Technical Specification -LPG Heater

TECHNICAL PROCUREMENT SPECIFICATION

8122-02-PS-001 PAGE 1 OF 1

TPS No:

8122-02-PS-001

STATUS

ENQUIRY

ORIGINATING DEPT.

PCE

P.O / W.O No: PROJECT

LPG BLENDING FACILITY

LOCATION

MANGALORE

CLIENT

M/s HPCL

PURCHASER VENDOR ITEM:

1

E 301

LPG Heater

1 No.

1

Revised

SK

AAN

JK

15.10.09

0

For Enquiry

SK

AAN

JK

24.09.09

Rev.

Details

By

Chkd

Apprd

Date

FACT ENGINEERING AND DESIGN ORGANISATION


TPS No.: S.No.

8122-02-PS-001 AT

ATTACHMENTS

PAGE

1 OF 1 Rev.1

8122-02-PS-001 Doc. No.

Description

Rev. No. with Issue

No. of pages

1

2

1

8122-02-PS-003 SPL

Special Requirements of Project - PCE

4

0

1

2

8122-02-PS-003 SW

Scope of Work

2

0

1

3

8122-02-PS-003 VDR

Vendor Data Requirements

1

0

1

4

8122-02-PS-003 VDI

Vendor Data Index

1

0

0

5

8122-02-PS-003 SPR

Spares

1

0

0

6

8122-02-PS-003 CS

Compliance Statement

1

0

0

7

8122-11-SE-E301

Process Data Sheet

2

1

4

3

1

ENGINEERING SPECIFICATIONS 8

00 ES 001 / 03

Vendor Data Submission Procedure

4

-

-

9

02 ES 018 / 94

Engg. Spec. for Tubular Heat Exchanger

14

-

-

10

02 ES 019 / 94

Engg. Spec. for Inspection and Testing of Vessels and Heat Exchangers

18

-

-

11

02 ES 023 / 97

Engg. Spec. for Painting

13

-

-

12

02 ES 041 / 94

Engg.Spec for Anchor Bolts

2

-

-

13

02 ES 022 / 94

Engg.Spec for Packing, Marking & Forwarding

5

-

-

DESIGN STANDARDS 14

02 DS 002 / 94

Design Standard - Anchor Bolts

3

-

-

15

02 DS 006 / 94

Design Standard - Earthing Boss

1

-

-

16

02 DS 009 / 94

Design Standard - Heat Exchanger Accessories

9

-

-

17

02 DS 020 / 94

Design Standard - Name Plate

3

1

1

02 DS 025 / 94

Design Standard -Saddles Support for Horizontal Vessels

3

-

-

LPG Heater

1

0

1

18

SCOPE DRAWING 19

8122-02-DG-10525

E 301

PRICE SCHEDULE 20

8122-02-PS-003 SIW

Price Bid - Supply (Indigenous)

1

0

0

21

8122-02-PS-003 RN1

Rate for Addition / Deletion of Nozzles (CS)

1

0

0

8122-02-PS-003 RN2

Rate for Addition / Deletion of Nozzles (CS + Cu / Ni Cladding)

1

0

1

22

1. The receipt of all attachments shall be checked and asertained.

Note :

2. All attachments of this TPS shall be retained since only revised sheets, if any, shall be issued. 1

15.10.09

Revised

SK

AAN

0

24.09.09

For Enquiry

SK

AAN

JK

Rev.No.

DATE

DESCRIPTION

PRPD

CHKD

APPRD


JK


SPECIAL REQUIREMENTS OF THE PROJECT

8122-02-PS-001 SPL Page 1 of 4

Item

:

L P G HEATER

Item No.

:

E 301

Project

:

LPG BLENDING FACILITY

Client

:

M/s HPCL

Location

:

MANGALORE

Rev. 1

1

15.10.09

Revised

SK

AAN

JK

0

24.09.09

Enquiry Release

SK

AAN

JK

REV.

DATE

DESCRIPTION

PREPARED

CHECKED

APPROVED



8122-02-PS-001 SPL SPECIAL REQUIREMENTS OF THE PROJECT Page 2 of 4

Rev. 1

1.0

GENERAL DESCRIPTION

1.1

M/s HINDUSTAN PETROLEUM CORPORATION LIMITED proposes to set up LPG Blending Facility at Mangalore. As part of this project, it is proposed to install 1 No. LPG Heater.

2.0

SCOPE OF WORK The scope of work includes but not limited to the following:

2.1

Detailed Engineering of the equipment based on the data sheet, drawing and specifications.

R1

2.1.1

Mechanical design of the equipment including Wind and Seismic analysis based on the data sheet, drawing and specifications listed in the Attachments (Doc. No. 8122-02-PS-001 AT) sheet.

R1

2.1.2

Impingement plates & Sealing strips shall be provided as per TEMA.

2.1.3

Submission of mechanical design calculations and fabrication drawings as per Vendor Data Requirements for approval to FEDO / HPCL.

2.2

Procurement and supply of all materials and bought-out items such as CS plates & Cu/Ni 70/30 plates for cladding / overlay materials, forgings, nozzle pipes and flanges, anchor bolts and fasteners, materials for painting, Anchor Bolts etc.

2.3

Preparation and obtaining approval of Welding Procedure Specification, Procedure Qualification Record and Welder Performance Qualification.

2.4

Transportation of the equipment to site with all internals.

2.5

Painting of the Equipment and structurals attached to the Equipment.

2.6

Any other items covered in Scope of Work and other documents / drawings attached with the enquiry but not specifically mentioned above.

3.0

DESIGN

3.1

The thicknesses and weights of various parts indicated in the Scope Drawing are indicative only. Vendor’s offer shall be based on his design of the equipment in accordance with the codes / regulations / standards / specified in the equipment drawing / specifications attached. The saddle support dimensions and size and quantity of anchor bolts shown in the equipment drawing are the minimum requirements and vendor shall include the design of the same also in the scope.

3.2

Tube thickness specified in the equipment drawing is the minimum required wall thickness.

3.3

Any change in dimensions / weight of the parts required as per codes / standards during review of vendor’s fabrication drawings / strength calculations by FEDO / HPCL and the third party inspection agency, shall be incorporated by vendor without any price or delivery implications.

R1




Rev. 1

4.0

MATERIALS

4.1

Vendor shall furnish complete, item wise MTO in the drawing.

4.2

All materials subjected to shell side design temperature (shell, tubesheet, saddle supports etc.) shall be impact tested as per code.

R1

4.3

Tubes shall conform to SB 111 C 71500 Seamless material.

R1

4.4

All tube side materials shall be cladded with Cu/Ni 70/30 as per the drawing / Process specification.

4.5

All materials supplied by the vendor shall meet the requirements of applicable codes and standards. Test Certificates for the materials shall be submitted for approval by M/s FEDO / HPCL.

4.6

Prior written permission shall be obtained from M/s FEDO / HPCL for any change in the material specification.

5.0

TESTING & INSPECTION

5.1

M/s FEDO / HPCL or their representative shall have free access to the works of the vendor or his sub-contractors (if any) to carry out the inspection of all items covered under the scope of purchase. Vendor shall submit a detailed quality plan for review and approval by M/s FEDO / HPCL.

5.2

Approval of work by M/s FEDO / HPCL shall in no way relieve the vendor of his responsibility in meeting all the provisions of the Enquiry conditions.

5.3

Testing of Equipment shall be as per the relevant sections of ASME Sec.VIII Div.1 and TEMA R.

6.0

PAINTING.

6.1

For detailed specification of painting refer FEDO specification for painting 02 ES 023 / 97.

7.0

GENERAL

7.1

Entire work shall be carried out in accordance with relevant standards and accepted codes of practices.

7.2

All butt welds shall have full penetration. When welding is carried out from both sides of a joint, the root of first side shall be dressed back to sound metal before commencement of weld on second side.

7.3

Structural items shall not be welded directly to the equipment. Pad plates of the same material as the shell plate shall be provided for this purpose.

7.4

Earthing Boss (2Nos.) shall be provided on equipment as per FEDO standard 02 DS 006/ 94.

7.5

Name Plates shall be provided on equipment as per FEDO standard 02 DS 020/ 94.

R1




Rev. 1

8.0

EXCLUSIONS

8.1

All civil works are excluded from the scope of the vendor. However foundation-loading data shall be furnished by the vendor.

9.0

GUARANTEE

9.1

The equipment and parts shall be guaranteed against defects in design, materials, workmanship and performance for a period stipulated in the commercial conditions of this enquiry.

10.0 DOCUMENTS TO BE SUBMITTED ALONG WITH THE OFFER 10.1 Dimensioned sketch of the Equipment (General Arrangement drawing with detailed Bill of Materials) along with the loading data. 10.2 Quality Assurance Plan. 10.3 Proposal for transportation of the Equipment to site. 10.4 Duly filled Scope of Work. (Doc. No. 8122-02-PS-001 SW). 10.5 Duly filled Spare Parts List. (Doc. No. 8122-02-PS-001 SPR). 10.6 Duly filled Vendor Data Requirements. (Doc. No. 8122-02-PS-001 VDR). 10.7 Duly filled Compliance Statement. (Doc. No. 8122-02-PS-001 CS). 10.8 Rate for Addition / Deletion of Nozzles. (Doc. No. 8122-02-PS-001 RN 1 & 2).

***********************


TECHNICAL PROCUREMENT SPECIFICATION ITEM:

LPG HEATER

PAGE 1 OF 2

Rev. 1

(space for vendor’s name, signature & seal)

1.

EQPT. Nos.

8122-02-PS-001 SW

SCOPE OF WORK HEAT EXCHANGER

E 301

The scope of work for the equipment listed above shall include design, manufacture, supply of material and engineering work as tick marked below. Vendor shall fill in the column marked as “offer from vendor” and return the same along with the offer, without which the offer will be considered as incomplete. Sl. No

Offer from vendor

Sl.N o

Description

Reqd.

Detailed design

YES

23

2

YES

24

YES

25

Third party inspection

5 6

Drawing Preparation Submission of documents as per VDR Procurement of materials Fabrication Testing and Inspection

Supply of spares as per spare part list Inspection

7

4

YES YES

Drawings for CCE Approval Calibration Equipment components: Shell, Channel & Channel cover Tube sheets Body Flanges Tie Rods, spacers, Bolts & Nuts

YES

26

YES YES

27

ASME Code Stamping

NO

28

8 9

Shop assembly Site assembly

YES NO

29 30

10

Equipment erection

NO

31

11

Internal lining Channel side Cu/Ni 70/30 cladding External surface preparation

YES

32

Dummy Tubes

YES

YES

33

Sealing Strips

YES

Guide Rails for Tube removal Companion flanges / bolts / nuts / gaskets for nozzles

R1

NO NO

R1

YES YES YES

13

Painting

YES

34

14

Corrosion inhibitor for inernal surface

NO

35

15

Corrosion inhibitor for external surface

NO

36

Bolts, nuts & gaskets

YES

16

Pickling

NO

37

Nozzle pipes & Flanges

YES

17 18

Passivation Hydro test at shop

NO YES

38 39

YES YES

19

Hydro test at site

NO

40

20 21

Pneumatic test at shop Pneumatic test at site Packing, marking & Forwarding

YES NO

41 42

Saddle Supports Anchor bolts / Nuts Supporting frame for connected eqpts. Stairway Sliding Plates

NO YES

YES

43

Rollers

NO

22

Offer from vendor

YES

YES

12

00FT013/94 00FT013/94

Reqd.

1

3

R1

Description

NO YES

R1 R1

NO

1 0

15.10.09 24.09.09

Revised For Enquiry

SK SK

AAN AAN

JK JK

REV. NO.

DATE

DESCRIPTION

PRPD

CHKD

APPRD


TECHNICAL PROCUREMENT SPECIFICATION Sl. No

Description

8122-02-PS-001 SW

SCOPE OF WORK HEAT EXCHANGER Reqd.

