GB/T 150.4-2024 Pressure vessels - Part 4: Fabrication, inspection and testing, and acceptance English
1 Scope
This document specifies the requirements for the fabrication, inspection and testing, and acceptance of steel pressure vessels.
This document is applicable to the fabrication, inspection and testing, and acceptance of steel pressure vessels, and non-alloy, low-alloy or high-alloy steel substrate of clad plate pressure vessels, lined pressure vessels, and pressure vessels with surfacing layer.
This document is applicable to single-layer welded (including tubular cylindrical shell) pressure vessels, forged-welded pressure vessels, shrink fit pressure vessels, wrapped (including multi-layer cylindrical shell sections wrapped, and multi-layer integrally wrapped) pressure vessels, and flat steel ribbon wound pressure vessels.
2 Normative references
The following documents contain provisions which, through reference in this text, constitute provisions of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
GB/T 150.1 Pressure vessels - Part 1: General requirements
GB/T 150.2-2024 Pressure vessels - Part 2: Materials
GB/T 150.3-2024 Pressure vessels - Part 3: Design
GB/T 151 Heat exchangers
GB/T 196 General purpose metric screw threads - Basic dimensions
GB/T 197 General purpose metric screw threads - Tolerances
GB/T 228.1 Metallic materials - Tensile testing - Part 1: Method of test at room temperature
GB/T 228.2 Metallic materials - Tensile testing - Part 2: Method of test at elevated temperature
GB/T 229 Metallic materials - Charpy pendulum impact test method
GB/T 232 Metallic materials - Bend test
GB/T 1804-2000 General tolerances - Tolerances for linear and angular dimensions without individual tolerance indications
GB/T 1954 Methods of measurement for ferrite content in austenitic Cr-Ni stainless steel weld metals
GB/T 2039 Metallic materials - Uniaxial creep testing method in tension
GB/T 3965 Determination of diffusible hydrogen in deposited metal
GB/T 5310 Seamless steel tubes and pipes for high pressure boiler
GB/T 6396 Clad steel plates - Mechanical and technological test
GB/T 6479 Seamless steel tubes for high-pressure chemical fertilizer equipments
GB/T 8923.1-2011 Preparation of steel substrates before application of paints and related products - Visual assessment of surface cleanliness - Part 1: Rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous coatings
GB/T 9948 Seamless steel tubes for petroleum cracking
GB/T 12337 Steel spherical tanks
GB/T 16749 Bellows expansion joints for pressure vessel
GB/T 21433 Detecting susceptibility to intergranular corrosion in stainless steel pressure vessels
GB/T 25198 Heads for pressure vessels
GB/T 30583 Specification for post weld heat treatment of pressure equipment
HG/T 20592 to 20635 Steel pipe flanges, gaskets and bolting
JB/T 3223 Welding consumables quality management procedures
JB/T 4734 Aluminium welded vessels
JB/T 4755 Copper pressure vessels
JB/T 4756 Nickel and nickel alloy pressure vessels
NB/T 10558 Coating and packing for pressure vessels transport
NB/T 11025 Reinforcing pad
NB/T 11270 Titanium pressure vessels
NB/T 47002 (All parts) Clad plate for pressure vessel
NB/T 47008 Carbon and alloy steel forgings for pressure equipment
NB/T 47009 Alloy steel forgings for low temperature pressure equipment
NB/T 47011 Zirconium pressure vessels
NB/T 47013 (All parts) Nondestructive testing of pressure equipments
NB/T 47014 Welding procedure qualification for pressure equipments
NB/T 47015 Welding specification for pressure vessels
NB/T 47016 Mechanical property tests of product welded test coupons for pressure equipments
NB/T 47018 (All parts) Technical permission of welding materials for pressure equipment
NB/T 47019.4 Purchase technical specification for boiler & heat exchanger tubes - Part 4: Low alloy steel for low-temperature service
NB/T 47020 to 47027 Flanges, gaskets, stud bolts & nut for pressure vessels
NB/T 47041 Vertical vessels supported by skirt
NB/T 47042 Horizontal vessels on saddle supports
NB/T 47065 (All parts) Vessel support
3 Terms and definitions
For the purposes of this document, the terms and definitions given in GB/T 150.1, GB/T 151 and GB/T 30583 as well as the following apply.
