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Project Specification

58-0100

FRP Process Vessels

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FRP Process Vessels

AMENDMENTS

Date Page Section Description


24 Mar,11 First Issue
16 Mar, ‘12 Change to latest version ASME RTP-1 2011 edition
26 Mar ‘13 Update document properties

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Table of Contents
1  Scope........................................................................................................................................6 
2  Normative References ..............................................................................................................6 
3  General Requirements..............................................................................................................6 
4  Schedules .................................................................................................................................8 
5  Shop Drawing Requirements ....................................................................................................9 
6  Materials .................................................................................................................................10 
7  Design.....................................................................................................................................10 
8  Fabrication ..............................................................................................................................12 
9  Quality Control ........................................................................................................................12 
10  Inspection and tests ................................................................................................................12 
11  Exterior Coating ......................................................................................................................14 
12  Documentation........................................................................................................................15 
13  Handling and Shipping............................................................................................................15 
14  Installation...............................................................................................................................15 
15  Warranty .................................................................................................................................15 

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FRP Process Vessels

This is the first update of 58-0100, FRP Process Vessels (Fiberglass Reinforced Plastic)

All references to the paragraphs of the ASME RTP1 standard have been updated in
accordance with the 2011 edition.

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Introduction

This document is for the procurement of FRP process vessels that meet the project requirments
and the ASME RTP-1 Standard, including those parts and appendices listed in paragraph 1.1. It
shall be considered a stand alone technology specific procedure to be adopted for equipment
design and fabrication.This document includes the ASME RTP-1 Users Basic Requirements
Specification (UBRS) a form that must be completed by the User, or the User’s representative,
to define the vessel, the installation and the performance requirements. The UBRS form provides
candidate Fabricators with materials, design, fabrication, inspection, test and shipping
requirements. An example UBRS form is included as table “1”.
Recognized international codes/Standards like EN 13121-3 or AD Merkblatt N1 can be adopted
under Owner approval at bid stage and before order is placed.
Where RTP1 stamp is not specifically requested, suitable process data sheet with appropriate
design, fabrication and test / inspection requirements can be used in lieu of UBRS form
Shop accreditation in accordance with ASME RTP-1 Parts 7 and 8 is highly desirable, but is not
required to comply with this specification.
In the event of discrepancies between the Purchase Order, User drawings, Job Specification, this
specification and ASME RTP-1, the governing document shall be in the sequence as follows:
Purchase Order
User drawings
Job Specification
This Specification
ASME RTP-1

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1 Scope

The purpose of this specification is to state the minimum requirements for materials, design, quality
control, fabrication, inspection, testing, handling and shipping of fiber reinforced plastic (FRP) process
vessels. This specification covers FRP vessels with thermoset corrosion resistant liners and “dual
laminate” construction FRP vessels with thermoplastic liners. This specification is applicable to
stationary vessels used for the storage, accumulation, or processing of corrosive substances at internal
pressures not exceeding 15 psig plus hydrostatic head, and / or not exceeding 15 psig external
pressures.

Pressure of 15 psig is equivalent to 1.034 barg or 1.02 atmospheres.

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 Society of Mechanical Engineers (ASME)


ASME RTP-1-2011 Edition Reinforced Thermoset Plastic Corrosion Resistant
Equipment
American Society for Testing Materials (ASTM)
ASTM D 5028 – 96 Standard Test Method for Curing Properties of Pultrusion
Resins by Thermal Analysis
Materials Technology Institute of the Chemical Process Industries, Inc. (MTI)
“Users Guide to ASME Standards for Fiberglass Tanks and Vessels”,
MTI Publication No. 50