Offer from vendor

Sl. No

PAGE 2 OF 2 Description

Internals: 44

Wire mesh

NO

45

Demister & supports

NO

46

Impingement Plates & Sealing strips

YES

47

Vortex Breaker

NO

48

Internal clips / anchors etc. for lining

NO

49

Refractory / castable lining

NO

External attachments:

R1

50

Insulation clips

NO

51

Fire proofing clips

NO

52

Platform & ladder clips

NO

53

Pipe support clips

NO

54

Support clips & brackets for other eqpt.

NO

55

Manhole/hand hole davit/hinge

NO

56

Name plate with bracket

YES

57

Earthing boss

YES

58

Channel cover davit

YES

59

Level Gauges Relief valves / breather valves Stairways

NO

Platforms / Ladders Test Rings wherever specified

NO

60 61 62 63

R1 R1

NO NO YES

64

Jack Screws

YES

65

Dowel Pins

YES

66 67

Lifting Lugs Pulling Eyebolts & Plug for removable bundles

YES NO

68

PWHT (as per code)

YES

69

Warning Plate for Stress Relieved Items (as per code)

YES

70

Radiography (as per code)

YES

71

Guarantee for design, materials and wokmanship for the period specified in the commercial terms.

YES

R1


Reqd.

Rev. 1

Offer from vendor


PAGE

PROJECT : LPG BLENDING FACILITY

M/s HPCL

CLIENT : STATUS Sl. No.

Grp Code

1 2 3 4 5

B A A A B

6

B

7 8 9 10 11 12 13 14 15 16

B B B B B A B B B B

8122-02-PS-001 VDR

VENDOR DATA REQUIREMENTS

ENQUIRY

COMMITMENT

Description Vendor data index Dimensioned outline drawing Foundation loading data Assembly drawing Design calculations for the following a. Shell, Channel, heads & Body Flanges b. Tube Sheet c. Saddle Support design & stress analysis d. Nozzle & Flanges e. Stiffener Rings & Special attachments f. Tube Vibration Analysis g. Lifting provisions Detailed fabrication drawings a. Equipment proper b. Shell, Channel, heads & supports c. Tube Sheet & Baffles d. Tie Rods, Spacers Dummy Tubes, etc. e Nozzles and Flanges f. Other Internals g. External attachments h. Lifting provisions i. Name plate & bracket j. Earthing boss k. Miscellanious items Quality Assurance Plan WPS & PQR Manufacturing Procedure Inspection and testing procedure Heat treatment procedure if applicable Spare part list with sketch Pert chart of shop activities Packing/marking/forwarding instructions with sketches. Installation & maintenance procedure Packing list

1 OF 2

R1

ITEM:

LPG HEATER (E 301) PHE 1508 TPS No. 8122-02-PS-001

PO No. Qty. with offer 6P 6P

1 After Commitment Qty. of final Lead time in weeks ** Qty. Reqd. Propd * Agrd 6P 4 6P 6P 4 6P 6P 4 6P 6P 6P 4 6P 6 6P

6P 6P

6P

6

6P

6P 6P 6P 6P 6P 6P 6P 6P 6P 6P

6 8 6 8 10 10 4 16 14 16

6P 6P 6P 6P 6P

6P 6P

Legend : Group code : A - For For review review and and detailed detailed engineering, engineering,BB- For Forreview, review, C - For information and record Document type : R - Reproducible, P - Print, M - Microfilm. F- floppy disc. Notes : * Vendor shall fill in proposed lead time if different from the required lead time. ** Each set of final documents shall be submitted in a folder. Two such folders shall be packed and

00FT017/00

despatched with the equipment. Balance documents shall be forwarded to FEDO.

1 0

15.10.09 24.08.09

Revised For Enquiry

SK SK

AAN AAN

JK JK

REV.

DATE

DESCRIPTION

PREPARED

CHECKED

APPROVED


TECHNICAL PROCUREMENT SPECIFICATION Sl. No.

Grp Code

17

C

1

8122-02-PS-001 VDR

VENDOR DATA REQUIREMENTS

Description

Qty. with offer

PAGE 2 OF 2 R1 After Commitment Qty. of final Lead time in weeks Qty. ** Reqd. Propd * Agrd

Data folder in addition to the documents mentioned in sheet 1 a. As built drawings b. Manufacturing records c. Material test reports d. Inspection/test records e. Third party inspection records f. Rubbing of Name Plate


6P+Softcopy

6P 6P 6P 6P 6P


PROJECT: LPG BLENDING FACILITY AT HPCL, MANGALORE ITEM:

LPG Heater (E 901)

Sl. No.

PAGE 1 OF 1

PROJECT NO. : 8122 P.O NO.:

DATE:

Rev. 1

Rev. 2

Rev. 3

Rev. 4

Rev. 5

Description Date

Date

Date

ISSUE NO. DATE 00FT020/94

R0

VENDOR:

Rev. 0 Doc. / Drawing No.

8122–02–PS–001 VDI

VENDOR DATA INDEX

SIGNATURE


Date

Date

Date

Relevant to This issue

8122-02-PS-001 SPR


SPARES PAGE 1 OF 1

Sl. No. 1

GASKETS

100%

2

BOLTS, NUTS, WASHERS , CLAMPS

10%

Description

Quantity

R0

Unit Price

Total Price

AAN

JK

CHECKED

APPROVED

( MINIMUM 2 NOS OF EACH SIZE)

00FT022 / 94

ABOVE SPARES SHALL BE APPLICABLE FOR ALL THE NOZZLES INCLUDING NOZZLES WITH BLIND FLANGES

0

24.09.09

For Enquiry

REV.

DATE

DESCRIPTION

SK PREPARED


PROCUREMENT SPECIFICATION

8122-02-PS-001 CS PAGE 1 OF 1 R0

COMPLIANCE STATEMENT

TPS NO. 8122-02-PS-001 We state that our Quotation No. …………………………… is in full compliance with the documents issued against the Enquiry No. ………………………..except for the deviations listed below. LIST OF DEVIATIONS Sl. No.

Description

Reasons for Deviation

00FT014/94

Name of vendor:

Date

Name and designation

Seal & signature


ENGINEERING SPECIFICATION

00ES001/03

VENDOR DATA SUBMISSION PROCEDURE PAGE

CONTENTS 1.0.0. SCOPE 2.0.0. VENDOR DATA REQUIREMENTS 3.0.0. CLASSIFICATION OF DOCUMENTS 4.0.0. VENDOR DATA INDEX 5.0.0. QUALITY OF VENDOR DRAWINGS 6.0.0. CONDITIONS OF FEDO REVIEW

PRPD.BY:-

CHKD.BY:-

APPRD. BY:-


ISSUED ON:-

1 OF 4


00ES001/03

VENDOR DATA SUBMISSION PROCEDURE

1.0.0. SCOPE 1.1.0. This

document

together

with

“VENDOR DATA REQUIREMENTS (VDR)” defines FEDO’s requirements

for vendor drawing and data for any enquiry, work order or purchase order. 1.2.0. Bidders unable to comply with these requirements must detail all exceptions in their proposal. The timely delivery of quality drawings and data is as crucial as delivery of the equipment itself and hence the same shall be strictly adhered to after commitment. 1.3.0. Failure to provide adequate preliminary data / drawing may render a proposal non-responsive and hence may be rejected. After commitment failure to provide documents as per purchase order may delay progressive payments and adversely affect future invitation to bids. 2.0.0 VENDOR DATA REQUIREMENTS (VDR) 2.1.0 FEDO will provide a partially completed VDR form along with each enquiry. This form explains group code of the document, quantity of each document required and lead time for submission. Columns are available for the vendor to fill in his deviations, if any, from FEDO’s requirements. 2.2.0 The vendor shall forward a filled-in VDR form along with his offer, if he has got any deviation from FEDO’s requirements. In the absence of a filled-in VDR form along with the offer, it will be presumed that the vendor is accepting FEDO’s requirements specified in the VDR. 3.0.0. CLASSIFICATION OF DOCUCMENTS

PAGE 2 OF

4

3.1.0. Documents are classified based on their status and nature of content. 3.1.1. Status of documents: 1. Preliminary documents required along with the offer. 2. Documents to be submitted after commitment. 3. Final documents. 3.2.0. The documents are further classified into Groups A,B and C, depending on the nature of the documents as explained below. 3.2.1. Group A requirements These documents are urgent in nature and contain information that is required for proceeding with the detailed engineering of surrounding / down stream equipments in the plant and hence are to be submitted on priority basis. 3.2.2. Group B requirements These documents are to be reviewed by FEDO for compliance with the purchase order / work order specifications but are not essential for other engineering activities of FEDO. 3.2.3. Group C requirements Documents in this group contains data / information / records which are final in nature and that are required for the equipment user and need not be reviewed by FEDO. 4.0.0. VENDOR DATA INDEX (VDI) 4.1.0. Vendor shall forward a filled up and updated VDI along with each vendor data transmittal. VDI shall list out all documents that are being prepared for the particular order, their current revision status and indicate the documents included in the present transmittal. A blank VDI is attached along with this document, which shall be used for this purpose.



00ES001/03


5.0.0. QUALITY OF VENDOR DRAWINGS 5.1.0. Vendor drawing and data shall be supplied in full size drawings, reproducible and CDs as specified in the VDR. 5.2.0. All drawings / documents shall be clear, legible, right reading and made out of originals prepared in black ink. English language and metric units shall be used for the preparation of all documents. 5.3.0. The documents shall be prepared n any of the following standard sizes. 5.3.1. 5.3.2. 5.3.3. 5.3.4.

A1: 594 mm x 840 mm A2: 420 mm x 594 mm A3: 297 mm x 420 mm A4; 210 mm x 297 mm

5.4.0. All documents submitted to FEDO shall be folded into A4 size (210 x 297 mm) except originals / reproducible which may be rolled. All reproducible shall be in high quality polyester films. Soft copies shall be furnished in CD for final drawings / documents. 5.5.0. Each drawing / document shall have a title block at the right hand bottom corner with the following information. 5.5.1. 5.5.2. 5.5.3. 5.5.4. 5.5.5. 5.5.6. 5.5.7.

Name of Vendor. Drawing title. Name of Project, Owner and location. Name of Consultant: FEDO FEDO Purchase Order Number. Equipment name & Number Drawing number, revision and page number.

5.6.0. All drawings shall be drawn to some standard scales only and the same shall be indicated in the drawing. 5.7.0. The status of the document like “PRELIMINARY, FINAL, FOR REVIEW” etc. shall be stamped on all copies forwarded to FEDO.

PAGE 3 OF

4

5.8.0. All documents shall have a block of 100 mm x 100 mm space left vacant for FEDO to put their stamp after review. 5.9.0. All drawing/document shall have a revision block explaining revision number, revision description, data of revision, revision authorization etc. When the revised drawings are submitted all currently revised area shall be clearly demarcated by clouding. Any revisions made on other parts of the documenting will not be reviewed by FEDO. 5.10.0. When drawings are received back from FEDO with comments, vendor shall incorporate all the comments and resubmit the same. If the vendor is not in a position to incorporate certain comment made by FEDO, then the reason for such deviation shall be highlighted in the forwarding letter to FEDO. 5.11.0 The respective engineering specification and other purchase order spec. Will explain the minimum data / details required in various drawings. In the absence of any such information in the purchase order documents, vendor shall follow the standard good engineering practices in detailing the drawing. 6.0.0. CONDITIONS OF FEDO REVIEW 6.1.0. FEDO and / or its client reserve the right to review the vendor documents. FEDO’s REVIEW WITH OR WITHOUT COMMENTS OF THE VENDOR DOCUMENTS SHALL NOT RELIEVE THE VENDOR OF RESPONSIBILITY TO COMPLY WITH ALL PURCHASE ORDER TERMS AND CONDITIONS, including

all implied requirements relating to fitness for service and good engineering practices. Approval or acceptance does not imply or infer any determination relating to compliance by the vendor with its full



00ES001/03


responsibilities under the purchase order. 6.2.0. FEDO’s comments are limited to identifying requirements within the scope of the purchase order or failure by the vendor to comply with the requirements of purchase order, as revealed by the limited review. Oversights in the above limited review cannot be taken as approval for the vendor to deviate from the purchase order conditions. FEDO reserve the right to point out any such deviations at any stage of the order execution. The vendor shall comply with all such requirements without any price / delivery implications. 6.3.0. FEDO review will be authorized by an official stamp as given below, properly filled and signed by the concerned. Comments if any will be indicated in red ink or clouded in the case of copies of commented drawings. Appropriate comment in the ‘comments’ column and ‘status of review’ column will be marked.

