DEP SPECIFICATION

FABRICATION OF HEATER PIPING

Copyright Shell Group of Companies. No reproduction or networking permitted without license from Shell. Not for resale

DEP [Link]-Gen.

September 2012

DESIGN AND ENGINEERING PRACTICE

© 2012 Shell Group of companies

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior
written permission of the copyright owner or Shell Global Solutions International BV.

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PREFACE

DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international,
regional, national and industry standards.
The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and
gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help
achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each
locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units 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 such use, including the
quality of their work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, the Principal will typically expect them to follow those design and engineering
practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or
Manufacturer/Supplier shall, without detracting from his own respons bility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is typically granted by Shell GSI (and in some cases by other Shell
Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and
other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three
categories of users of DEPs can be distinguished:
1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these
Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of
a Service Agreement or otherwise).
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2)
which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims
any liability of whatsoever nature for any damage (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, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The
benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these
companies, that may issue DEPs or advise 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 Shell GSI, be disclosed by users to any company or person 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 Shell GSI. The
copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell
GSI 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 Shell GSI.

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TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................ 4
1.1 SCOPE........................................................................................................................ 4
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 4
1.3 DEFINITIONS ............................................................................................................. 4
1.4 CROSS REFERENCES.............................................................................................. 5
1.5 SUMMARY OF MAIN CHANGES ............................................................................... 5
1.6 COMMENTS ON THIS DEP ....................................................................................... 5
1.7 DUAL UNITS ............................................................................................................... 5
2. GENERAL................................................................................................................... 6
2.1 DESIGN CODE ........................................................................................................... 6
2.2 DOCUMENTATION .................................................................................................... 6
3. MATERIALS ............................................................................................................... 6
3.1 GENERAL ................................................................................................................... 6
3.2 MATERIAL CERTIFICATION ..................................................................................... 6
3.3 TRACEABILITY .......................................................................................................... 6
3.4 BENDS ........................................................................................................................ 6
4. FABRICATION ........................................................................................................... 7
4.1 ASSEMBLY ................................................................................................................. 7
4.2 CUTTING AND BEVELLING ...................................................................................... 7
4.3 WELDING ................................................................................................................... 7
4.4 FINAL CORRECTIONS .............................................................................................. 7
4.5 TOLERANCES ............................................................................................................ 8
5. INSPECTION AND TESTING..................................................................................... 9
5.1 GENERAL ................................................................................................................... 9
5.2 PRESSURE TESTING................................................................................................ 9
5.3 HARDNESS TESTING ............................................................................................... 9
5.4 POSITIVE MATERIAL IDENTIFICATION................................................................... 9
5.5 TUBE FINNING ........................................................................................................... 9
6. REFERENCES ......................................................................................................... 10

APPENDICES
APPENDIX 1 INSPECTION CLASSES FOR COILS ............................................................ 11

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1. INTRODUCTION

1.1 SCOPE
This DEP specifies requirements and gives recommendations for the shop and field
fabrication, inspection and testing of piping (tubing) to be used in fired heaters and waste
heat boilers. Fired steam boilers are excluded from the scope of this DEP.
This is a revision of the DEP of the same number dated November 2006; this revision has
been purely editorial, with no technical changes.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated
by them. Any authorised access to DEPs does not for that reason constitute an
authorisation to any documents, data or information to which the DEPs may refer.
This DEP is intended for use in oil refineries, chemical plants, gas plants and, where
applicable, in exploration and production facilities and supply/marketing installations. This
DEP may also be applied in other similar facilities.
When DEPs are applied, a Management of Change (MOC) process shall be implemented.
This is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements could be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regards to the safety, environmental, economic and legal aspects. In all
cases, the Contractor shall inform the Principal of any deviation from the requirements of
this DEP which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned, the objective
being to obtain agreement to follow this DEP as closely as possible.

1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The word should indicates a recommendation.

1.3.2 Specific definitions

Term Definition
Design Code Standard specified by the Principal to which the equipment shall conform
(if not already dictated by the equipment standard).
GTAW Gas Tungsten Arc Welding
HAZ Heat Affected Zone
Hydrogen All process conditions with a hydrogen partial pressure greater than
Service 7 bar (abs) (100 psia).

