B101FS301 Convection, Rev II

TECHNICAL SPECIFICATION FOR

FABRICATION & ASSEMBLY OF CONVECTION MODULE FOR HEATER B101 NOCL CUDDALORE, INDIA EF 10013

B101-FS-301

Onshore or Offshore Fabrication

PREFABRICATION OF B101 ATMOSPHERIC SERVICE HEATER CONVECTION MODULE

2

20/07/2011

TECHNICAL SPECIFICATION SPECIFI CATION

LAHTI

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B101-FS-301

TABLE OF CONTENT Page 1

INTRODUCTION....................................................................................................................................... 3

2

DESIGNATION................................................... ........................................................... ............................ 3

3

CONTRACTUAL DOCUMENTS .......................................................... ................................................... 3 3.1 GENERAL ...................................................................................................................................................... 3

4

SCOPE OF SUPPLY .................................................................................................................................. 4 4.1 GENERAL ...................................................................................................................................................... 4 4.2 DESCRIPTION OF WORKS ............................................................................................................................... 5 4.2.2 Convection modules (for Heater B-101) Fabricator’s Responsibilities: ................................................ 5 4.3.1 Structure & Plate Steel: (Fabricaot Supply) ............................................................... ............................ 6 4.3.2 Bolts: (Fabricator Supply + 10% spare) .............................................................. ................................... 6 4.3.3 External painting: Heurtey Supply)........................................................... ............................................. 6 4.3 WEIGHTS & QUANTITIES: PER HEURTEY DRAWINGS & DATA SHEETS .................................................. ....... 6 4.5.1 Marking .................................................................................................................................................. 7 4.5.2 Trial assembly ........................................................................................................................................ 7 4.5.3 General ................................................................................................................................................... 7 4.6. Pressure parts ........................................................................................................................................... 7

5

MISCELLANEOUS ................................................................................................................................... 8 5.1.

PLANNING ............................................................................................................................................ 8

5.2.

R ESPONSIBILITY OF HPC ..................................................................................................................... 9

5.3.

GUARANTEE................................................... ........................................................... ........................... 9

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FABRICATION & ASSEMBLY OF CONVECTION MODULE FOR HEATER B101 NOCL CUDDALORE, INDIA EF 10013 1

B101-FS-301

INTRODUCTION This specification defines the minimum requirements to prefabricate one Convection Section to be installed at the NOCL Refinery in Cuddalore, India. The works include all structural and plate fabrication and any required shop detailed drawings. Anchor, mastic and castable refractory installation, coil installation and welding, hydro-testing, blastcleaning, painting and transport preparation. Any concerns or comments shall be addressed to Heurtey Project Manager, Mr. Antoine Fauqembergue.

2

DESIGNATION 

Client: NOCL (OWNER)  Engineering: HEURTEY PETROCHEM  Heater manufacturer: PER FURNACE

3

CONTRACTUAL DOCUMENTS

3.1

General

Fabrication Contractor shall comply with project specifications. Contractor shall assure the edition of all drawings or documents in his hands shall be in their latest edition. In case of conflict, the following list of precedence shall be applied: CODES: 

ASME B16.5: Pipe Flanges and Flanged Fittings NPS ½ through NPS 24 metric/inch Standard.  ASME B31.3 Process Piping.  ASME Section II: Material Specifications  ASME Section IX: Welding and Brazing Qualifications.  ASME B1.20.1 Pipe Threads, General Purpose. STANDARS/RECOMMENDED PRACTICES: API STD 530 / ISO 13704: Calculation of Heater Tube Thickness in Petroleum Plants.  API RP 531M: Measurement of noise from Fired Process Heaters.  API STD 560: Fired Heaters for General Refinery Service

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REFERENCE SPECIFICATIONS: 

: Basis for Steel Stack-Fired Equipment (doc no: CC-000-ME40-0010).  : Civil/Structural Design (doc no: CC-000-CI-40-0001).  : Surface Preparation and Painting (doc no: CC-000-ME-420004).  : Nozzle Loadings for Equipment (doc no: CC-000-ME-420005).  : Welding of Pressure Vessel Equipment (doc no: CC-000-PR42-0005).  ANSI/AWS D1.1 Structural Welding Code Shop fabrication drawings shall be submitted to Heurtey for review per PO reference. Fabricator shall be responsible for the accuracy of all shop drawings. Heurtey shall review for conformance to design intent only. Heurtey review of drawings shall not be held responsible for fabricator’s schedule. However, should Heurtey discover discepancies, the fabricator must correct these discrepancies in a timely manner. Vendor shall provide (an itemized) Master Shipping Bill of materials for the entire scope of fabrication works. The following minimum information shall be provided for field erection drawings: Piece Marks for all assemblies to be erected. Field bolting requirements for all connections including all nuts and washers, plus 10% spare. Field weld requirements The bill of material

4

SCOPE OF SUPPLY

4.1

General

Goods shall conform to the documents listed in the present specification. Contractor shall provide all additional drawings (in English to be submitted to HPC) necessary for the manufacture, including the checking (with calculation notes submitted to HPC) of the annex equipments (lifting lugs, crossbar, temporary stiffeners, cradle meant to the lifting operations of the heavy and large elements.