3 General Requirements

3.1 Vessel Specification

3.1.1 Applicable Standard


Proposed vessels shall comply with the geometry, the design detail and the performance
requirements in the UBRS form as supplied by the User or the User’s representative. Proposed
vessels shall also comply with the ASME RTP –1 Parts and Mandatory Appendices that follow.
Compliance with the Non-mandatory Appendices shown below is suggested as well.
a. Parts
Part 1 General Requirements
Part 2 Materials
Part 3 Design
Part 4 Fabrication
Part 5 Overpressure Protection
Part 6 Inspection and Tests
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b. Mandatory Appendices
M-1 Reinforcement Material Receiving Procedures
M-2 Matrix Material Receiving Procedures
M-4 Quality Control Program
M-5 Qualification of Laminators and Secondary Bonders
M-7 Repair Procedures
M-10 Reference Documents
M-12 Guidelines for Dual Laminates (if applicable)
c. Non-mandatory Appendices
NM-2 Design of Integral Body Flanges
NM-4 Hold-Down Lug Design
NM-5 Ring Support of Vessels
NM-8 Handling and Shipping
NM-12 FRP Flange Design

3.1.2 Fabrication Method


Vessels fabricated in accordance with this specification shall be constructed from cylinders
fabricated by filament winding or by contact-molding techniques. Dual laminate construction
must be used if specified in the User’s Basic Requirement Specification (UBRS). Vessel heads
may be fabricated by contact molding or variations thereof.

3.1.3 Fabrication Location


ASME RTP-1 applies generally to shop fabricated vessels. The User will indicate in the UBRS
if outdoors or outdoors on-site fabrication is allowed as alternatives to shop fabricated vessels
for a specific procurement.

3.1.4 Resins Allowed


ASME RTP-1 applies generally to vessels fabricated from polyester and vinyl ester resins. The
User will indicate in the UBRS if alternative resins are allowed for a specific procurement.

3.1.5 Temperature Limit


ASME RTP-1 applies generally to operating temperatures equal to or less than 180F (82C).
To comply with this specification, vessels with service temperatures greater than 180F (82C)
will require high performance construction resins, supporting performance data for the service
environment and post cure of the vessel after construction. Only dual laminate vessels may be
used in high temperature service without post cure.

3.1.6 Critical Service


The User must indicate in UBRS Par.15.6 if the proposed vessel is to be used in critical service.
Critical service designation depends on the operating pressure, the proximity of the vessel to
areas frequented by personnel, the toxicity of the vessel contents or the flammability of the
vessel contents. Details of the criteria for critical service designation are presented in ASME
RTP-1 Section 1-210.

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4 Schedules

4.1 Proposed Project Schedule


As part of the bid proposal, the Fabricator shall indicate the proposed time interval, in weeks,
from order placement until delivery of the finished vessel to the FOB point or to the User’s
installation site.

4.2 Schedule after Project Award


The successful bidder/fabricator shall submit a detailed project execution schedule in the form of
a Gantt chart showing the work to be performed to meet the requirements of this specification,
the requirements specified in the Purchaser’s UBRS, the requirements of ASME RTP-1 and the
accepted delivery date.

4.2.1 Submittal of Fabricator Design Report


The schedule shall indicate the number of days required for preparation and submittal of the
Fabricator Design Report including all engineering design calculations and shop drawings for
the proposed vessel facility.

4.2.2 Approval of Design Report by User


The schedule shall allow 14 days for review and approval of the Fabricator’s proposed design.
User approval of the design may be based on review and approval by a licensed professional
engineer (PE).

4.2.3 Project Execution Schedule


A project execution schedule shall be prepared including the following list of activities in
accordance with the procedures of ASME RTP-1:
 Vessel design
 Fabrication and Quality Control Plan
 Preliminary shop drawings
 Fabricator’s Data Report
 Review Fabricator’s Data Report
 Final shop drawings
 Initiate fabrication
 Accumulation of materials
 Delivery of Fabricator purchased components and sub-contracted
items
 Fabrication of shells, heads, nozzles and other components or
accessories
 Post cure of components, as applicable
 Inspections
 Inspections by Purchaser representative, as applicable
 Qualification tests
 Hold and witness points
 “As Built” shop drawings
 Shipping
 Installation (optional)

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5 Shop Drawing Requirements

Shop drawings developed in the execution of the project shall meet the following requirements:

5.1 Design Conditions


Vessel design conditions shall be shown on the shop drawings.

5.2 Reference Lines


Major centerlines or reference lines as well as the designations, orientations and/or elevations for
nozzles, internals, attachments and accessories shall be the same as those shown on User’s
drawings.