Comment As noted No comments Not reviewed

PAGE 4 OF

4

Status of Review Revise and resubmit for review Proceed as noted and submit revised docs. For records No further review required Forward final docs. As per P.O.

6.4.0. All documents received in FEDO shall be dispatched after review within 15 days from the date of receipt. Vendor shall notify FEDO of non-receipt of reviewed documents in time immediately, to take corrective actions. 6.5.0. The delivery of the equipment shall in no case be linked with the review of the vendor drawings and data by FEDO. It is the sole responsibility of the vendor to execute the job as per the purchase order conditions. If required the vendor shall depute his technical personnel to FEDO after submission of documents for timely finalisation of documents.

***********************



TUBULAR HEAT EXCHANGER

02ES018/94 PAGE 1 OF 14

CONTENTS 1.0.0

GENERAL

1.1.0

Scope

1.2.0

References

1.3.0

Exclusions

2.0.0

DESIGN

2.1.0

Thermal Design

2.2.0

Mechanical Design – General

2.3.0

Shell side design

2.4.0

Tube side design

2.5.0

Supports

2.6.0

Flow induced vibration

2.7.0

Alloy lined tube sheets

2.8.0

Guide pins/pulling eyes

2.9.0

Nozzles and flanges

2.10.0 Kettle type re-boilers

PRPD.BY:- MVS

3.0.0

MATERIALS

3.1.0

General

3.2.0

Tubing

3.3.0

Bolting and gaskets

4.0.0

FABRICATION

4.1.0

Welding

4.2.0

Post weld heat treatment

4.3.0

Tolerance

4.4.0

Painting

4.5.0

Identification

4.6.0

Earthing boss

4.7.0

Insulation clips

5.0.0

TESTING AND INSPECTION

5.1.0

Pressure testing

5.2.0

Inspection

5.3.0

Protection

6.0.0

GUARANTEE

7.0.0

SPARES

8.0.0

DOCUMENTS AND DRAWINGS

CHKD.BY:- JR

APPRD. BY:- KKR


ISSUED ON:- Mar”94

02ES018/94 ENGINEERING SPECIFICATION 1.0.0

GENERAL

1.1.0

SCOPE


1.0.1 This specification covers the requirements for design, materials and fabrication of unfired Tubular Heat Exchangers of shell and tube type. The intent of this specification is to supplement, the reference codes and standards. However code requirements shall be fully complied with, even if this specification/data sheet/setting plan does not specifically mention the requirements. 1.1.3 All design, materials, fabrication, inspection and testing requirements detailed in FEDO engineering specification for pressure vessel shall be complied with, wherever applicable. 1.1.4 FEDO means FACT ENGINEERING AND DESIGN ORGANISATION, their client or representative. 1.1.5 No variations from Equipment Specification/data sheet/setting plan and this specification are permitted unless approved by FEDO. 1.1.6 Conflicts, if any, among the exchanger data sheets, setting plans, this specification, applicable standards, codes and purchase order shall be referred to FEDO for clarification prior to the manufacture, changes in price and delivery due to the conflict is considered nil by the supplier. If, due to conflict, a price/ delivery change could occur, the conflict must be resolved prior to the acceptance of quotation by purchaser, If a conflict is not cleared, FEDO reserves the right to mandate the clarification or interpretation and any price increase will be absorbed by the successful bidder/supplier and shall meet the delivery schedule of the Purchase Order.

1.2.3

ASTM specifications / IS specifications as specified in the data sheet/setting plan.

1.2.4

ASME Section VIII-Division 1/Division 2.

1.2.5

AWS-ASME Specifications for welding electrodes.

1.2.6

BS 5500 - for analysis of local stress on shell due to Saddle supports/other attachments.

1.2.7

Standards of Expansion Joint Manufacturers Association (EJMA)

1.2.8

ANSI B16.5 for steel pipe flanges and flanged fittings and B 1 6 . 1 1 for forged steel fittings, socket welded and threaded.

1.2.9

ASME SECTION II - Material specification.

1.2.10

ASME SECTION IX - Welding specification.

1.1.2

1.1.7

The issue of applicable codes and standards shall be the latest edition or as specified in this purchasing specification or equipment specification / setting plan.

1.2.11 IBR (wherever applicable). 1.2.12 National, State and local codes. 1.2.13 Other standards/specifications mentioned elsewhere in this specification. 1.3.0

EXCLUSIONS

1.3.1

Unless stated otherwise in data sheet/Equipment specification/setting plan, anchor bolts, gaskets and bolts for external piping, insulation with cladding and sliding plate shall not be supplied by the supplier.

2.0.0

DESIGN

2.1.0

THERMAL DESIGN

2.1.1

When thermal design is specified in the scope of the vendor, the dimensions shown in the data sheet / equipment specification / setting plan are the minimum requirements only. Thermal design. Calculations shall be furnished by the vendor for FEDO review.

2.1.2

Where thermal design is included in vendor's scope, he shall provide a satisfactory design, for which he shall be fully responsible.

2.1.3 1.2.0

REFERENCES

1.2.1

FEDO engineering specification 02ES025 for pressure vessel.

1.2.2 TEMA, standards of Tubular Exchanger Manufacturers Association (class will be specified in the eqpt. data sheet/Eqpt. specification/setting plan).

PAGE 2 OF 14

Effective surface is calculated as outside surface based on length of tubes measured between inner faces of tube sheets. For UTube bundles the exposed surface at UBend portion is admissible, provided-shell nozzle location is beyond U-Bends and velocity of flowing fluid makes this surface effective.


02ES018/94 ENGINEERING SPECIFICATION


2.1.4 When alternate operating conditions are specified, the exchanger unit shall be designed to handle either conditions without exceeding the allowable pressure drop and the estimated pressure drop shall be stated by the vendor for all alternatives. 2.1.5 Fouling factors are net. Tube side values shall be increased by ratio of outside to inside surfaces. 2.1.6

Bidders shall consider pressure drops to include entrance and exit losses also.

2.1.7

When viscosity values are omitted, it shall be the responsibility of the bidder to establish proper values for their calculations.

2.1.8

Unless otherwise specified on the exchanger data sheet. Split ring floating head construction shall not be used when: a. Tube side design exceeds 42 kg/cm2g.

2.1.14 Tube sheets, for economic or other justifiable reason, may be provided as clad and faced type, with the concurrence from FEDO. 2.1.15 Use of integral low fin tubing per ASTM A 498 (ferrous) or B 359 (non-ferrous) is permitted provided the fluid film coefficients, when corrected for fouling, show the shell side controlling by a ratio of 2:1 or more. Low fin tubing may also be used when it permits use of increased MTD values due to film temperature limitation of shell side medium, such as Sulfolane. 2.2.0

2.2.2

Mechanical design of the equipment is in the scope of vendor. The dimensions shown in the data sheet/equipment specification/setting plan are the minimum requirements only. Mechanical design calculations shall be forwarded to FEDO for review.

2.2.3

Materials selected for the design of the equip ment shall be as specified in the equipment Specification. Materials of parts not specified in the equipment datasheet/ drawing shall be decided by the fabricator and shall be shown on his fabrication drawing for FEDO approval. Cast iron shall not be used.

pressure

For vertical type thermosyphon re-boilers the allowable boiling side pressure drop includes friction, acceleration, static head, and nozzle inlet and outlet losses. Supplier shall guarantee the allowable boiling side pressure drop.

2.1.10 Minimum tube side velocity for cooling water shall be 1.5 m/sec. at mean temperature. If this requirement conflicts with the allowable pressure drop, an alternate proposal shall indicate pressure drop necessary to satisfy this requirement. When oil is used as the reboiler-heating medium, the minimum velocity is 1 m/sec, at mean temperature. 2.1.11 Maximum tube side velocity shall be 2.5 m/sec. when water carries solids, and shall not exceed 3 m/sec. when water is clean and without solids. 2.1.12 Parts subjected to both shell and tube side fluids shall be designed to withstand the pressure on shell side only and tube side only, and the most severe combination of the pressure unless FEDO drawings explicitly require other design conditions. 2.1.13 Where slated, tube bundles may be designed for the differential pressure given in Equipment specification. Vendor shall provide visible warning plate adjacent to, or as a part of, nameplate outlining test pressure regulations, when differential pressure design is used.

MECHANICAL DESIGN - GENERAL

2.2.1 TEMA class R shall be followed unless specified otherwise.

b. When nominal shell diame ter exceeds 635 mm. 2.1.9

PAGE 3 OF 14

2.2.4

Designer of exchanger unit shall be responsible for furnishing equipment that is free of over-stressing for any loading listed below in addition to the design conditions specified in the eqpt. Data sheet / spec. a. Wind loads or seismic loads. b. Loads of internals and inside fluid.

c. Weights of piping, platform and other attachment. d. Loads due to vibration. e. Reactions from piping system. f. Loads during transportation and erection. 2.2.5 Vendor's strength calculation shall cover the following: (All calculations shall be done in MKS / SI units) a. All pressure holding parts. b. Nozzle reinforcements. c. Lifting lugs d. Supports




e. Local stress on shell due to supports. f. Local stress on shell due to external loading or nozzles from connected piping. The loads/ moments acting on the nozzle will be specified along with the Purchase Order/ during detailed engineering. Loads normally allowed for various nozzle sizes are indicated in engg. spec. for pressure vessels.

lifting lugs on shell shall be designed to take the weight of complete unit with full of water. 2.2.11 Corrosion allowance Corrosion allowance shall be as specified in the datasheet / equipment specification / setting plan In the case of TEMA - class 'B' or class 'C heat exchangers when the specified corrosion allowance for carbon and low-alloy steel shell and channel is greater than that specified in TEMA Standards (i.e. 1.5 mm), the minimum thickness of shell and channel shall be computed by adding the excess corrosion allowance (i.e. the difference between the specified corrosion allowance and 1.5 mm) to the mini mum thickness given in TEMA.

g. Calculations to check the necessity of expansion bellows. h. Design of expansion bellows, if any. i. Calculations for channel, Pass partition plates for tube side pressure drop. J. Bearing stress calculation of heat barrier in case or low temp, heat exchangers. 2.2.6

k. Flow induced vibration of tube bundle. Wherever it is practical, exchanger shall be designed for maximum interchangeability of parts.

2.2.7

For units greater than the limits specified in TEMA, the recommended good practices (RGP section) of TEMA shall be mandatory.

2.2.8

The following points shall be noted while designing the tube sheets of fixed tube sheet type heat exchangers: a. Calculations shall be done for both corroded and new conditions. b. Consideration must be given to the stresses induced at operating, alternate operating, start-up, shutdown and other upset conditions.

