B101FS302 Radiant Arch, Rev II

TECHNICAL SPECIFICATION NAGARJUNA NAGARJUNA OIL OIL CORPORATION CORPORATION LTD, LTD, CUDDALORE CUDDALORE

B101 RADIANT ARCH FABRICATION B-101-FS-302

Job N°: EF10013

Dated: March 04, 2011

Revised: July 20, 2011

Shop & Site Work Scope

REVISION II

PREFABRICATION OF RADIANT ARCH FOR ATMOSPHERIC SERVICE HEATER B101 RADIANT SECTIONS B101 A & B101 B

2 0 Révision

JULY 20,2011 FEB 2011 Date

Revision 2 First Issue Description

LAHTI LAHTI Par

Revision

Date

Description

By

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TECHNICAL SPECIFICATION NAGARJUNA OIL CORPORATION LTD, CUDDALORE


Job N°: EF10013



TABLE OF CONTENT Page 1

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

2

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

3

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

3.2.1

SCOPE OF SUPPLY .................................................................................................................................. 5

4.1 GENERAL ...................................................................................................................................................... 5 4.2 DESCRIPTION OF WORKS ............................................................................................................................... 5 4.2.1 Radiant section arches (2 per heater) Fabricator Supply and Responsibilities: ...................................... 6 4.3 MATERIALS .................................................................................................................................................. 6 4.3.1 Structure ................................................................................................................................................. 6 4.3.3 External painting .................................................................................................................................... 7 4.4 WEIGHTS & QUANTITIES PER HEURTEY DRAWINGS AND DATA SHEETS ....................................................... 7 4.4.4 Marking .................................................................................................................................................. 7 4.4.5. Trial assembly ....................................................................................................................................... 8 4.5 BILL OF LADEN FOR MATERIAL SUPPLY ........................................................ ............................................... 8 4.6.1 General ................................................................................................................................................... 8 4.6.2 Pressure parts ......................................................................................................................................... 8 5.1.

R ESPONSIBILITY OF HPC ................................................................................................................... 10

5.2.

GUARANTEE................................................... ........................................................... ......................... 10

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1


INTRODUCTION This specification defines the design requirements, fabrication requirements and the standard of acceptance for fabricated sturcutral steel components for the fabrication of one completed arch section for Heater B-101 A&B The B101 heater consists of 2 separate radiant chambers and thus 1 radiant arch section must be fabricated per radiant chamber (2) total. This technical specification shall be used as a guideline in conjunction with supplied Heurtey Petrochem drawings for the fabrication and installation contractor proposals. The fabrication scope of work includes the fabrication of the radiant steel structures (2), refractory anchor installation, mastic application, refractory installation, coil installation & welding, coil hydro-testing and preservation for shipment. The Fabricator shall have the ultimate responsibility to create any required shop fabrication drawings for review by Heurtey prior to start of works. Any comments or concerns shall be addressed to Heurtey Project Manager, Mr. Antoine Fauqenbergue for imediate consideration.

2

DESIGNATION 

Client: NOCL (OWNER)  Engineering: HEURTEY PETROCHEM SA  Heater manufacturer: AS PER HEATER

3

CONTRACTUAL DOCUMENTS

3.1

General

Shop Fabricator shall be in compliance with Heurtey specifications and NOCL project requirements. Shop Fabricator shall ensure that the edition of every drawings or documents in his hands shall be in their latest edition. Shop shall allow Heurtay to inspect all materials supplied by Heurtey as they arrive for any shipping damage. Shop Fabricator to prepare a work schedule and submit to Heurtey prior to start of work. This schedule shall be update weekly or as required to reflect the current production status of order.

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Shop fabrication drawings shall be submitted to Heurtey for review per contract terms of agreement. Vendor shall provide an itemized shipping bill of materal for the entire scope of supply. Provide within the fabricator’s business structure the production and quality control necessary to meet the requirements of the purchase order and this specification for promised delivery, workmanship, and function of materials being fabricated. The fabricator shall submit their QC plan along with and Inspection Test Plan to Heurtey in accordance with the Vendor Data Requirements (VDA) form referenced in the purchase order. After receipt of Heurtey arrangement drawings, but prior to start of fabrication, check and confirm shipping clearances for assemblies for transit to the job site or port of exit. The following minimal information shall be included on the field erection drawings: piece marks for all assemblies erected, Field bolting requirements for all connections including nuts and washers, Field weld requirements, and bill of material required. In case of conflict, the following list of precedence shall be the latest project specifications  HPC drawings  The client specifications mentioned in the list of technical documents: o Surface preparation and painting for Structural Steelwork (material, o Specification fabrication & erection) Standard drawings o

CODES : 



ASME B16.5 : Pipe Flanges and Flanged Fittings NPS ½ through NPS 24 metric/inch standards. 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.



STANDARDS/RECOMMENDATIONS :

  

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

API STD 530/ ISO 13704 : Calculation of Heater Tube Thickness in Petroleum Refineries.  API RP 531M : Measurement of Noise from Fired Process Heaters.  API STD560 : Fired Heaters for General Refinery Service.