5.3 Section Definitions


Vessel wall sections shall be defined by minimum thickness, materials of construction, laminate
reinforcement, types, sequences and orientations, inside diameters and section lengths.
Heads shall be defined by minimum thickness, laminate reinforcement types, sequences and
orientations, inside diameter and straight flange lengths.
Joints (head/shell, shell/shell, skirt/shell etc.) shall be located on the drawing and shall be
defined by minimum thickness, laminate reinforcement types, sequences and orientations, and
the joint laminate length on each side of the joint.

5.4 Nozzles and Supports (Lugs, Legs or Skirt)


Locations and details of nozzles, clips, lugs, hold down rings, support rings and the types and
sequences of reinforcements making up these components and associated tie-ins shall be shown.
Specifications for stainless steel components shall be shown.
The drawings shall include a schedule of nozzles and nozzle details. The bolt torque loads
required to seal nozzle flanges without overloading shall be noted on the nozzle schedule.

5.5 Internal Supports


If internal supports or attachment points are specified in the UBRS, the drawings shall include a
developed view of the interior vessel surface showing the location and orientation of all internal
supports and/or attachment points.

5.6 Post Cure


The post cure to be used, if required, shall be noted on the drawings.

5.7 Qualification Tests


The qualification tests (resin cure tests, hydrostatic tests, acoustic emission tests etc.) to be
performed on the vessel shall be included on the drawings.

5.8 Preliminary Shop Drawings


The preliminary shop drawings will be included in the Fabricators Design Report and will be
submitted for review and approval by the User.

5.9 Approved Shop Drawings


Shop drawings will be revised to reflect changes resulting from the approval process and
submitted for approval by the User. Fabrication shall not begin until the User has provided
written approval of the revised drawings.

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5.10 “As Built” Shop Drawings


The approved drawings shall be updated to show the “as built” configuration when fabrication of
the vessel is complete. The final measured vessel weight shall be indicated on the “as built”
drawings. The Fabricator shall send a final “as built” set of reproducible prints for User’s records
within 3 weeks of vessel shipment.

6 Materials

6.1 Vessel Shell, Heads and Nozzles


All materials of construction for the vessel and appurtenances shall be in compliance with the
provisions of ASME RTP-1, Part 2 Materials. Materials proposed for Dual Laminate Vessels
shall also be in compliance with Mandatory Appendix M-12, Article B. The fabricator shall
identify all resin and reinforcement materials intended for construction of the proposed vessel by
manufacturer and by manufacturer’s trade or brand name.
The use of resin fillers, pigments and other additives are restricted per ASME RTP-1 Paragraph
2-300.

6.1.1 Requirements for Physical and Mechanical Properties


The Fabricator shall report design basis properties for the proposed construction in accordance
with ASME RTP-1, Paragraph 2A-300.
Operating temperatures  180F (82C) - Room temperature tests may be used to establish
design basis properties for operating temperatures equal to or less than 180F (82C).
Operating Temperatures > 180F (82C) – Design basis properties must be established by tests
conducted at temperatures equal to or greater than the system design temperature (ASME RTP-1
Paragraph 2A-300(b)).
The corrosion barrier shall be excluded from the design as a contributor to the structural strength
in accordance with 2A-300 (a) 2 (b).
The fabricator must also present the temperature limits of construction resins/polymers by
reporting glass transition (Tg) data for all thermoset resins, and heat distortion temperatures
(HDT) for all thermoplastic polymers as cured in the proposed fabrication process. The
construction resins/polymers must have a 36F (20C) margin in temperature capability above
the system design temperature specified by the User in the UBRS, as demonstrated by Tg and
HDT data.

6.2 Lifting Lugs, Support Lugs and Mounting Lugs


All lifting lugs, support lugs and mounting lugs shall be fabricated from corrosion resistant
alloys. The specific alloy will be noted on the Job Specification.