2.2.9 When shells are stacked, removable bundles shall be made symmetric for interchangeability. For stacked units 2 sets of carbon steel shims of sizes 1,2,3,4 &5 mm each shall be provided with each section. The vendor shall supply for intermediate supports the shims, service bolts, nuts and washers for each pair/set. The stacked units shall b e set up in the shop and checked for nozzle match. In no case shall the gasket faces of mating flanges be out of parallel by more than 0.8 mm. Bolts between connecting nozzles shall be removable without moving the exchangers. Gaskets, bolts, nuts and washers for interme diate nozzles shall be in vendor's scope. 2.2.10 Lifting lugs made of killed carbon steel shall be provided on the shell, shell cover, channel, channel cover, floating head and tube sheet of removable tube bundles. The

PAGE 4 OF 14

2.3.0 2.3.1

2.3.2

2.3.3

SHELL SIDE DESIGN If type is not specified in data sheet, preferred type shall be horizontal single pass shell with conventional floating head tube bundle having rolled in tubes and arranged with two or more tube passes per shell. When U-tube bundle or kettle type re-boiler shell (TEMA "K") is used, the shell cover shall be integral with shell. The use of removable longitudinal shell baffle is not permitted except as follows: a. For TEMA shells. Type "G” or "H" when applied to low-pressure drop (0.14 Kg/cm2 max.) Re-boiler or condensing operations. b. For TEMA shell, type "F", when applied pressure drop does not exceed 0.335 kg / cm2. Limit shell side differential to 135°C. c.

Seal strips shall be of replaceable type and be securely attached to longitudinal sides of baffle plate adjacent to shell wall. They shall be Multiflex of an alloy appropriate for the service, or Neoprene rubber or equal, subject to design temp: limit recommended for the material being used. When metal seals. Are used, fabricator shall provide three copies of instructions to FEDO that outlines proper steps for folding seal strips inward so that edges do not rub unduly against inside of flange when tube bundle is inserted into shell.

2.3.4 Impingement baffles shall be provided, wherever required by TEMA / equipment specification. When impingement baffles




are welded to tie rod or spacers, they shall be supported by at least two tie rods or spacers. Minimum thickness of impingement baffles shall be 6 mm for carbon and lowalloy steel and 3 mm for high-alloy steel and non-ferrous.

PAGE 5 OF 14

exchanger, as far as possible, to avoid dissimilar weld joints. If supplier intends to use any other material, prior approval from FEDO / FEDO s hall be obtained. d. The expansion bellow shall be designed for both new and corroded conditions.

2.3.5 Impingement baffles shall be no closer to the inlet nozzle than is required for escape height and flow area.

e. Stress relieving shall be done after forming of bellows. If made out of austenitic stain less steel, solution annealing shall be done.

a. They shall be of sufficient size so that the distance from the projected inside of the nozzle to the edge of the plate, in any direction, is at least equal to the distance of the plate from the nozzle opening.

f.

The thickness variation after forming shall be inspected.

g. Suitable venting and draining connections shall be provided.

b. Perforated baffles are not permitted, unless otherwise specified in the equipment data sheet / dwg.

h. Fabrication and stress relieving procedure shall be submitted for FEDO approval.

2.3.6 Tube bundle baffles shall be of segmental cross-flow type, unless otherwise specified.

2.3.11 Guide rails shall be provided for all types of exchangers with a removable tube bundle weighing 10 tons and over.

2.3.7

When longitudinal baffles are welded to the shell, the weld seams shall not be close to the longitudinal weld seams of the shell. The fixed tube sheets shall be provided with the gasket grooves for the baffles.

2.3.8

De-burr and ream all tube holes in baffles / support plates to eliminate all sharp edges. Also deburr edges on cut for baffle window.

2.3.9

Sealing strips shall be provided wherever the same is required as per the equipment specification/data sheet. Minimum thickness of sealing strips shall be 6 mm for carbon and low-alloy steel and 3 mm for high-alloy steel and non-ferrous. The width of sealing strips shall be such that the clearance between the strip and the nearest tube/spacer O/D does not exceed the nominal clearance between tubes.

2.3.10 Fixed tube sheet exchangers shall be analysed to find any necessity for expansion joints and setting plan. The following requirements of expansion joints shall be satisfied: a. Design of expansion joint shall be in accordance with EJMA - Standards of Expansion Joint Manufacturer Association. b. Minimum number of cycles to be used for fatigue analysis shall be 7000 unless other wise specified. c.

Expansion bellows shall be of the same material as the shell of the

2.4.0

TUBESIDE DESIGN

2.4.1

On heat exchangers of 400 mm diameter and above, a fitting allowance shall be provided on pass partition plates to enable the clearances in the tube plate grove to be maintained as speci fied in the code. 6 mm dia weep holes shall be provided on partition plates for proper venting and draining.

2.4.2

Pass partition groves shall be machined to rectify any distortion, which may be caused by the tube fixing. The minimum design tube plate thickness shall be maintained.

2.4.3

Pass partition grove corners shall be machined to chamfer of to clear the fillet welds of the channel partition.

2.4.4

Pass partition plates shall be designed for tube side pressure drop if specified in the equipment specification / data sheet / setting plan, but not to be thinner than the minimum thickness specified in TEMA Standards.

2.4.5

Single pass tube bundle exchangers, having a bellows type expansion joint between floating head and shell covers, are permitted. Such de signs shall include provisions (guide device) that allows quick and easy mating of expansion joint and flange to its companion flange on the inside face of shell cover. Expansion joint shall be the hydraulically formed type and it shall also permit replacement in the field




2.4.6 Single pass tube bundle with floating head and having packed gland in shell cover is acceptable only for water tube flue gas heat recovery exchanger units. 2.4.7 U-tube bundle construction is permitted when tube side medium is clean; i.e. steam, boiler feed water, heat stable re-boilering oils, reactor efflu ent streams containing hydrogen gas (Plat f orming, Unibon, etc.) and / or it is desirable for process reasons, to minimize the number of joint closures. Stress investigations shall be con ducted whenever temperature differentials of 110 deg. C or greater, are assigned over both legs of any U-tube. When steam is in Utubes and process is controlled by low control of condensate, U-tube shall be in a horizontal plane. 2.4.8

2.4.13

PAGE 6 OF 14

The reduction ratio of the tube thickness due to the expanding of tube-to-tube sheet joints, shall be with in the range listed below.

Tube Material Carbon steel Low alloy steel

PR (%) 5 - 10 5 - 10

High alloy steel

5 -10

Copper alloy

4 -8

PR = (d2-d1) (D-do) (do-d1)

X 100

Where: PR = Percentage reduction in tube thk. (%) d1 = inside dia of tube before expansion (min.) d2 = inside dia of tube after expansion (mm)

The stationary head for the U-tube construction outlined above shall be TEMA type "B" or "C" for all applications except when tube side medium is water or tube side design pressure is higher than 140 Kg/cm2. Above 140 Kg/cm2 use the TEMA Type "C" head with internal pass partition to assure against inter-pass leak age. When "8' head is used, the tube sheet shall be full diameter type with threaded holes that permits testing or shell side when the stationary head is removed, or, if full diameter tube sheet is not provided, a test ring shall be furnished with the exchanger.

2.4.14 Tube thickness specified is the required minimum wall thickness, unless otherwise specified.

All tube sheet holes and the grooving in them shall conform to TEMA and the following supple ments. Grooves shall be square edged and concentric. When heat treatment of tube sheet is required, final tube hole sizing shall be attained by reaming after heat treatment.

2.4.16 The minimum mean radius of U-bends shall be 1-1/2 times the O.D. of the tube. Flattening at the bends shall not exceed 10% nominal O.D of straight portion tube. Proposal shall be based on the use of heavier wall tubing for short radius U-bends when design pressure demands thicker tube walls.

2.4.10 When austenitic tubes are rolled into t u b e sheets (or any tube material tubes are to have welded tube to tube sheet joints], the special close fit tolerances stated in TEMA shall be used.

2.4.17 Thickness reduction after bending of Utubes shall be inspected by suitable means such as ultrasonic thickness gauge

2.4.9

2.4.11 The type of tube-to-tube sheet joint shall be as specified in the equipment data sheet/setting plan. If not specified, it shall be considered as expansion with double grooves with seal welds. 2.4.12 When welded tube-to-tube sheet joints are specified in the equipment data sheet/ setting plan, supplier shall submit complete welding and testing procedures.

D = inside dia of tube hole of tube sheet. do = outside dia of tube before expansion (mm) outside dia of tube before expansion (mm)

2.4.15 For U-tube the wall thickness specified applies to the tubing before bending except as noted below. All tubes including Utubes shall be formed from a continuous length of tubing free on girth welds.

2.5.0

EXCHANGER SUPPORTS

2.5.1

Equipment specification / setting plan shall be referred for the type and number of supports. If the support details are to be generated by the vendor, then the same shall be suitably designed by him. Base plate and anchor bolt details indicated in the eqpt. data sheet shall be accommodated by the vendor, to the extend possible, orientation of the support and anchor bolt locations shall be finalised in consultation with FEDO.




2.5.2 Saddle supports for Horizontal exchangers shall comply with the Standard Drawing attached or as shown in the equipment drawing. When it is important, FEDO will indicate which support shall be fixed and which support shall be sliding; otherwise the vendor shall indicate this on his proposal drg. Supports welded to the heat exchangers shall not interfere with inspection of heat exchanger circumferential seams.

2.7.1 When tube sheets are specified to be alloy lined type, the same may be achieved by cladding or weld deposit over lay with the following restrictions: a Cladding shall be integrally and continuously bonded to the base metal. b Lining shall not be accounted for t h e Strength it adds to the tube sheet. c When other parts in contact with the same fluid are specified as “killed steel”, the base metal of the clad or faced tube sheet shall also be killed steel.

2.5.3 Saddle supports must withstand a tube bundle pulling force equal to the weight of the removable bundle. 2.5.4 Foundation bolt details, if specified in Equip ment specification shall be checked and approved by supplier, and shall be modified only after agreement in writing with FEDO. Bolts shall have a minimum nominal diameter of 20 mm. 2.5.5

Exchangers designed for low temperature service shall be provided with a wooden heat barrier under the saddle supports.

2.6.0

FLOW INDUCED VIBRATION

2.6.1

The vibration analysis of the exchanger is included in the scope of supplier.

2.6.2

For Exchanger Units subject to vibration, the tube bundles shall be designed as follows: a Maximum baffle spacing shall be 450mm when process stream is either all vapour, or two phase, or 750mm when it is all liquid. b Consider split flow segment type baffles to obtain minimum span between adjacent baffles. Irregular baffle spacing is permitted. C For baffles spaced less than 300 mm apart tube hole diameter shall not exceed the O.D. of the tube plus 0.5mm. For baffles and tube support plates spaced 300 mm or more apart the tube hole diameter shall not exceed the O.D. of the tube plus 0.3 mm. d Minimum baffle thickness shall be 10 mm. Otherwise follow TEMA. e Provide full periphery distribution belt at s h e l l i n l e t o r p r o v i d e a d e q u a t e i n t e r n a l dome space and impingement protection In either case. Limit PV2 into bundle to 500.

2.7.0 ALLOY LINED TUBE SHEETS

PAGE 7 OF 14

d

Minimum thickness of lining/weld overlay shall be 8 mm after machining.

e.

Silver soldered or brazed bonded liners shall not be used.

2.7.2 Linings shall be either integrally bonded clad ding conforming to ASTM A263, A 264, A255 or weld deposit overlay by a qualified welding procedure and properly machined, also refer engg. Spec for pressure vessel 02ES25. 2.7.3 Clad tube sheets that have grooved tube holes, shall have one full groove in the cladding and at least one groove in the base material. Alternatively, seal welding shall be provided for the tube-lo-tube sheet joint. Shell side claddings on tube sheets are not acceptable. 2.8.0

GUIDE PINS/PULLING EYES

2.8.1

Guide pins shall be placed in tube sheets to facilitate assembly and to keep tube sheets (or channels with integral tube sheets) from dropping out of position when the bundle is to be withdrawn from the shell. a. Provide three guide pins approximately 120 deg. apart with one located on top of vertical centreline of a horizontal unit, the outside edges are to be 0.75 mm clear of the shell I.D. and are to be the same material as the tie rods.