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4.2

B101-FS-301

Description of works

The goods to be delivered to site by road transportation according to this contract are as follow:  The newly fabricated convection section for heaters B-101 including: Shop fabrication drawings Lined panels and roof; Convection coils; Jumpovers & crossovers; • • • •

4.2.2 Convection modules (for Heater B-101) Fabricator’s Responsibilities: 

Supply of detailed fabrication drawings for review by Heurtey prior to start of works  Supply for structural steel & plate for the prefabrication of module (including header boxes, end tube sheets) with welded stiffeners;  Supply of lined end tube sheets;  Supply & installation of access / inspection doors, connections for instruments;  Installation of end tube sheets;  Installation of refractory anchors (Heurtey supply)  Installation of mastic paint material (Heurtey s upply)  Installation of castable refractory (Heurtey supply)  Installation and welding of coil tubes and fittings;  Drilling of convection beams & columns for the installation of platforms (by others);  Drilling of Connection Boltholes for Field Installation  Supply of all connection bolts plus 10% spare  Protection of tube ends with plastic caps/ blind wood for flange faces;  NDT of structural and tube coils  Hydrotest of coils (including necessary material for carrying out + water) shall be in accordance with ANSI B31.3, Section 337.4.1.  Application of painting system per Heurtey painting requirements (Heurtey supply)  Blastcleaning & final painting.  Supply and assembly of lifting lugs or trunions (with calculations)  Transport to site

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B101-FS-301

4.3.1 Structure & Plate Steel: (Fabricaot Supply) Main beams / columns: (doc no: CC-000-CI-40-0001) Secondary beams / casing: (doc no: 000-CI-40-0001)

4.3.2 Bolts: (Fabricator Supply + 10% spare) For Mains assemblies: Grade 8.8 For secondary assemblies: Grade 4.6

4.3.3 External painting: Heurtey Supply) According to CBI/NOCL Document: CC-000-ME-42-004 Rev 2.  Surface preparation: SA 2.5 (ISO 8501-1) / SSPC SP10  Painting system “C” (attachment 2.1) on heater and structural steel: Primer: Zinc rich epoxy 75 microns Intermediate: High build MIO epoxy 125 microns Finish: Polyurethane 40 microns (finish coat not required where fireproofing is applicable)  Color: Furnace including steel structures, stack and ducts: Grey Aluminum RAL 7038. Platform frame and brackets, stairs: Grey Aluminium RAL 7038. Safety cages, ladders, handrails of stairs and platforms: RAL 1004. Internal coating to be Carboline Bitumastic 1248, with a tolerance thickness of 16 mils after receiving a surface preparation of SSPC SP6. All “TEMPORARY” steel bracing shall be painted RAL 1012 Lemon Yellow. • • •

•

•

•

•

•

4.3

Weights & quantities: Per Heurtey Drawings & Data Sheets 4.4.1 Steel structure estimated weights Convection section

4.4.2 Insulation Convection section:

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4.4.3 Welds Convection Structural Steel & Process Coil

4.5.1 Marking Marking of all prefabricated elements in order to make erection easier:  Marking shall contain: heater assembly reference, letter of sub-assembly, part reference;  Bolts shall be packaged by: quality, diameter, and length (with these indications on each label).

4.5.2 Trial assembly The B101 convection box sections are to be fabricated in such a manner that each module shall be prefit in the workshop prior to acceptance as per HPC specifications.

4.5.3 General 

Reception, verification, unloading, storage and protection of all material supplied by HPC;  Segregation between stainless steel and carbon steel works;  Protection against winterizing during concrete application phases;  Suitable packing;  Marking piece drawings for site erection activities;  Electricity, water & other facilities for lining activities;  Supply + installation of scaffolding, lagging;  Temporary beams and other structures for storage (including shims) and transportation;  Material for handling (crane, sling, hoist, crossbar, etc.); of all insulated materials during  Suitable reinforcement transport & handling;  The well and careful adjustments of all elements lined by concrete (precautions must be done to avoid any shocks, deformation. Addition of temporary stiffeners for transport shall be mandatory.