7 Design

7.1 Vessel Design


The proposed vessel design shall comply with all the provisions of ASME RTP-1, Part 3. Dual
laminate vessel designs shall also be in compliance with Mandatory Appendix M-12, Article C.
The vessel design shall be based on the material properties generated in accordance with section
4.1.1 of this specification. The cylindrical shell shall have a minimum thickness of 0.25 inches
(6.0 mm). Vessels with inside diameters greater than 16 feet shall be designed with Subpart 3B
design rules.
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The vessel design shall include provisions for all local codes, specifications, ordinances etc. and
for design conditions as specified in the UBRS. The design shall include consideration of all
anticipated forces incurred short-term in handling, shipping and installation as well as those
incurred long-term in service. Design for seismic, wind and snow loads shall be in accordance
with ASME RTP-1, paragraph 3A-400. Hold –down lugs shall be designed in accordance with
Nonmandatory Appendix NM-4 or equivalent.
Refer to Appendix NM-3 for examples of vessel design for seismic, wind and snow loads.

7.2 Safety Factors


The vessel design shall be based on design safety factors (stress ratios) in accordance with
ASTM RTP-1 Paragraph 3B-500 with the exception of sub-paragraph (c).
Vessels designated for critical service by the User’s UBRS shall be based on design safety
factors at least 125% of those specified elsewhere in the ASME RTP-1 Standard in accordance
with Paragraph 1-220.

7.3 Large Diameter RTP Equipment Body Flanges


Large diameter flanges with full-face gaskets shall be designed in accordance ASME RTP-1 Non
mandatory Appendix NM-2, or equivalent.

7.4 Vessels Supported by Shell Attachments


If metallic ring-lug supports are used to support the vessel, the design shall be in accordance
with ASME RTP-1 Nonmandatory Appendix NM-5. The alloy to be used in lug construction
will be specified in the Job Specification.

7.5 Reinforcement of Circular Openings


Openings cut for nozzles and manways shall be designed in accordance with ASME RTP-1,
Section 3A-700.

7.6 Overpressure Protection


Vessel designs shall include provisions for overpressure protection in accordance with the
operating conditions and pressure relief devices specified by the User in the UBRS and the
design requirements of ASME RTP-1, Part 5.
The responsibility for design and/or selection of pressure relief devices is the responsibility of
the User.

7.7 Design Review


The details of the vessel design shall be documented in the Fabricators Design Report. The
design report will include material properties, design calculations, safety factors for the
appropriate load combinations, detailed shop drawings including all the information required to
comply with Section 3.
User approval of the design may be based on review and approval by a licensed professional
engineer (PE) if indicated in the UBRS.

7.8 Final Design Approval


After review of the design calculations and the shop drawings by the User, the Fabricator will
finalize the design calculations and prepare final shop drawings incorporating changes that result
from the review process. The Fabricator will provide a copy of the final design calculations and
reproducible prints of the final shop drawings to the User.
Fabrication shall not begin until the final design calculations and shop drawings have been
reviewed by the User, and written approval to proceed has been received by the Fabricator.
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8 Fabrication

All fabrication and dimensional tolerances shall satisfy the requirements of the UBRS and
ASME RTP-1 Part 4. Dual laminate vessels shall be fabricated in accordance with ASME RTP-1
Appendix M-12, Article D. The laminate sequences and ply orientations for all fabrications shall
be as detailed on final shop drawings and shall be documented on quality control forms.

8.1 Vessel Cylinder


The vessel cylinder must be fabricated by filament winding or by contact molding techniques.

8.2 Heads
Vessel heads may be fabricated by contact molding or variations thereof.

8.3 Nozzles
All nozzles shall be flanged, flat faced and drilled to match Class 150 ANSI B16.5 flanges.
Nozzle dimensions, lay-up and installation shall be in accordance ASME RTP-1 Part 4, Figures
4-4, 4-5, 4-6 and 4-10. Gusset plates shall be utilized to reinforce nozzles with inside diameters 
6.0 inch (150 mm) in accordance with Figure 4-1. Flange tolerances shall comply with Table 4-
13 and Figure 4-14.

8.4 Internal Support Rings and Clips


All internal support rings, clips, baffles etc. shall be contact molding construction and surfaced
with the specified corrosion barrier construction, or thermoplastic liner in the case of dual
laminate construction.

9 Quality Control

The Fabricator shall have and maintain a Quality Control Program that is in compliance with
ASME RTP-1 Appendix M-4. The Fabricator shall maintain quality control documents
distributed and filed in accordance with ASME RTP-1 Table NM6-4. The quality control files
shall be available for inspection by the User.