2.8.2 Guide pins are not required when the lubes sheets are held in position by: a. Tube sheets with tapped holes for stud bolts, nuts at both ends. b. Tube sheets having drilled holes when adjoining flanges are tapped for studs. c. When the distance from the tube sheet to the second segment cut baffle is 450mm or l ess, or when the tube bundle




is made up of baffles spaced 225 mm center to center or less, regardless of the distance from the tube sheet to the first baffle. 2.8.3

2.8.4

2.8.5

2.9.0

Alignment marks shall be provided to prevent m i s a s s e m b l y o f c h a n n e l c o v e r s , c h a n n e l flanges, shell flanges, shell cover flanges and floating heads. For removable tube bundles, the tube sheet shall be provided with 4 Nos. tapped holes and pulling eye bolts, and plugs for closing the holes while the exchanger is in operation, as per the standard drawing attached.

2.9.7

2 Nos. lapped holes and eyebolts shall be provided on the outer periphery of tube sheets of removable bundles and floating head cover flanges, for lifting.

2.9.2 PI/TI connections shall be provided on nozzles, if required by TEMA/ Equipment specification/data sheet/ setting plan. 2.9.3 A vent and drain connections shall be provided at the high and low points of exchanger respect i v e l y w h e n t h e e x c h a n g e r i s n o t v e n t e d o r drained by nozzles. 2.9.4 For total condensing service, a flanged 25 NB vent nozzle shall be provided on the top of shell at end opposite to shell inlet. For stacked units provide vent and drain in each shell. Rating, flange facing etc. shall be equal to that provided for main shell side/channel side nozzles. Standard confined joint construction shall be used for flanged girth joints. All Girth flanges for exchanger proper shall be of the through bolted type with stud bolts, threaded full length with a removable nut on each end, unless otherwise specified. The minimum permissible bolt size for girth flanges shall be as follows:

Shell ID (mm)

Bolt size

Up to 550

M20

600-1400

M22

1500 • 2000

M24

2100 and over

M30

The facing of intermediate nozzles between stacked units shall be FF or RF type. Ring flanges for internal floating covers shall have: a. Counter bored facing with nubbin. b. Bolt hole max. clearance 1.5 mm larger than the bolts. c. Corrosion allowance added to all exposed surfaces.

NOZZLES AND FLANGES

2.9.1 The minimum nominal pipe size of threaded connections shall be 20 NB pipe size. Couplings s h a l l b e r a t e d a s p e r T E M A r e q u i r e m e n t s . Threads shall be NPT conforming to ANSI B 2.1.

2.9.5

2.9.6

PAGE 8 OF 14

d. Solid metal or jacketed gaskets only. 2.9.8

Main girth type flanges shall be machined after welding or stress relieving.

2.9.9

T h e minimum thickness of flat gaskets f o r flanged girth joints shall be 3 mm.

2.9.10

All joints shall be easily accessible for replacement of gaskets.

2.9.11

All bolt holes in nozzle and manhole flanges shall straddle the principal vertical and horizontal center lines of the equipment, unless other wise specified.

2.9.12

One set of jack screws shall be fitted in the flanges of all removable parts as per the standard drawing attached. Davits for removal of manhole covers/channel covers shall be provided as per standard drg. attached.

2.9.13

2.9.14 When appurtenances of carbon steel such as external clips, sup ports, brackets etc. are to’ be connected to alloy steel parts, a pad plate of min 5 mm thick of the same alloy shall be placed on the part to be welded. 2.10.0

KETTLE TYPE REBOILERS

2.10.1

Shell shall be TEMA Type "K" with weir plate directly behind tube bundle. Weir s h a l l b e welded rightly to shell, contain no drain holes and have sufficient height to flood top of top tubes with a minimum or 50 mm of process fluid, for normal operation.




2.10.2 Provide sliding rails (or tracks) that are fully seal welded to shell sides to support and guide tube bundle. Also, provide a "hold" angle iron above tube bundle to keep bundle in place during shipment and handling. It is to be located directly above and close to the floating head flanges [TEMA Type "T") or the 16 mm thick [minimum) full diameter support plate when u-tube construction is used. 2.10.3 General arrangement and connections shall be as shown on Standard Drawing attached. 2.10.4 If Kettle type Re-boiler is used as a steam generator, the general arrangement similar to Std. Drg. shall be followed except: a.

A weir is not required and minimise dimension "L".

b.

Steam outlet shall employ a steam separating device, the lowest part of w h i c h i s 500mm above the normal water level.

c.

A clearance of 50 mm (Minimum) shall be provided between the outside layer of tubes and shell.

d. If thermal design is under the scope of vendor, he shall guarantee that the unit will produce steam or 99.5% (minimum) quality when operated at 125% of design capacity. 2.10.5 The angle of conical section of kettle t y p e re-boilers shall be 30 deg. unless otherwise specified in the equipment data sheet.

3.0.0 MATERIALS 3.1.0 GENERAL 3.1.1 Heat Exchangers shall be constructed from the materials specified on the Data Sheet, or equivalent materials approved in writing by FEDO. 3.1.2

Where a heat exchanger has la be lined internally with corrosion resistant material, vendor shall get approval from FEDO en the method of application of the lining. Special attention shall be given to the joints or edges of the lining to ensure that the base metal is fully protected, and that the efficiency of the lining is not impaired by contamination from the base metal. The supplier shall notify FEDO of his intentio n to use integrally clad plates when the vessel design takes account of the strength of the liner, and shall

PAGE 9 OF 14

obtain FEDO approval in writing before proceeding. 3.1.3

Materials specified for heat exchanger supports are suitable for the temperatures expected during operation, bearing in mind that for insulted heat exchangers the point of contact with the shell will be insulated together with the heat exchanger. Supports made from two different materials may be used if justified economically by the supplier and approved by FEDO in writing.

3.1.4 If material of any part is not mentioned in the datasheet / equipment specification / setting plan supplier is at liberty to choose suitable material. He will then be fully responsible for the suitability of materials for the conditions and duties speci f i e d in the equipment specification / data sheet / setting plan. 3.2.0 TUBING 3.2.1 All nonferrous U-bends shall be stress relief annealed after bending. Austenitic alloy steel exchanger U-tube bundles shall be heat treated to relieve the stress caused by cold bending the tubes. For tubes of type 304 L, 3 1 6 L, 321 or 347, heat treatment shall consist of furnace heating to 871 to 899 deg. C and holding for 10 minutes minimum. Heat Treatment shall be applied to the whole length of the bent tubes before installation in the tube sheet or to a portion assembled bundle which includes the tube bends and a minimum of 300 mm of the straight tangents. Alternate solution annealing at 1066 plus or minus-14 deg. C followed by rapid air cooling may be applied. A sample shall be submitted to show the surface condition after heat treatment and cleaning. 3.2.2 Tubing shall be in the fully heat treated conditions as received from the mill. Heat treatment may be annealing, normalizing, or normalizing and tempering per the ASTM specification used. 3.2.3 Seamless cold drawn tubes shall be used for all exchangers unless otherwise specified. 3.2.4 When welded stainless steel tubes are specified in equipment data sheet/dwg. shall be in accordance with ASME SA 249. 3.2.5 Welded austenitic stainless steel tubes shall be cold drawn to a minimum reduction of 15% in wall thickness prior to a final full solution annealing.




3.2.6 All welded tubing shall pass a nondestructive electric test per ASTM A 450. When the entire cross-section of the tubes meets the requirements of this test, the hydrostatic test may be-waived. 3.2.7 Integral low tin tubing shall conform to ASTM A 498 (ferrous) or B 359 (non ferrous).

PAGE 10 OF 14

testing etc. and the inspection procedures together with a representative sample of the tube to tube sheet weld shall be furnished to FEDO inspector for review and comments before commencing fabrication. 4.1.3

For expanded and welded tube to tube sheet joints:

3.2.8 Non-ferrous tubing shall be supplied in the temper per B 359.

a. Expansion to be done first, followed by welding.

3.3.0

b. Graphite or water-soluble lubricant shall be used for expansion tool to avoid weld defect caused by oil.

BOLTING AND GASKETS

3.3.1 Bolting for channel and girth flanges shall consist of continuously threaded bolls conforming to ASTM A193-B7 with nuts in accordance with ASTM A 194-2H unless otherwise specified. a. Vendor shall guarantee lightness and compatibility of their closure designs. This, especially, pertains to closures where designer amalgamates components having different thermal expansion properties. b. When diameter of bolting exceeds 40 mm, the bolting desig n shall provide clearance dimensions that permit use of a stud and bolt tensioner device. It may be, the hydraulic type, the spring tension resilient washer type or the electric stud heater type. Installer of exchanger unit shall control nozzle orientation and support saddle locations that assures clearance for adaptation of the chosen tensioner. 3.3.2

Floating heads shall be through bolted type.

3.3.3

The gaskets for intermediate flanges of stacked units and to manholes and nozzles with blind flanges shall be supplied by the supplier along with bolt, nuts and washers.

3.3.4

All gaskets shall be made in one continuous piece all around including the pass partition ribs nd therefore must be cut from one sheet.

4.0.0

FABRICATION

4.1.0 4.1.1

WELDING Girth, longitudinal and nozzle attachment welds in exchanger shall be full penetration weld.

4.1.2

For units requiring strength welding of tubes to tube sheets, the proposed method of fabrication including complete sequential joint preparation, cleaning, assembly, welding,

4.2.0

POST WELD HEAT TREATMENT

4.2.1 Requirement of post weld heat treatment of equipments shall be as specified in the eqpt. Data sheet/setting plan and applicable codes. Also refer relevant clauses in FEDO engg. spec. for pressure vessel. 4.3.0

TOLERANCE

4.3.1 Unless otherwise specified, tolerances shall conform to the applicable code and TEMA standards. 4.3.2

The dimensions, weights and permissible tolerances of U-bend steel heal exchanger tubes shall conform to the requirements of ASME SB395

4.4.0

PAINTING

4.4.1

Exchanger shall be shop painted in accordance with the standard specification for painting worn for equipment, steel structure and piping and. Data sheet/Equipment specification/setting plan.

4.4.2

Machined gasket surfaces and Earthing clip shall not be painted.

4.5.0

IDENTIFICATION

4.5.1

The code stamp ( i f applicable) and other identification marks shall be so located as to be accessible after installation. 4.5.2 The nameplate and nameplate bracket shall be as per FEDO design standard. 4.6.0 EARTHING BOSS 4.6.1

Earthing boss as per FEDO design standard shall be provided on the support of heat exchanger.




4.6.2

All heat exchangers shall be provided with two earthing bosses, (one in each support).

4.6.3

If the support is not welded to shell or only tack welded, the earthing boss shall be provided on the shell.

4.6.4

4.7.0 4.7.1

5.0.0

In the case of stacked heat exchangers shells -of, which are bolted together, they shall be treated separate units as far as earthing Boss is concerned.

TESTING AND INSPECTION Refer FEDO Engg. spec for Inspection and Testing and engg. spec, for pressure vessel for minimum requirement on shop inspection, NDT, heat treatment etc.

5.1.0

PRESSURE TESTING

5.1.1 Heat exchangers shall be hydraulically tested in accordance with applicable code or as specified in the data sheet/equipment specification/setting plan. 5.1.2

The test pressure shall be maintained for at least half an hour.

5.1.3

When exchanger is tested for the differential pressure, testing shall be done to each side simultaneously with final raising of shell to top pressure with tubes at top pressure or tube to top pressure with shell at top pressure, as the case may be. Supplier shall provide a conspicuously visible caution plate near to or as a part of the nameplate, indicating that the internals of the exchanger have been designed for differential pressure and that any operating conditions of testing conditions must not be allowed to exceed this differential.

