostatic testing.

6.4.4 All locations of temporary attachments shall receive a (MT) after removal.

6.4.5 The acceptance standard shall comply with Code Division 2, Article 9, Section 9-130.

6.5 Weld Overlay Cladding

6.5.1 The chemical composition of the 317L SS layer shall be checked for Cr, Ni, Cb (Nb),
Mo and C content and shall comply with ASME Specification SFA-5.4.

At least two locations shall be checked for each shell ring and head. At least one
location shall be checked for each nozzle and each Category A, B, C, and D weld
seam. Portable nondestructive instruments can be used, but the procedures must be
submitted to the purchaser for approval.

6.5.2 The ferrite content of the 317L SS layer shall be determined before PWHT by a
magnetic instrument according to the requirements of Section 5.4.1.4.

At least ten locations selected at random shall be checked for each shell ring and head.
At least one location shall be checked at both ends of nozzles and each Category A, B,
C, and D weld seam.

6.5.3 PT complying with Code Division 2, Article 9-2 shall be performed after final PWHT.
The entire surface of all weld overlay cladding shall be examined, including all internal
attachment welds.

6.5.4 UT complying with SA-578, acceptance level S6 shall be performed for bond flaw
indications after final PWHT. One 3-inch (76 mm) wide strip in each quadrant for the
total length of each shell ring and head shall be examined. One 3-inch (76 mm) wide
strip in each nozzle shall be examined.

6.6 Repair Procedures

6.6.1 Repair procedures for all rejectable flaws detected by the nondestructive examinations
required by Sections 6.1-6.5 shall be submitted to the Purchaser for approval in writing
before repairs are made. The repair procedures shall include the method(s) of flaw
removal and nondestructive examinations.

6.6.2 All completed repairs shall meet the requirements of Sections 6.1-6.5.

7.0 HYDROSTATIC TESTING

7.1 The reactor(s) shall be hydrostatically tested according to Code Division 2, Section AT-301.

7.2 The minimum hydrostatic test pressure shall be that shown on the attached drawings.

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7.3 No paint or primer shall be applied prior to hydrostatic testing.

7.4 The reactor(s) shall be free of any kind of coating, soil, and debris before testing. All dirt,
scale, sand, and foreign material shall be removed.

7.5 The test water shall contain no more than of 25 ppm chlorides.

7.6 The reactor(s) metal temperature shall not be lower than 60°F (15°C) or higher than 120°F
(49°C) during hydrostatic testing.

7.7 The reactor(s) shall be immediately drained and completely dried after hydrostatic testing.

8.0 NAMEPLATE

An austenitic SS nameplate shall be mounted on a bracket that is welded to the support skirt of the
reactor(s) below the hot box. The bracket must extend beyond the insulation (or fireproofing) and
weather shielding.

9.0 PREPARATION FOR SHIPMENT

9.1 The manufacturer is responsible for preparing the reactor(s) for shipment in such a manner that
they will arrive undamaged and ready for installation.

9.2 The reactor(s) shall be internally cleaned and dried.

9.3 All openings shall be sealed with a metal cover and gasket and the reactor(s) shall be filled with
nitrogen gas at a pressure of 0.5 barg minimum.

9.4 All exposed machined metal surfaces (such as flange faces and bolting) shall be protected by
applying a suitable grease, rust preventive oil, or coating.

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