10 Inspection and tests

10.1 Inspection Requirements


The schedule of inspections desired by the User will be included in the UBRS.
Inspections by the Fabricator’s quality control department are required in accordance with
ASME RTP-1, Part 6.
The User’s inspector will conduct the final inspection with the assistance of the Fabricator’s
quality control personnel. The Fabricator will provide documents for final inspection as
indicated in Paragraph 6-900, section (a). The tests in paragraphs 6-910 through 6-960 must be
made, witnessed, or verified by the User’s inspector prior to or at the time of final inspection

10.2 Testing Requirements


Testing shall be conducted in accordance with the minimum basic test requirements described in
ASME RTP-1, Sections 6- 910 through 6-940. The test program includes tests of resin cure,
laminate thickness, glass content, laminate property proof tests and visual inspection.
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Nonconformity’s shall be resolved in accordance with Appendix M-7 and documented in


accordance with Appendix M-4, paragraph M4-400 (e).
Pressure testing requirements will be stated in the Users UBRS form. Pressure tests may include
hydrostatic tests, internal pressure tests, or combinations thereof. Pressure tests may also include
vacuum tests.

10.2.1 Resin Cure


Resin cure must be verified by glass transition temperature (Tg) measurements on laminate
samples by differential scanning calorimetry (DSC). Laminate samples representative of the
lower, middle and upper portion of the vessel structure and each of the covers must be evaluated.
The representative Tg value is determined by calculating the mean of all measured values minus
one standard deviation. The representative Tg must exceed the design temperature as specified in
the UBRS, by 36F (20C).

10.2.2 Laminate Property Proof Tests


Laminate proof tests shall be conducted in accordance with ASME RTP-1 Paragraph 6-930 by
an independent accredited and ISO certified laboratory. Test results shall be reviewed by an
independent and qualified Registered Engineer.
Proof tests are required for vessels a) with internal or external design pressures equal to or
greater than 2 psig, b) with inside diameter greater than or equal to16 feet, or c) all vessels
fabricated outside or outside on-site. Strength and modulus properties must be determined both
in the axial and hoop directions. If the design temperature is greater than 180F, the proof tests
shall be conducted at a temperature equal to or greater than the system design temperature.
All laminate property proof test values must equal or exceed the properties used in design of the
vessel.

10.2.3 Visual Inspection


The Inspector shall perform visual inspection of the vessel and vessel components in accordance
with ASME RTP-1 Paragraph 6-940 to assure that imperfections are in compliance with Level 2
requirements unless a) Level 1 is specified in the UBRS or b) critical service is specified in the
UBRS. Level 1 compliance is required for vessels designated for critical service
The Fabricator shall make repairs, if required, in accordance with ASME RTP-1 to bring the
vessel in compliance with the designated Visual Inspection Acceptance Level.

10.2.4 Lift Test


The completed vessel, except for exterior coating, shall be lift tested and rotated into the
installation orientation prior to hydrostatic testing. The lift test shall be conducted with only the
installed lift clips and tailing lugs. The lift test is to verify the structural integrity of the clips/lugs
as installed.

10.2.5 Hydrostatic Test


Hydrostatic pressure tests are required in accordance with the UBRS. As a minimum, vessels
must be filled with water to the maximum liquid level and held for a minimum duration of 2
hours. Internal pressure may be required in addition to the hydrostatic test. Vacuum tests may
also be required
The closed vessel shall have a vent designed with appropriate size and location to allow the
removal of air during filling and the prevention of vacuum during emptying of the test fluid.
The vessel shall be positioned with the same orientation intended in service and shall be
supported on its own in-service support system during hydrostatic and pressure tests.
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Hydrostatic tests shall be performed with clean water at temperatures between 50 F (10C) and
100F (40C).
Test gaskets shall be used on all nozzles and manways. Test gaskets shall be of similar thickness,
hardness and surface texture as the service gaskets. Bolt torque shall be limited to the values
shown on the drawings. Permission to exceed the specified torque must be obtained from the
User or the User’s representative prior to the application of increased torque, and the use of
increased torque must be noted in the Inspectors report.
All manway covers and blind flanges shall be match marked to insure proper alignment and
sealing in the future.
Vessels must survive the applicable hydrostatic and pressure tests without visible leakage or
evidence of structural damage.
Upon completion of hydrostatic and pressure tests, the vessel shall be drained and wiped dry. All
manway covers, nozzle blinds, and temporary test blinds shall be removed to facilitate internal
inspection.