5.1.4

Prices for the above items are indicated in the purchase order separately. Drgs/calculations for these items shall be submitted for approval. 5.1.6 Pneumatic test shall be carried out for the following: a.

INSULATION CLIPS When insulation is specified on the heat exchanger data sheet/drawing, insulation clips shall be provided on the shell/channel/head portions as per FEDO design standards.

b.

In order to check the leak tightness of tube-to-tube sheet joint, pneumatic test shall be conducted from shell side. Test pressure shall be 6kq/cm g or shell side design pressure, whichever is less, unless otherwise specified. Reinforcement pads, slip -on flanges and linings at a pressure of 2-kg / cm2 g.

5.1.7 If any of the pressure part is found to be damaged after a successful test, the exchanger shall be retested after repairs. 5.1.8 When integral finned tubes are used they shall meet the requirements of ASTM A 498 after finning or shall be hydro-tested after finning. 5.2.0 INSPECTION 5.2.1 Exchangers shall be subject to inspection by FEDO. 5.2.2 Prior lo the final inspection of exchangers, ail slag, loose scale, dirt, grit, weld spatter, paint, oil and other foreign matter are to be thoroughly removed in order that the inspection can be conducted to the best advantage. 5.2.3

The approval of the work by FEDO inspector and/or his release of the exchangers for ship ment shall in no, way relieve the supplier of, any responsibility from carrying out all the provisions of the purchase order specifications.

5.2.4

If exchanger is covered under IBR the same shall be designed, fabricated, inspected and tested as per the requirements of the regulation. Necessary approval from IBR of drawings/design calculations shall be obtained by supplier. The supplier shall provide all technical documents/supports needed for the same. Responsibility of FEDO with respect to the Boiler In spectorate is limited to paying the .Registration fees only. All other fees and expenses in connection with IBR approvals shall be borne by the supplier.

5.2.5

Supplier shall also arrange ail other statutory inspections, approvals /

Exchangers which are to be stacked in service shall be stacked in the shop and pressure tested as a combined equipment.

5.1.5 Test rings/flanges shall be supplied for all heat exchangers except for fixed tube sheet type. Dummy shell shall be supplied for stabin type heat exchangers. Material used for fabricating these shall be of tested quality.

PAGE 11 OF 14




documentation if required, in addition to the IBR requirement. 5.3.0

PROTECTION

5.3.1. After completion of all testing and inspection the inside of complete equipment shall be thoroughly drained and dried out by blowing hot air for sufficient time until no further increase in -relative humidity of outgoing air is observed. Drying-out shall be done simultaneously on both shell and tube sides. All spare tubes, if supplied, shall be protected with caps on both ends of the tubes, packed separately with a tag indicating item no., make, material and marked "SPARES. 5.3.2 Also refer FEDO engg. spec, for pressure vessels engg. spec for packing, marking and forwarding. 6.0.0 GUARANTEE 6.1.0 Vendor must guarantee that all materials used for the equipment have been submitted to regular acceptance procedure and free from any defect regarding quality, form and appearance. 6.2.0 Equipment must be guaranteed for design, materials, workmanship, and performance (if thermal design is included in scope) for a period as specified-in the commercial conditions of the Purchase Order. 6.3.0 Any equipment, or its part not having been submitted^ to wrong operating service or faulty manipulation and found defective during test after installation or during operation, shall be replaced and reinstalled by vendor without delay and free of cost within the guarantee period. 6.4.0 In case of detective equipment, FEDO shall have the option lo replace the equipment after intimating to the vendor, in order to avoid time delay. In such an event, FEDO shall be entitled to recover the cost of such replacement from the vendor.

7.0.0 SPARES 7.1.0 Supplier shall supply spares as specified in the Purchase Order. If not specified the minimum requirement of spares shall bre as mentioned in FEDO engg. spec, for pressure vessel.

8.0.0

PAGE 12 OF 14

DOCUMENTS / DRAWINGS

8.1.0 Vendor shall submit the documents listed in the enclosed 'Vendor Data Requirements' form in accordance with the "Vendor Data Submission Procedure'. Each category of vendor data shall contain the following information as a minimu m requirement: 8.1.1

Dimensioned outline drawings These drawings shall include: a. Exchanger outline showing all dimensions, size, location, projection and orientation of every connection; locations of the supports to the Process connections and their projections; the size and locations of the anchor bolt holes and slots; base plate and sliding plate thickness: clearances for removal of bundle and shell cover bonnets (when applicable). b. Arrangement drawings of platforms and ladders ( i f applicable). c. Arrangement of clips and insulation support rings (If applicable), lifting lugs, name plate with bracket and earthing boss. d. Approximate shipping weight and total weight of equipment when full of water.

e. The design and test conditions, corrosion allowances, working fluids, nozzle and connection summary and bill of materials. 8.1.2 Foundation loading diagrams. These drawings shall show: a. The Empty weight, Operating weight (including all dead and live loads) and weight full of water of the equipment. b. Forces and moments due earthquake and wind loads applicable).

to (if

c.

Dimensions of base plate and sliding plate (if applicable) complete with diameter, number and location of hold down bolts or- anchors and thickness of metal through which bolts must pass. 8.1.3 Schematics or flow diagrams a. Where a vendor supplies equipment which includes, any instrumentation, instrument connections, valves, safety devices, or control schemes, these components shall be shown on a schematic diagram identifying vendor




and type and listing respective operating conditions or settings. 8.1.4 Detail drawings These drawings shall include: a. Weld details. b. Details of appurtenances including nozzles and reinforcement plates. c. Details of platforms ladders etc. (as applicable) d. Details of clips and insulation support rings (if applicable) e. A non-dimensioned scaled tube hole layout showing: the shell inside diameter and the maximum outer tube limit, all baffle cuts and ears, all support plate cuts, all pass partition lanes, all tie rod and seal strip locations, all impact plates and their supports or their equivalent, the long baffle section for "F" t ype shells, all vent and drain notches, any handling device holes or any other construction details that affect the flow and/or bypass of the shell side fluid, all peripheral tubes of each tube pass, all of the above, when applicable, shall be superimposed on a large enough layout so that it is readily and easily interpreted^ In addition to the above, a sketch showing the pass arrangement and the numerical tube count in each pass (including one pass) shall be furnished f.

Drg. shall show the location of all parts which are to be stress relieved, gasket sketches for all internal and external joints, the method of holding gaskets in place during assembly when joints are not of the confined type, fabrication details of any specially constructed parts and of parts constructed of alloy materials, and other fabrication details when required by the purchase order. 8.1.5 Erection / assembly Drawings a Drawings or diagrams showing all mark numbers, sequence of assembly or erection, and any notes necessary to ensure satisfactory assembly, preparation for ship ment and erection.

c.

8.1.6

PAGE 13 OF 14

For items part shop and part field fabricated, drawings shall indicate extent of shop and field fabrication. Calculations

a. Detailed thermal design of the exchanger shall be furnished (if applicable). b. Detailed Mechanical calculations shall be furnished in accordance with code requirement and this specification. 8.1.7 Predicted performance curves Required only if requested on 'Vendor Data Requirements' form. 8.I .8 Manufacturer's data reports a. Heat Treatment Charts. b. Documentation of non-destructive testing c. Impact test results. e. Mill test and material test certificate. f. Hydro test certificates. 8.1.9 Performance Test Reports Required only when specified on 'Vendor Data Requirements' form. 8.1.10 Installation, maintenance & operating instructions When specified on 'Vendor Data Requirements' form the instructions shall be in a completely self-contained manual including the following as a minimum. a. Equipment description with outline, cross section and details. b. Full installation instructions. c. Full pre-comissioning check list: d. Details of routine maintenance and repair procedure. 8.1.11 Governmental or third party requirements a. All local authority or third party data such as design calculations, test certificates and performance data. 8.1.12 Recommended spare parts lists. a. Unless otherwise specified, the vendor shall provide priced recommended spare parts list including all items of equipment within his scope of supply. Quantities shall be sufficient for TWO year's operation.

b. For steel work, include material summaries and placement list and indication of material weights




8.2.0 Certified Equipment Data Report 8.2.1 Contents of data shall be as given below: Index Manufacturer's Data report (for specified code) WPS PQR Inspection specifications including weld-map for radiography. Material test results / mill test certificates. Radiographic examination record sheets Any other NDT records Hydraulic/Pneumatic test certificates Stress relieving charts/procedure. Rubbing of Name plate. Rubbing of hard stamping on equipment.

8.2.2

PAGE 14 OF 14

Final certified 'As Built’ drawings. The data must be fastened into folder titled “Certified Equipment Data Report”. The following information shall be printed on the cover of theFolder. Name of vendor Project reference Project No. Equipment No. P.O. No. Supplier's shop/Job No

***********************



02 ES 019/ 94

INSPECTION AND TESTING OF VESSELS AND HEAT EXCHANGERS

PAGE 1 OF 18

CONTENTS 1.0.0. SCOPE 2.0.0. BASE DOCUMENTS 3.0.0. WITNESSING 4.0.0. INSPECTION AND TEST RECORDS 5.0.0. INSPECTION AND TEST ITEMS 6.0.0. MATERIAL TEST 7.0.0. WELDING INSPECTION 8.0.0. VISUAL INSPECTION 9.0.0. POST WELD HEAT TREATMENT 10.00. HYDROSTATIC AND PNEUMATIC TEST 11.0.0. RADIOIGRAPHIC EXAMINATION 12.0.0 ULTRASONIC EXAMINATION OF WELDED JOINTS 13.0.0. MAGNETIC PARTICLE OR LIQUID PENETRANT EXAMINATION 14.0.0. MOCK-UP TEST INSPECTION AND TEST REQUIREMENT FOR: CLASS - A1 CLASS – B1 CLASS – A2 & B2 CLASS – C1 CLASS – C2 CLASS – D CLASS – S CLASS – SC CLASS – M CLASS - T

PRPD.BY:- PSK

CHKD.BY:-

GPN

APPRD. BY:- KKR


ISSUED ON:- Oct `94



1.0.0 SCOPE 1.1.0 This specification covers the requirements for the procedures of inspection and tests to be carried out by Vendor, and the acceptance standards of FEDO to such procedure. 1.2.0 This specification shall apply to shop inspection arid tests of tanks, pressure vessels, shell-and-tube type heat exchangers, etc. (hereinafter referred to as vessel) fabricated in accordance with the FEDO Engineering Specifications and specified codes. The requirements specified in this spec, shall supplement the requirements specified in the design and fabrication codes or other stipulations mentioned elsewhere in the enquiry/p.o spec. 1.3.0 SPECIAL REQUIREMENTS 1.3.1 Special requirements, if any specified along with the eqpt. spec or the enquiry / P.O shall be supplemented to this specification. 1.4.0 VENDOR'S RESPONSIBILITY 1.4.1 Vendor shall carry out all inspection and tests specified in this specification, and shall prepare the records for each item to show that the vessels having been constructed in accordance with the purchase order specifications. 1.5.0 All reference to FEDO shall mean FACT ENGINEERING AND DESIGN ORGANISATION, their client, authorised representative, third party inspector or statutory authority like IBR. 1.6.0 Any reference to vendor shall also include their sub-vendor, if any, as applicable. 2.0.0 BASE DOCUMENTS 2.1.0 CODE AND STANDARDS

02 ES 019/ 94 PAGE 2 OF 18

2.1.1 The codes and standards mentioned in the eqpt. data sheet / dwg. shall also be referred. 2.2.0 SPECIFICATIONS AND DRAWINGS 2.2.1 Inspection and tests shall be carried out based an FEDO specifications, and vendor drawings. Such specifications and drawings shall be of the latest. 2.2.3

Where there are conflicts, at the time of inspection and tests, between the specifications and the drawings, FEDO shall be promptly notified. 2.3.0 VENDOR'S INSPECTION PROCEDURE 2.3.1 Where application of any item in this specification is considered impractical, Vendor shall. prior to it to FEDO for approval. 2.3.2 Vendor shall submit to FEDO his own standard inspection procedure (for special items) when so requested by FEDO. 3.0.0 WITNESSING 3.1.0 Witness inspection shall, as a rule, be carried out at Vendor's shop. 3.2.0 Witness (here in after referred to as FEDO inspector} shall, mean inspectors of FEDO, his designated representative, customers and / or a third party. 3.3.0 At any time during manufacturing, FEDO inspector shall have free access to any of vendor1 shop concerned with manufacture of the vessels. 3.4.0 Vendor shall provide all facilities reasonably necessary to satisfy FEDO inspector that the vessels are being furnished in accordance with the specifications. 3.5.0 Inspections shall be witnessed by way of stage inspection, and final inspection, depending on the design, fabrication methods, and service Condition of the vessels.