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Term Definition
PWHT Post Weld Heat Treatment
Very Toxic Substances that are very hazardous for the environment or human
(substances) health. See DEP [Link]-Gen.

1.4 CROSS REFERENCES

Where cross-references to other parts of this DEP are made, the referenced section
number is shown in brackets ( ). Other documents referenced by this DEP are listed in (6).

1.5 SUMMARY OF MAIN CHANGES

This DEP is a revision of the DEP of the same number dated November 2006; this revision
has been purely editorial, with no technical changes.

1.6 COMMENTS ON THIS DEP

Comments on this DEP may be submitted to the Administrator using the DEP Feedback
Form by:
• Entering comments directly in the DEP Feedback System on the Technical
Standards Portal [Link] (mandatory for users with access
to Shell Wide Web);
• Clicking on the DEP Feedback Form button on the DEPs DVD-ROM main page
(for users without access to Shell Wide Web);
• Requesting a copy of the DEP Feedback Form from the Administrator at
standards@[Link] (for users without access to Shell Wide Web).
For the last two options, the completed DEP Feedback Form can be attached to an email
and submitted to the Administrator at standards@[Link]. Only feedback that is entered
into the Feedback Form will be considered.

1.7 DUAL UNITS

This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When
agreed by the Principal, the indicated USC values/units may be used.

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2. GENERAL

2.1 DESIGN CODE

If not already dictated by the equipment standard, the design code shall be specified by the
Principal (e.g., ASME VIII, ASME B31.3).

2.2 DOCUMENTATION
The Principal shall provide the Manufacturer with drawings and related requisitions giving
all information on the coils to be fabricated.
In addition to the data stated on these drawings, shop drawings provided by the
Manufacturer shall state:
• details of the welded joints with reference to the welding procedure specification,
pre- and post-weld heat treatment procedures and all non destructive examinations
required;
• hydrostatic test pressure.
Before the start of manufacture, all shop drawings, weld procedure specifications including
pre-and post-weld treatment procedures, welding procedure qualification records, welder
performance qualifications and non-destructive examination procedures shall have been
reviewed by the Principal.
The Manufacturer shall comply with these drawings.
Upon completion, the Manufacturer shall supply a manufacturing report containing all the
relevant documentation. The format for this report should be in accordance with
DEP [Link]-Gen., making use of all the applicable sections.

3. MATERIALS

3.1 GENERAL
The materials shall comply with the specification given on the drawing and/or requisition.
Unless otherwise specified, only seamless pipe and fittings shall be used.
Metallic construction materials standards shall be in accordance with the design code.

3.2 MATERIAL CERTIFICATION

All materials used for pressure-containing parts shall be traceable to inspection certificates
in accordance with ISO 10474 Type 3.1.B.

3.3 TRACEABILITY
The heat numbers (or other codes traceable to the heat numbers) of certified materials (see
(3.2)) shall be recorded on an as-built drawing of the heater piping.

3.4 BENDS
Welding return bends in accordance with ASME B16.9 shall be used in coils.

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4. FABRICATION

4.1 ASSEMBLY
The type of flanges, fittings and connections and the extent to which welded joints are
applied shall be indicated on the Principal's drawings.
No intermediate welds shall be made in the pipes used for the coils, unless approved by the
Principal. Any dissimilar welds to pressure containing parts (e.g., tube guides) shall be
subject to the approval of the Principal.
All branch welds and structural attachment welds shall be dressed to a smooth finish, free
from undercut and merging smoothly into the pipe surface, and without any sharp corners
or other stress raisers.

4.2 CUTTING AND BEVELLING

Cutting and bevelling of pipes may be done either by mechanical means or by thermal
(flame, arc or plasma) means or by water cutting. The following shall apply:
• For carbon steel, thermal cutting and bevelling may be used only if the cut is
reasonably smooth and all oxides are removed from the surface.
• For low and intermediate alloy steel, after thermal cutting, approximately 2 mm
(0.08 in) of material shall be removed from the surface of the bevel by grinding or
machining. The dressed bevels then shall be examined by either magnetic particle or
liquid penetrant methods prior to welding, to confirm that the bevel is free from linear
indications 1.6 mm (0.06 in) or longer.
• Stainless steel shall not be flame or arc cut. Plasma or water cutting may be applied.
The surface shall be ground to bright metal after plasma cutting. The quality of water
used for cutting shall be reviewed by the Principal prior to use.
If preheat is specified for welding, the same preheat shall be applied for thermal cutting.
Weld bevels for butt-welding shall be in accordance with ASME B16.25.