3.1
forged-welded pressure vessel
pressure vessel made with cylindrical shell sections and heads (or ends) machined from forgings in cylindrical or other shapes which are connected by circumferential welded joints
3.2
layered pressure vessel
pressure vessel (excluding lined pressure vessel) with cylinder or heads composed of two or more layers of plates or strips, which are connected by non-welding methods
3.3
wrapped pressure vessel
layered pressure vessel formed by wrapping the laminates layer by layer onto the cylinder
Note: Wrapped pressure vessels can be classified into two types by structure: multi-layer cylindrical shell sections wrapped pressure vessels and multi-layer integrally wrapped pressure vessels. Multi-layer cylindrical shell sections wrapped pressure vessel refers to a pressure vessel formed by wrapping laminates layer by layer onto single cylinders to form multi-layer cylindrical shell sections which are then assembled via circumferential welded joints; multi-layer integrally wrapped pressure vessel refers to a pressure vessel formed by wrapping laminates layer by layer onto the cylinders forming a whole.
3.4
flat steel ribbon wound pressure vessel
layered pressure vessel formed by winding flat steel ribbon layer by layer in a staggered manner at a certain inclination angle on the cylinders forming a whole
3.5
shrink fit pressure vessel
pressure vessel formed by assembling shrink fit cylindrical shell sections with circumferential welded joints, in which, several layers of cylindrical shell sections with certain magnitude of interference are fitted by heating (or cooling) and then subjected to heat treatment to eliminate the shrink fit prestress to form the shrink fit cylindrical shell sections
3.6
thickness of steel material
feeding thickness of steel plates, steel pipes, forgings, etc., for fabricating pressure components
3.7
cold forming
plastic deformation processing performed below the recrystallization temperature of the workpiece material
Note: In engineering practice, it includes 1) room temperature forming for plastic deformation processing at ambient temperature; and 2) warm forming for plastic deformation processing at a heating temperature not exceeding the recrystallization temperature of the material.
3.8
hot forming
plastic deformation processing conducted above the recrystallization temperature of the workpiece material
3.9
forming temperature
temperature at plastic deformation for forming the workpiece
3.10
thermal treatment
fabrication and repair processes of non-alloy or low-alloy steel pressure vessels or pressure components which are heated to 490°C or above during fabrication and use, and those of high-alloy steel pressure vessels or pressure components which are heated to 315°C or above, neither including thermal cutting or in-process welding
3.11
minimum thermal treatment; Min. TT
specific heat treatment of a test piece (or specimen) to simulate the minimum thermal cycles of a pressure vessel or pressure component during fabrication
3.12
maximum thermal treatment; Max. TT
specific heat treatment of a test piece (or specimen) to simulate the maximum thermal cycles possible of a pressure vessel or pressure component during fabrication and use
Note: The repair conducted during fabrication is included according to the actual thermal cycles during rework, while that conducted during use, unless otherwise specified, shall be included according to the thermal cycles during one repair.
3.13
minimum postweld heat treatment; Min. PWHT
specific heat treatment of a test piece (or specimen) to simulate the minimum thermal cycles during fabrication
Note 1: For test pieces (or specimens) of the same austenitized and tempered heat treatment conditions as the material upon delivery, all heat treatments above 490°C during fabrication are accumulated for the simulated heat treatment, including intermediate stress relief (when not combined with postweld heat treatment) and one postweld heat treatment.
Note 2: For Cr-Mo and Cr-Mo-V steels, the equivalent holding time may be calculated using the Larson-Miller Parameter for heat treatment not higher than the final postweld heat treatment temperature, and the result shall be approved in writing by the design organization.
3.14
maximum postweld heat treatment; Max. PWHT
specific heat treatment of a test piece (or specimen) to simulate the maximum thermal cycles possible during fabrication and use
Note 1: For test pieces (or specimens) of the same austenitized and tempered heat treatment conditions as the material upon delivery, all heat treatments above 490°C during fabrication are accumulated for the simulated heat treatment, including intermediate stress relief, all postweld heat treatments, one postweld heat treatment after repair by the manufacturer, and at least one postweld heat treatment to be conducted by the user.