4.6. Pressure parts 

Pressure parts shall be free of any foreign body and blowing shall be provided after hydrotests;

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B101-FS-301

Welding and NDE shall be in accordance with the following requirements:

a) Applicable National / International / Indian Codes & Directives ASME B16.5: Pipie Flanges and Flanged Fittings NPS  ½ through NPS 24 metric/standard ASME B31.3: Process Piping  ASME Section II: Material Specifications  ASME Section IX: Welding and Brazing Qualifications  Applicable code and specifications  Heurtey Technical description “Inspection and Test  Plan” for Heater B-101, document no: B-101-FQ-001. CB&I & NOCL specification no: CC-000-PR -42-005  for Welding of Pressure Vessel Equipment API Standard 560 last edition  AWS D1.1  5

MISCELLANEOUS

5.1. Planning Fabricator shall provide a global planning project form based on the main HPC targets and must be sufficient detailed to follow the progress. It will be regularly updated. Fabricator shall assure the work is conscientiously executed in order to permit its completion within the required time, or within the shortest normal delay compatible with a standard execution. Fabricator shall not take advantages of constraints due to normal exploitation of public or private ownership and public services to evade its commitment or not to address any complain. Fabricator shall not take advantages of constraints due to other contracts performed simultaneously on shop for which HPC has given its agreement. Fabricator shall inform HPC in writing and within 48 hours maximum of any major circumstances which may occurred to delay the work on shop. Normal bad weather for the season will not be considered as a major circumstance. If the work is stopped due to bad weather,

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Fabricator shall present reports showing stop and restart work periods which will be signed by the HPC representative. If at any time during the execution of contract, Fabricator finds necessary to modify the program, he shall inform immediately HPC and submit him the modified schedule for approval. All delays on jobs, which are under Fabricator’s responsibility, must be made up during the due date with no repercussion on this date.

5.2. Responsibility of HPC Drawing and other documentation issued by HPC are under his responsibility.

5.3. Guarantee Fabricator guarantees that all the equipments and materials forming the subject of the present order are: 

Designed, dimensioned, selected, installed and inspected so that they will correctly execute their function throughout the normal period of use, and satisfy the contract and production requirements as to quantity and quality for the planned operating conditions.  Free from all design, manufacture and assembly faults as well as all defects due to the use of inferior materials from those in the specifications. During the guarantee period, the contractor undertakes to replace any faulty equipment at his own cost, including equipment, accommodation, transport costs, etc.

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ANNEXE B – TECHNICAL DATA BOOK Documents shall be in English (issued with Autocad, Excel, Word, Project softwares) and sent to our DCC (as per PO) as follow; - For approval / information : 1 electronic file - For Final data book : 1 hard copy + 1 CDrom

Mailing date (weeks) with proposal

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For approval

For info.


FABRICATION & ASSEMBLY OF CONVECTION MODULE FOR HEATER B101 NOCL CUDDALORE, INDIA EF 10013 -

B101-FS-301

As built drawings. Welding procedures of structural Welding procedure of coils Heat treatment procedure NDT procedures (PMI, Hydrotest, Heat Treatment) Welding book Map with weld location

J J J J

+ + + +

4 4 4 4

R Typ.

J: Date of initial letter of intend or order R: Date of the final acceptance in the work shop

ANNEXE C – MANUFACTURING DATA BOOK Documents shall be in English (issued with Autocad, Excel, Word, Project softwares) and sent to our DCC (as per PO) as follow; 1 hard copy + 1 CDrom - For Final data book :

As per summary data book issued by HPC: Requested

STRUCTURAL STEEL WORKS -

Certificate of compliance for material (plates, beams, shapes,

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R

X

Observation



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B101-FS-301

bolting, other structure…) Inspection certificates as per specification and/or additional requirements for material (tubes & fittings) Inspection certificate of filler material Welding procedure qualification record Welders and/or operators performance qualification Welds inspection and radiographic examination records Map of radios

X X X X X X

COILS -

Certificate of compliance for material without pressure and/or welding (plates, beams, shapes…) Inspection certificates as per specification and/or additional requirements for material (tubes & fittings) Inspection certificate of filler material Welding procedure qualification record Welders and/or operators performance qualification Welds inspection and radiographic examination records Map of radios Heat treatment curve of welds Hydrotest report

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B101FS301 Convection, Rev II

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