3.6.0 In general, items to be witnessed shall be, prior to fabrication of the vessels, mutually agreed between Vendor and FEDO. Vendor shall submit to FEDO a written request for witnessing inspection sufficiently in advance of the inspection operation to permit FEDO inspector to arrive at Vendor's shop. 3.7.0 Vendor shall, at the time of inspection, submit to FEDO inspector one copy of the records of his own prior inspection and tests. This copy shall be in addition to the number specified in the VDR. 3.8.0 Witnessing by the FEDO Engineer shall in no way relieve Vendor of his responsibility to meet the specification. 4.0.0 INSPECTION AND TEST RECORDS 4.1.0 Vendor shall submit to FEDO the following records of each vessel. a. b. c. d. e. f.

Material mill test certificate Hydrostatic and pneumatic test Dimensional inspection Non- destructive examination Post weld heat treatment Welding procedures and qualification

g. Production weld test h. Other inspection and test, where specified 4.2.0 Vendor shall provide the following information in the first part of all the records of inspection and tests a. Name of the client (end user) b. Job No: Item No: and name of the vessel c. Name of the manufacturer d. Date of manufacture and inspection e. Short specification of the vessel 5.0.0 INSPECTION AND TEST ITEMS

02 ES 019/ 94 PAGE 3 OF 18

5.1.1 CLASSIFICATION OF VESSELS Unless otherwise specified in the FEDO purchase order spec. or drawings, the application of the inspection and tests for each vessel shall be as shown in the “ Inspection and Test requirements” for various classes (class A to T) as listed below. The tables for various classes are attached at the end of this specification. However this list shall not limit / dilute the code requirements.

Material and service

Low alloy steel for high temp service ½ Mo, Cr-Mo, Mn-Mo, Mn-Mo-Ni Carbon steels for high and medium temp service C, C-Si, Si-Mn (Design temp>= -10oC) Carbon steels for low temp service (Design temp, -50oC to 11oC) Low alloy steels for low temp service 2.5 Ni, 3.5 Ni, (Design temp, 105oC to -51oC Austenitic Stainless steel Austenitic Stainless steel clad vessel Multi layer cylindrical vessel Storage tank

Classification Design Pressure 50 kg/cm2 Up to 50 g and kg/cm2 g above A1

A2

B1

B2

C1

C2

D S SC M T

5.1.2 Where the application of any item in the list is considered impractical. Vendor shall submit a suggested alternative in detail to FEDO for approval. 5.1.3 Inspection and test items specified in the codes and standards shall govern where applicable. 5.2.0 WELD JOINT LOCATIONS AND CATEGORIES The categories of the weld joints indicated in the attached Inspection and Test Requirement tables are illustrated as follows:




5.2.1 Solid Single Wall Vessel : Refer fig.-1 5.2.2 Multi-Layer Wall Vessel : Refer fig. 2 A: Pressure retaining joint to be subjected to full load B: Pressure retaining joint to be subjected to a half load C: Fillet nozzle-to-flange welds D: Shell-to-nozzle welds E: Attachment welds F: Butt welded joint of inner shell G: Longitudinal welded joint of shell layer H: Circumferential welded joint of full thickness shell layer' I:

Circumferential shell layer-tosolid wall welds J: Shell layer-to-nozzle welds K: Fillet weld of shell layer wound end T: Tube-to-tube plate welds 6.0.0 MATERIAL TEST 6.1.0 Vendor shall submit the mill test certificates for the following: a. Shell, Head, Nozzle

02 ES 019/ 94 PAGE 4 OF 18

b. Tube plate, Channel cover, Flange c. Tube, Tray made of alloy steel (Including high and low alloy steel such as C-Mo, Cr-Mo 3.S Ni Steel, etc.) d. Pressure retaining bolt and nut, and alloy steel (Including high and low alloy steel such as CMo, Cr-Mo 3.5 Ni Steel, etc.) bolt and nut 6.2.0 Submission of mill test certificates for materials may be exempted for any of the followings: 6.2.1 Materials conforming to IS-226 Rolled Steel for General Structure and their ASTM equivalent (A 283 GR.C). 6.2.2 Stocked materials not used in pressure retaining parts. Stocked materials used in pressure retaining parts, but not for main parts, where their mill test certificates are not readily obtainable. In such cases, Vendor's certificates may be substituted for the original mill test certificates. 6.2.3

Materials conforming with IS-1239. Carbon Steel Pipes for Ordinary Piping or their ASTM equivalent;( A 53 Type F). 6.3.0 Vendor shall, prior to fabrication of the vessel, check the charge number and the following items for the materials: a. Chemical compositions b. Mechanical properties c. Heat treatment d. Other items specified in the applicable codes and standards. 6.4.0 Materials shall be free from injurious defects, such as surface flaw and lamination, and these shall be visually inspected. 6.5.0 Material conforming with AISI (Austenitic stainless steel containing molybdenum) or their ASTM equivalent not used in major parts of any



6.6.0

6.6.1 6.6.2 6.6.3 6.6.4

7.0.0


vessel and without mill test certificates, shall be checked for molybdenum content by qualitative analysis. IMPACT TESTS OF MATERIAL FOR LOW TEMPERATURE SERVICE Test procedure shall be in accordance with-ASTM A370. Test specimens of 2 mm (ASTM A370 Type A) shall be used. Test temperature shall not be warmer than the minimum design temperature. Acceptable impact energy are: Average for three specimens: 15 ft-lb and over Minimum for one specimen: 12 15 ft-lb and over WELDING INSPECTION

7.1.0 WELDING PROCEDURE QUALIFICATION 7.1.1 Test procedures and acceptance standards of the welding procedure qualification shall be in accordance with the applicable codes and standards or special requirements, whichever is specified. 7.2.0 INSPECTION AND TESTS OF WELDS 7.2.1 Welders who participate in the welding operation of the main seams of vessels, such as longitudinal and circumferential welding seams, nozzle- to- shell welds and other pressure retaining welds, shall be checked for their qualification licenses. FEDO may request Vendor, requalification of the welders, when necessary. 7.2.3 Prior to or during welding, the following items shall be inspected: a. Dimension of welding groove b.

Alignment tolerances of plate edges.

Nominal plate thickness t (mm) t ≤ 4.5 4.5 ≤ t ≤ 6 6 ≤ t ≤ 20 20 < t ≤ 38 t > 38 Nominal plate thickness t (mm) t ≤ 4.5 4.5 < t ≤ 6 t>6

02 ES 019/ 94 PAGE 5 OF 18

Circumferential joint (mm) 1.0 1.5 t x 0.25 5 t x 0.125, max 6.0 Longitudinal joint (mm) 1.0 1.5 t x 0. 25, max 3.0

Remark: For clad steel, alignment tolerances of both longitudinal and circumferential joins shall be 1.0 mm c. Suitability of welding procedures, such as selection of welding rod or electrode, pre- heating etc d. First pass weld shall be chipped and then inspected b magnetic particle or liquid penetrant method. e. Neither slag inclusion nor crack shall be found at the finish of each welding pass. 7.2.4 After completion of the welding following items shall be visually inspected: Crack

None permitted, remove if any

Over lap

Not to exceed 1.5 mm

Under Cut


Bead width non uniformity

Not to exceed 5 mm

Bead height Non Uniformity Incomplete penetration and lack of fusion


Insufficient toe length of fillet weld


None permitted

Add welding



Crater

Remove

Bead dripping

Remove

Spatter

Remove

Slag and porosity Fittings and weld spot for temporary assembly

None exposed

Eccentricity of weld seam

Not abnormal

9.1.5

Deformation due to welding stress

Not abnormal

9.2.0 9.2.1

Plate thickness ‘t’ mm t ≤ 12 12 ≤ t ≤ 25 t > 25

9.13 Remove 9.1.4

Not to exceed the following values Allowable thickness of reinforcement (mm) 1.5 2.5 3

9.2.2

7.3.0 PRODUCTION WELD TESTS 7.3.1 Procedures and acceptance standards of the production weld tests shall be in accordance with the applicable codes and standards. 8.0.0 POSTWELD HEAT TREATMENT 8.1.0 Vessels shall prior to post weld heat treatment be carefully inspected by visual and nondestructive examination for dimensions and any defect so as to avoid welding repair after completion of heat treatment. 8.2.0 Vendor shall submit to FEDO the time-temperature chart of post weld heat treatment. 9.0.0 VISUAL INSPECTION 9.1.0 The visual inspection carried out as follows:

PAGE 6 OF 18

9.1.1 The vessel and its parts to be assembled at the Job site shall be temporarily assembled and checked where necessary at the vendor’s shop. 9.1.2

Thickness of reinforcement

02 ES 019/ 94

shall

be

9.2.3

Direction and orientation of nozzles and other fittings of vessels shall be checked. Deformation of vessels shall be checked. Machined surfaces shall be checked. Internal cleanliness of vessels shall be checkedDIMENSIONAL INSPECTION Dimensions of the vessel and its parts shall be checked to meet Vendor's latest drawing asreviewed by FEDO, and their records shall be submitted lo FEDO. Dimensional tolerances for equipments shall be as per the respective codes and as supplemented by the corresponding FEDO engineering specifications attached along with the enquiry / purchase order. Actual wall thickness of pressure retaining parts shall be measured, and shall not, as a rule, be thinner than the calculated thickness.

9.2.4 The inside diameter shall be, measured at four or more positions for each section at a distance of about 100 mm from each side of a circumferential welded seam. When direct measurement of the inside diameter is impractical, the external circumference may be measured and the inside diameter calculated. 9.2.5 The camber of shells shall be measured in accordance with the following procedures: a. Place the tower horizontally on tower supports so that deflection of the shell is kept at a minimum.




b. Stretch a piano wire along the shell parallel to the tower support level. c. Measure the distance between the piano wire and the external surface of the shell at four positions on the circumference corresponding to each 90 degree arc of the shell section.

02 ES 019/ 94 PAGE 7 OF 18

10.1.5 Water temperature of the hydrostatic test shall be determined with consideration to brittle-fracture. 10.1.6 The pneumatic test of heat exchangers, which are to be stacked, shall be carried out in the stacked condition.

10.0.0 HYDROSTATIC AND PNEUMATIC TEST

10.1.7 Special vessels shall, where specified, be leak tested by use of halogen gas, and test procedures and pressures will be indicated separately.

10.1.0 SCOPE OF TEST 10.1.1 Hydrostatic test shall normally be carried out for all vessels. Pneumatic proof test may be used in lieu of the hydrostatic test, when filling with water is considered impractical cal due to design, construction, and service of the vessel. The pneumatic test pressure will be specified separately. 10.1.2 Pneumatic test shall only be carried out for any of following cases.