Note 2: For Cr-Mo and Cr-Mo-V steels, the equivalent holding time may be calculated using the Larson-Miller Parameter for heat treatment not higher than the final postweld heat treatment temperature, and the result shall be approved in writing by the design organization.
3.15
intermediate stress relief; ISR
process where the weldment is evenly heated to a certain temperature, held for a certain time, and then evenly cooled before the final postweld heat treatment to eliminate welding residual stress
3.16
pressure vessel designed by simple fatigue analysis
pressure vessel which has been successfully applied, approved by the technical director of the design organization to design in accordance with GB/T 150.3, with the fatigue analysis and evaluation supplemented according to the analysis and design, and meets relevant fabrication, inspection and testing, and acceptance requirements
3.17
weld metal replacement
operation involving re-welding after removing the original splicing weld metal of heads (including cones) and other parts and components that have been hot formed after plate splicing
4 General
4.1 Fabrication, inspection and testing, and acceptance requirements for pressure vessels
4.1.1 Additional requirements shall be imposed on the fabrication, inspection and testing, and acceptance of pressure vessels in different structural forms apart from those for fabrication, inspection and testing, and acceptance of single-layer welded (including tubular cylindrical shell) pressure vessels:
a) See Annex A for additional requirements for the fabrication, inspection and testing, and acceptance of forged-welded pressure vessels;
b) See Annex B for additional requirements for the fabrication, inspection and testing, and acceptance of shrink fit pressure vessels;
c) See Annex C for additional requirements for the fabrication, inspection and testing, and acceptance of wrapped pressure vessels;
d) See Annex D for additional requirements for the fabrication, inspection and testing, and acceptance of flat steel ribbon wound pressure vessels.
4.1.2 Additional requirements for the fabrication, inspection and testing, and acceptance of pressure vessels designed to prevent brittle fracture at low temperature are specified in Annex E.
4.1.3 For low temperature pressure vessels made of chromium-nickel austenitic stainless steel (designed for temperatures below -196°C), additional requirements for their fabrication, inspection and testing, and acceptance shall be specified through consultation among the parties involved in the construction and shall be stipulated in the design documents by the design organization.
4.2 Basis for the fabrication, inspection and testing, and acceptance of pressure vessels
The fabrication, inspection and testing, and acceptance of pressure vessels shall comply with the following requirements in addition to those in this document and the design documents:
a) The fabrication, inspection and testing, and acceptance of heat exchangers, spherical tanks, vertical vessels supported by skirt, and horizontal vessels shall comply with GB/T 151, GB/T 12337, NB/T 47041, and NB/T 47042, respectively.
b) The fabrication, inspection and testing, and acceptance of non-ferrous metal liners, surfacing layers, and clad plate coatings for pressure vessels shall comply with JB/T 4734, NB/T 11270, JB/T 4755, JB/T 4756, and NB/T 47011, respectively.
4.3 Raw materials and parts and components (including self-made, outsourced and purchased parts and components)
4.3.1 Raw materials
4.3.1.1 Plates, pipes, forgings, bars and clad plates shall be subject to the following requirements.
a) Plates, pipes, forgings, and bars shall comply with the relevant requirements of GB/T 150.2, GB/T 151, GB/T 12337, JB/T 4734, NB/T 11270, JB/T 4755, JB/T 4756, and NB/T 47011. Material suppliers shall provide the heat treatment process parameters for the materials as delivered. When necessary, the pressure vessel manufacturer may specify performance requirements for materials subjected to minimum and/or maximum thermal treatment.
b) Clad plates shall comply with NB/T 47002 (all parts). When heat exchange tubes are subject to axial compressive stress, if clad plates are used to manufacture tube sheets, requirements on bonding strength of the clad plates shall be specified and bonding strength tests shall be conducted in accordance with GB/T 6396.
c) Non-ferrous metal liners shall be selected in accordance with the relevant provisions of JB/T 4734, NB/T 11270, JB/T 4755, JB/T 4756, and NB/T 47011.