4.3 WELDING
No production welding shall be performed until the welding procedure specifications have
been approved by the Principal and the welding procedures and welders have been
qualified in accordance with the design code.
If internal trimming of butt-welded piping components is necessary to achieve the required
alignment, it shall be done by internal tapering (with a taper no steeper than one-to-four).
Backing rings shall not be used.
The following welding process restrictions shall apply:
• The GTAW process shall be employed for pipes, branch fittings and flanges in sizes
DN 50 (NPS 2) and smaller.
• For stainless steel piping not back-welded inside, the root pass shall be carried out
by the GTAW process with an inert gas purge which shall be maintained until at least
the second pass has been completed.

4.4 FINAL CORRECTIONS

4.4.1 General
Final corrections are modifications to the dimensions of a fabricated coil in order to allow
stress-free installation. No final corrections shall be performed until the related correction
procedure has been reviewed by the Principal.
The following methods of correction shall be used, in order of preference:
• Cutting and re-welding;

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• Local non-uniform heating or cooling;

• Application of force with local heating.

The following restrictions apply to the heating, cooling and forcing of piping made from
carbon steel, low alloy steel or austenitic stainless steel:
Temperature-indicating crayons or contact thermometers shall be used to measure the
maximum temperature. If temperature-indicating crayons are used, a margin of 50 °C
(122 °F) shall be taken to allow for measurement inaccuracy (i.e., the reading with the
crayon shall not exceed the maximum stated temperature minus 50 °C (122 °F)).
4.4.2 Carbon steel which does not require a PWHT
The maximum temperature during alignment corrections shall be 600 °C (1100 °F). Forcing
may be applied if necessary. Cooling in still air shall be applied.
4.4.3 Carbon steel which requires a PWHT
The maximum temperature during alignment corrections shall be the maximum PWHT
temperature. Forcing may be applied if necessary. No quenching shall be used. The area
shall either be heated in full compliance with the PWHT procedure or the area which is
heated (and corrected) shall be subject to PWHT.
4.4.4 Cr-Mo steels
The maximum temperature during alignment corrections shall be the maximum PWHT
temperature. Forcing may be applied if necessary. Cooling in still air shall be applied.
Hardness measurements shall be taken on the heated and forced area and the hardness
shall not exceed 248 HV 10.
4.4.5 Austenitic stainless steel
The maximum temperature during alignment corrections shall be 500 °C (930 °F). The
duration of heating shall be kept as short as possible and forcing may be applied if
required.
4.5 TOLERANCES
4.5.1 Dimensions
For dimensions stated on the Principal's drawings, the following tolerances shall apply:

Length Tolerance
< 1.5 m (0.06 in) ± 1.5 mm (0.06 in)
≥ 1.5 m (0.06 in) ± 3 mm (0.12 in)

4.5.2 Flange alignment

Flange alignment shall be in accordance with DEP [Link]-Gen.
If branches are in the same plane and their flanges are also positioned in one plane, the
flange facings shall not deviate more than 1 mm (0.04 in) from the latter plane in the same
direction.

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5. INSPECTION AND TESTING

5.1 GENERAL
All inspection and testing is the responsibility of the Manufacturer. All dimensions shall be
checked to ensure that the fabrication meets the requirements of the coil drawings and this
DEP, within the specified tolerances.
The Principal shall specify whether, and to what extent, he wishes to witness the
Manufacturer’s inspection and testing.
Inspection of welds shall be carried out after final heat treatment in accordance with the
inspection classes shown in (Appendix 1).
The methods to be employed for the inspection and the acceptance criteria shall be in
accordance with the design code.
NOTE: Coil service (pressure, temperature and fluid) shall be indicated on the Principal's drawings or
requisition.

5.2 PRESSURE TESTING

Pressure testing shall be performed in accordance with the design code. For field pressure
testing, reference is made to DEP [Link]-Gen.