      

3.2.1

4.1

REFERENCE SPECIFICATIONS : Basis for Steel Stack-Fired Equipment (doc no : CC000-ME-40-0010). Indian Boiler Regulations (doc no : CC-000-ME-400008). Civil/Structural Design (doc no : CC-000-CI-40-0001). Surface Preparation and Painting (doc no : CC-000ME-42-0004). Nozzle Loadings for Equipment (doc no : CC-000-ME42-0005). Welding of Pressure Vessel Equipment (doc no : CC000-PR-42-0005). ANSI/AWS D1.1 Structural Welding Code

SCOPE OF SUPPLY

General

Equipment shall conform to the documents listed in the present specification. Shop Fabricator shall be responsible to provide all additional shop fabrication 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.

4.2

Description of works

The equipment to be delivered according to this contract is as follow:  The radiant section arches for both radiant sections of the B101 A&B heater including: Castable Refractory Lined Roof; Radiant coils; • •

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4.2.1 Radiant section arches (2 per heater) Fabricator Supply and Responsibilities: 

Supply of all shop fabrications drawings to be reviewed by Heurtey Petrochem prior to start of works.  Supply of all carbon steel structural and plate materials for the prefabrication of two (2) (NEW) radiant arch casings with welded beams & stiffeners.  Welding of refractory anchors (Heurtey Supply)  Application of mastic paint for interior (Heurtey Supply)  Application of refractory on radiant panels per Heurtey specification and requirements in thickness and material Heurtey Supply).  Installation & Welding of radiant coils and crossovers (location of welds as per HPC coil drawings);  NDT of radiant coils  NDT of structural steel  Hydrotest of radiant coils (including necessary material for carrying out + water) in accordance with ANSI B31.3, Section 337.4.1.  Installation of cast tube supports (including drilling of the casing holes) for the radiant coil;  Drilling of radiant beams & columns for the installation of the platforms by others (where applicable);  Supply of all field connection bolts plus 10% spare  Blastcleaning of External Shell  Final Painting (Heurtey Supply).  Supply and installation of all lifting devices required for transport.  Supply and installation for all temporary bracing required for transport purpose.

4.3

Materials

The quality of material, unless otherwise noted in the HPC structure detail drawings, shall conform to grade listed here below. 4.3.1 Structure Main beams / columns: CC-000-CI-40-0001 Secondary beams / casing: CC-000-CI-40-0001 Applicable code: AWS D1.1

Bolts.3.2 Bolts For Mains assemblies: Grade 8.8

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For secondary assemblies: Grade 4.6 Fabricator to supply all connection bolts plus 10% spare

4.3.3 External painting According to Specification: CC-000-ME-42-0004.  Surface Preparation: 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: Aluminium RAL 7038. Platform frame and brackets, stairs: Aluminium RAL 7038. Safety cages, ladders, handrails of stairs and platforms: RAL 1004 Safety Yellow. • • •

•

•

•

4.4

Weights & quantities per Heurtey Drawings and Data Sheets 4.4.1 Steel structure estimated weights Radiant section (Arch) Heater B101:To be provided by HPC •

Radiant coilss: Heater B101: To be provided by HPC •

4.4.2 Insulation Heater BA101: Radiant Arch section Concrete 1.2.4 : To be provided by HPC •

•

4.4.3 Estimated weights for lifting / transport Radiant Arch section To be provided by HPC 4.4.4 Marking

Marking of all prefabricated elements in order to make erection easier:

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

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).

4.4.5. Trial assembly Trial assembly for radiant arch fabrication is not possible.

4.5

Bill of Laden for Material Supply 4.6.1 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; 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 stiffeners for shipment is required.

4.6.2 Pressure parts 

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

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

a) Applicable National / International / Indian Codes & Directives - CB&I & NOCL specifications

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-ASME B31.3 Process Piping -ASME Section II Material Specifications -ASME Section IX Welding and Brazing Qualifications - API 560 last edition - ASME B31.3 -Heurtey Petrochem “Inspection and Test Plan” for B-101 as per document no: B-101-FQ-001

Planning Shop 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. Shop Fabricator shall ensure that 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. Shop 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. Shop Fabricator shall not take advantages of constraints due to other contracts performed simultaneously on shop for which HPC has given its agreement. Shop 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, Shop 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, Shop Fabricator finds necessary to modify the program, he shall inform immediately HPC and submit him the modified schedule for approval. All delays which are under Shop Fabricator responsibility must be made up during the due date with no repercussion on this date.

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

5.2. Guarantee Shop Fabricator guarantees that all 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.

ANNEXE B – TECHNICAL DATA BOOK

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

Mailing date (weeks) With Proposal

-

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

For Approval

J J J J

+ + + +

R

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

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For Info.



Job N°: EF10013



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, 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 radiographs

X 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 radiographs Heat treatment curve of welds Coil contractor hydrotest report

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X X X X X X X X X

Observation

B101FS302 Radiant Arch, Rev II

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