4.3.1.2 Welding materials shall comply with NB/T 47018 (all parts) as well as GB/T 150.2. When necessary, the pressure vessel manufacturer may specify performance requirements for welded materials subjected to simulated minimum and/or maximum thermal treatment.
4.3.2 Parts and components (including self-made, outsourced and purchased parts and components)
4.3.2.1 Additional requirements for heads, in addition to GB/T 25198, are as follows:
a) Hard markings shall not be adopted for heads with a thickness not exceeding 6 mm, stainless steel heads, heads for low temperature pressure vessels, and heads for pressure vessels designed by simple fatigue analysis, as well as coatings on heads for clad plates.
b) Cold-formed chromium-nickel austenitic stainless steel heads shall be tested using a ferrite tester along two mutually perpendicular bus bars, by referring to GB/T 1954. For ellipsoidal heads and dished heads, the test points shall include at least the apex, four points at the small-radius corner, and four points near the port on the straight edge. For conical heads, the test points shall include at least four points near the ports at the large and small ends, respectively, and four points in the middle. For hemispherical heads, the test points shall include at least the apex, four points near the port, and four points between the apex and the port. The measured ferrite content shall comply with the requirements of 8.3.1.4 and 8.3.1.5, and the pressure vessel manufacturer shall re-test each head formed. For heads formed after plate splicing, the test parts shall include the weld seams.
c) For heads assembled after being formed in flaps, if the assembly is not completed by the head manufacturer, the head manufacturer shall pre-assemble the heads. The inspection items and results of the pre-assembled heads shall comply with the relevant standards or technical documents for ordering.
4.3.2.2 The flanges of a pressure vessel and their components shall comply with NB/T 47020 to NB/T 47027 and the design documents.
4.3.2.3 The pipe flanges of a pressure vessel and their components shall comply with HG/T 20592 to HG/T 20635 and the design documents.
4.3.2.4 The expansion joints shall comply with GB/T 16749 and the design documents. In addition, cold-formed chromium-nickel austenitic stainless steel expansion joints shall be tested using a ferrite tester along four bus bars spaced 90° apart by referring to GB/T 1954. The test points shall include at least the wave crest, wave trough, and the part between the crest and trough. The measured ferrite content shall comply with the requirements of 8.3.1.4 and 8.3.1.5, and the pressure vessel manufacturer shall re-test each expansion joint formed. For expansion joints formed after plate splicing, the test parts shall include the welds.
4.3.2.5 The reinforcing pads shall comply with NB/T 11025 and the design documents.
4.3.2.6 Suppliers of purchased finished parts and components shall provide the pressure vessel manufacturer with complete and authentic product quality certificates. When requested by the pressure vessel manufacturer, the suppliers shall provide the thickness of the steel material used in the finished parts and components.
4.4 Fabrication environment
4.4.1 The fabrication of high alloy steel pressure vessels should be conducted in a clean and relatively independent environment.
4.4.2 The fabrication environment for non-ferrous metal liners shall comply with the relevant provisions of JB/T 4734, NB/T 11270, JB/T 4755, JB/T 4756, and NB/T 47011.
Foreword I
Introduction X
1 Scope
2 Normative references
3 Terms and definitions
4 General
5 Material re-inspection, cutting and mark transplantation
6 Cold/thermal forming and assembly
7 Welding
8 Heat treatment
9 Test pieces and specimens
10 Non-destructive testing
11 Pressure test and leakage test
12 Hot gas cycle test
13 End-of-manufacturing requirements for pressure vessels
Annex A (Normative) Additional requirements for the fabrication, inspection and testing, and acceptance of forged-welded pressure vessels
Annex B (Normative) Additional requirements for the fabrication, inspection and testing, and acceptance of shrink fit pressure vessels
Annex C (Normative) Additional requirements for the fabrication, inspection and testing, and acceptance of wrapped pressure vessels
Annex D (Normative) Additional requirements for the fabrication, inspection and testing, and acceptance of flat steel ribbon wound pressure vessels
Annex E (Normative) Additional requirements for the fabrication, inspection and testing, and acceptance of pressure vessels checked and designed to prevent brittle fracture at low temperature