5.3 HARDNESS TESTING

The hardness shall be measured on the welding procedure qualification test plates and on
10 % of the production welds. No part of the weld, HAZ or base metal shall exceed
248 HV 10.
5.3.1 Hardness measurement method
Hardness measurements for welding procedure qualification shall be performed by the
Vickers method, with hardness traverses in accordance with ISO 9015-1. The series of
readings shall extend from unaffected base material on one side, across the weld to
unaffected base metal on the other side. Three traverses shall be made: one 2 mm
(0.08 in) below the outer surface, one 2 mm (0.08 in) below the inner surface and one
across the centre. The distance between measurements across the weld shall not exceed
2 mm (0.08 in).
Transverse weld hardness testing of production welds shall be carried out using a portable
Vickers or Rockwell tester in accordance with ASTM E110 or by another method capable of
detecting a hard HAZ if approved by the Principal. Hardness tests shall be performed on
properly ground surfaces. For each set of hardness measurements required, the average of
three measurements on the weld and on each HAZ shall be reported.
Hardness measurements shall be carried out after any PWHT and final corrections.

5.4 POSITIVE MATERIAL IDENTIFICATION

For all materials other than carbon steel, the alloying elements in materials and weld
deposits shall be verified by chemical, spectroscopic or X-ray fluorescence methods after
fabrication of the coils. The results shall be included in the manufacturing report.

5.5 TUBE FINNING

Finned tubes shall be inspected to ensure that the fins are perpendicular to the tube within
15°. The maximum discontinuity of the resistance weld shall be 64 mm (2-1/2 in) in any
2500 mm (100 in) of weld.

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6. REFERENCES
In this DEP, reference is made to the following publications:
NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at [Link]

SHELL STANDARDS
Definition of temperature, pressure and toxicity levels DEP [Link]-Gen.
Welding of metals (amendments/supplements to API RP 582) DEP [Link]-Gen.
Manufacturing report for pressure vessels DEP [Link]-Gen.
Piping - general requirements DEP [Link]-Gen.
Shop and field pressure testing of piping systems DEP [Link]-Gen.

AMERICAN STANDARDS
ASME Boiler and Pressure Vessel Code – Section VIII - Rules for ASME BPVC SEC VIII
construction of pressure vessels
Factory-made wrought buttwelding fittings ASME B16.9
Buttwelding ends ASME B16.25
Process piping ASME B31.3
Standard test method for indentation hardness of metallic materials ASTM E110
by portable hardness testers

EUROPEAN STANDARDS
Destructive tests on welds in metallic materials - Hardness testing - ISO 9015-1
Part 1. Hardness test on arc welded joints

INTERNATIONAL STANDARDS
Steel and steel products - Inspection documents ISO 10474

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APPENDIX 1 INSPECTION CLASSES FOR COILS

Coil material Service ASME Inspection levels in %

rating (see legend)
class
(A)
Radiography MT PT

(B), (C), (D) (E) (E)

Carbon steel, Utilities < 1500 10 10
including fine-
grain carbon Utilities ≥ 1500 100 10
steel
(1)
Very toxic service All ratings 100 100
(1)
Hydrogen service All ratings 100 100
Other services < 1500 10 10

≥ 1500 100 100

Ferritic low alloy All services All ratings 100 100
steel
(1)
Stainless Hydrogen service All ratings 100 100
(2)
steels
(1)
Very toxic service All ratings 100 100
Other services < 600 10 10
Other services ≥ 600 100 100

NOTE: (1) "Hydrogen service" and "very toxic" are defined in (1.3.2).
(2) The ferrite number of austenitic stainless steel welds shall be measured in accordance with
DEP [Link]-Gen.

Legend:
(A) The indicated percentage of welds to be inspected shall apply to all welders involved
(B) Ultrasonic examination may be applied instead of radiography if:
(i) the configuration precludes radiography
and (ii) pipe diameter >DN 100 (NPS 4)
and (iii) nominal wall thickness >10 mm (3/8 in)
(C) Branch connections, including small nipples, shall be radiographed unless waived by the
Principal
(D) Film quality requirements:
Fine grain film (Class II) for x-ray
Ultrafine grain film (Class I) for gamma ray
(E) MT = magnetic particle examination
PT = liquid penetrant examination

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