10.2.6 Acoustic Emission Tests


Acoustic emission tests are required only if specified in the UBRS. Acoustic emission testing is
an optional verification of structural integrity that may be specified in the UBRS for vessels
designated for critical service as defined in ASME RTP-1 Section 1-220.
Please refer to ASME RTP-1 Section. 3B-500 sub.(c) for strength ratio in case of
acoustic emission test is performed.

10.3 Final Inspection


The vessel interior and exterior shall be inspected after completion of the lift test and the
hydrostatic test, but before the application of exterior coatings. The final inspection shall be
conducted by the Fabricator’s quality control department in the presence of a User’s
representative.
The Fabricator must ensure that the vessel is safe for inspection and must provide safe access
consistent with OSHA or local jurisdiction requirements as a minimum.
The vessel must be in compliance with the visual inspection acceptance criteria in Table 6-1.
Nonconformities shall be repaired in accordance with ASME RTP-1 Paragraph 6-960. The
Inspector shall include a record of all repairs on the inspection report.
If repairs are made to pressure containing parts the hydrostatic and pressure tests shall be
repeated and the inspection shall be repeated until the vessel passes the visual inspection
acceptance criteria.

11 Exterior Coating

An exterior coating may be specified in the UBRS for insulation or UV resistance. Exterior
surface preparations for exterior coatings shall not be started until the testing and inspection
tasks are complete and approved by the Inspector and the User’s representative if specified in the
UBRS. After approval, the Fabricator shall prep and coat all exterior surfaces including brackets,
clips, pipe supports, lifting lugs, platforms and all attachments bolted to the vessel in accordance
with the Job Specification.
FRP vessels shall be external protected to atmospheric agents and UV rays. The
thickness of external coat shall not be less than 0.3mm and in any case sufficient to
completely cover all the fibres emerging from the mechanically-resistant layer.

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12 Documentation

The Fabricator will provide the User with documentation in accordance with ASME RTP-1 and
this specification, including
Fabricator’s Design Report
Project Execution Schedule
Final Shop Drawings
Fabricator Data Report, including materials, fabrication, inspection, repair and test data
“As Built” Shop Drawings
Quality control files (available for inspection by the User)

13 Handling and Shipping

The Fabricator shall provide a nameplate with the finished weight and the User’s item number.
The Fabricator will tag the vessel with the same information prior to shipping.
All flange faces, nozzles, lugs, supports, etc. shall be protected from damage during shipment.
All vessel openings shall be covered to prevent damage and to prevent foreign matter from
entering the vessel during shipment.
a. Install manway and blind flange covers with the specified service gaskets and bolts.
b. Install plywood protective covers on the remaining flange openings. Ship the service
gaskets and bolts for these openings in separate package.
c. Gasket materials and bolt alloys will be indicated by the User on the Job Specification.
d. Threaded connections shall be covered with PVC plugs or caps.
e. In addition to handling and shipping provisions included in this specification, the
Fabricator should follow the handling and shipping guidelines in ASME RTP-1 Appendix
NM-8.
f. Fabricator shall issue proper handling and shipping drawings showing all requirement to
be adopted during handling shipping and erection activities

14 Installation

When requested on material requisition for inquiry followed confirmation on the order:
a. The Fabricator shall provide a qualified technician to inspect the vessel after shipping,
during transportation to the installation site and during installation.
b. The Fabricator shall provide a qualified representative to train the User’s employees in the
operation and maintenance of the vessel.
c. The Fabricator shall provide a qualified representative to assist User employees during
start-up of vessel operation.

15 Warranty

The Fabricator shall provide a warranty for the vessel in accordance with the requirements in the
UBRS. The Fabricator is responsible for inspecting the vessel at the end of the warranty period.

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