11.0.0 RADIOGRAPHIC EXAMINATION 11.1.0 Degree of radiographic examination shall be as shown in the eqpt. data sheet / drawing. 11.2.0 Portions to be radiographed shall be as follows: 11.2.1 When full radiography is specified, main longitudinal and circumferential welding seams, butt welded joints of nozzles made of steel plate and butted shell-to-nozzle welds shall be 100 percent examined.

a.

10.1.3

Shell side of shell-and-tube type heat exchanger (to check leakage from tube-totube sheet joint). b. Reinforcing pad of nozzle. c. Welds of slip on flanges. d. Lined vessel, when necessary. Test pressure and holding time shall be as follows: a. The hydrostatic test pressure shall be as specified in the reviewed vendor's drawing, and it shall be held for at least half an hour.

11.2.2

When spot radiography is specified, at least one spot for each welded seam and every cross longitudinal to circumferential welded shall be examined.

11.2.3

Radiographic examination shall be performed in accordance with ASME Code Section VIII Par. UW-51.

11.3.0

Acceptance-Rejection standards shall be as follows: Porosity shall be per par. UA-65, Section VIII. Other defects showing any of the followings which are specified in Par. UW-51 of Section VIII shall be judged unacceptable. a. Any crack and incomplete penetration b Any elongated slag inclusion which has length greater than as given in the following table.

11.3.1 11.3.2

b.

For reinforcing pads and linings, during pneumatic test, the test pressure shall be 2.0 kg/crrt2g and held for at least 5 minutes. 10.1.4 The jacketed vessels shall be tested before mounting the jackets.




Weld thk, ’t’ mm

Length 0f slag

up to 18 18 to 54 above 54

6 1/3 x t 18

11.3.3 When the radiograph shows welding which does not meet the requirements of above para, repair and reexamination shall be done as explained below. a. In case of full radiography, unacceptable parts shall be repaired and re-examined. b. in case of spot radiography, two additional spots shall be examined in the same welded seam at locations away from the original spot. c. When either of the two additional spots shows welding which does not meet the requirements, the entire weld length represented by the spot radiograph shall be fully examined and the defective welds shall be repaired. 12.0.0 ULTRASONIC EXAMINATION OF WELDED JOINTS 12.1.0 The procedure and acceptance standards shall be in accordance with the manufacturer’s standards as approved by FEDO.

PAGE 8 OF 18

acceptance or rejection shall be made taking, into account the results, when practical, by radiography, and other results of similar welds by ultrasonic examination.

Incl. mm

c. Any group of slag inclusions in line that have an aggregate length greater than t in a length of 12t, except when the distance between the successive imperfections exceeds 6L. where L is the length of the longest imperfection in the group.

02 ES 019/ 94

13.0.0

MAGNETIC PARTICLE OR LIQUID PENETRANT EXAMINATION

13.1.0 Magnetic particle or liquid penetrant examination of the following items shall be carried out after the completion of the hydrostatic test. a. Bent portions of the vessel heads with design pressure 20 kg/cm2G and over. b. Metal deposited lining c. Butted welds of lining and clad steel. d. Welds of dissimilar materials 13.2.0 Any of the following defects shall be unacceptable: a. Crack and linear discontinuities b. Length of indication exceeding 4.8 mm c. Four or more rounded defects in a line separated by 1.6 mm or less (edge to edge) d. Ten or more rounded indications in any 37.5 cm2 of area whose major dimension is not more than 150 mm with the dimensions taken in the location most unfavourable for the indications. 14.0.0 MOCK-UP TEST 14.1.0 When tube sheet thickness exceeds 150 mm, mock up test shall be carried out in. accordance with ASME Boiler and Pressure Vessel Code, Section VIII, Division 1, Appendix A.

12.2.0 When doubtful and questionable echoes are found by ultrasonic examination, the decision of FACT ENGINEERING AND DESIGN ORGANISATION

( L..ALLOY STEEL FOR HIGH TEMP. < 50kg/cm2g ) parts

NOMENCLAURE

@

@

@

@

@

@

@

@

@

Accessories Parts welded to shell / head Internals not welded foundation bolts

Heat exchanger tubes bolts & nuts

forgings

@

pipes & fittings

inspection & test as per relavnt matl, code high temp, tensile test at design temp Impact test (1) hardness test UT(2) ET MT

weld joint categories

Pressure parts

pipes

@ - Required RT - Radiographic UT - Ultrasonic ET - Eddy Current MT - Magnetic Particle PT - Liquid Penetrant

PAGE 9 OF 18

@

@

A

B

C

D

@

@

@

@ @

@ @

@ @

@

@

@

@ @ @ @ @ @(9)

@ @ @ @ @ @(9) @

@ @ @

E

T

@

@

@

@

COMPLETED EQUIPMENT

INSP.& TEST REQMT. FOR CLASS – A1

Materials

02 ES 019/ 94


gaskets (12)


@

@

PT @

@

Complet ed eqpt.

on the weld Inspection

eld

prew

Production weld test

Welding procedure qualification test

@ transfer of identification marks (3) transverse tensile test all-weld metal tensile test high temp, tensile test at design temp. bending test impact test (4) hardness test macro test micro test trasverse tensile test all-weld metal tensile lest high temp, tensile test at design temp. bending test impact test hardness test macro test micro test Weld prepararion (5)

fit-up for bud weld after back gauging (5) visual inspection of weld RT [if soeafied) UT (7) MT (12) PT hardness test visual inspection dimensional inspection hydrostatic lest leakage test

@(6) @(8) @

@ @ @

@(11

Notes: 1 Impact test required for plates and forging materials (except for standard nozzle flanges) of the following parts when thickness is l00 mm and over. Shell & head, girth flange, forged nozzle, tube sheet. Channel & channel cover 2 UT required for: (a) all plates of a nominal thickness 50mm and over (b) all forgings (except for Std. nozzle flanges) with nominal thickness of 100 mm and over. 3 Transfer of identification marks are required if materials are cut into two or more. 4 Impact test required for weld metal and heat affected zones when shell thk is more man 100mm 5 Required to be supplemented by MT or PT, if accessible, when shell thk. is 25mm and over. 6 RT required for category -D if readily radio graphed (for butt welds only) 7 U/T required category -A.B and D when shell thk. is 50mm and over.(for shell/heads) 8 Applied to full penetration welds where nominal Size of nozzle exceeds 150mm NB. When UT for category-D is specified. 9 MT required for category -A & B when shell thk. is 25mm and over.4 10 MT required for all welds before PWHTand after hydrostatic test when shell thk. is 50mm and over. 11 Gas/air leakage test is required for reinf. pads, sleeve type liners, shell side of heat exch. and nozzle connections for stacked exchangers. 12 Hardness test of gasket required only in the case of solid metal type. 13 PT may be substituted for MT, if MT is impractical.


02 ES 019/ 94


( C.S FOR HIGH & MEDIUM TEMP. < 50kg/cm2g ) parts

NOMENCLAURE


PAGE 10 OF 18


Pressure parts

Accessories

@

@

@

@ @

@ @

@

@ @

@

@

@

fit-up for butt weld

@

@

@

after back gauging (5) visual inspection of weld RT [if soeafied) UT (7) MT (12) PT hardness test visual inspection dimensional inspection hydrostatic lest leakage test

@ @ @ @ @(

@ @ @ @ @(

@

@

@

@

@

@

@

@

@

@

@

@

@

E

T

@

@

@

Complet ed eqpt.

Inspection on the weld

d inspn

Prewel-



Materials

@

gaskets (13)

@

inspection & test as per relevant matl, code high temp, tensile test at design impact test (1) hardness test UT(2) ET MT PT transfer of identification marks (3) transverse tensile test all-weld metal tensile test high temp, tensile test at design bending test impact test (4) hardness test macro test micro test trasverse tensile test all-weld metal tensile lest high temp, tensile test at design bending test impact test hardness test macro test micro test Weld prepararion (5)


D

pipes & fittings

C

forgings

B

plates

A

COMPLETED EQUIPMENT

INSP.& TEST REQMT. FOR CLASS – B1

Parts welded to shell / head Internals not welded foundation bolts


@ @ @ @(6) @(8) @(10 @(10 @( @

@

@

@ @ @ @

Notes: 1 Impact test required for plates and forging materials (except for standard nozzle flanges) of the following parts when thickness is l00 mm and over. Shell & head, girth flange, forged nozzle, tube sheet. Channel & channel cover. 2 UT required for: (a) all plates of a nominal thickness 70mm and over. (b) all forgings (except for Std. Nozzle flanges) with nominal thickness of 100 mm and over. 3 Transfer of identification marks are required if materials are cut into two or more. 4 Impact test required for weld metal and heat affected zones when shell thk is more man 100mm 5 Required to be supplemented by MT or PT, if accessible, when shell thk. is 25mm and over. 6 RT required for category -D if readily radiographed (for butt welds only) 7 U/T required category -A .B and D when shell thk. is 50mm and over.(for shall/heads] 8 Applied lo full penetration welds where nominal Size of nozzle exceeds 150mm NB. When UT for category-D is specified. 9 MT required for category -A & B when shell thk. is 38mm and over. 10 MT required for category -C & D that cannot be radiographed, where full radiography is specified. 11 MT required for category –E when shell thk. Is 50mm and over. 12 MT required for all welds before PWHT and after hydrostatic test when shell thk. is 50 mm and over. 14 Hardness test of gasket is required only in case of solid metal gaskets. 15 PT may be substituted for MT, if MT is impractical.



02 ES 019/ 94


PAGE 11 OF 18

INSP.& TEST REQD.FOR CLASS – A2&B2 (L.ALLOY FOR HIGH TEMP.& CS FOR HIGH & MED. TEMP>=

50kg/cm2g) parts

foundation bolts

@

Parts welded to shell / head Internals not welded


@

Accessories

@

@

@

@

@ @ @

@ @ @

@ @ @

@1 @1 @1 @1 @1 @1 @ @

@


@

@

@


@ @ @ @ @

@ @ @ @ @

@ @ @ @(7) @(9) @ @

@ @

gaskets (14)

@

@

@

@

1 2 3 4 5 6 7 8 9 10 11

d inspn

D

E

T

@ @(

@

@( @( @

@ @

@

Production weld test Prewel

Inspection on the weld Complete d eqpt. Notes:

C

@ @ @ @


UT ET MT PT transfer of identification marks (4) transverse tensile test all-weld metal tensile test high temp, tensile test at design bending test impact test (5) hardness test macro test micro test trasverse tensile test all-weld metal tensile lest high temp,tensile test at design bending test impact test(5) hardness test macro test micro test Weld prepararion (6)

forgings

B

plates

A

inspection & test as per relevant matl, code high temp, tensile test at design impact test (1) hardness test

Materials

Pressure parts pipes & fittings



COMPLETED EQUIPMENT

NOMENCLAURE

@ @ @

@1

@

@

@ @ @ @13

Impact test required for plates and forging materials (except for standard nozzle flanges) of the following parts: Shell & head, girth flange, forged nozzle, tube sheet. Channel & channel cover. UT expected for all standard nozzles flanges. Required either UT or ET for tubes. Transfer of identification marks are required if material are cut in to two or more. Impact test required for weld metal and heat affected zones (except for category A & B with in nozzles) Required to be supplemented by MT or PT if accessible. RT required for category- D if readily radiographed (for butt welds only) UT required category-A & B and D when shell thk. is 50mm and over(for shell/heads) Applied to full penetration welds where nominal size of nozzle exceeds 150 NB, when UT for Category-D is specified. MT required for all welds before PWHT & after hydrostatic test. High temp. tensile test required when the design is based on AD-Merkblatter or BS-5500 & design temp. is 100B C & above .

12 Production weld test is reqd. for vessels designed to “high stress” codes. 13 Gas/air leakage test is required for reinf. pads, sleeve type liners shell side of heat exch. and nozzle connections for stacked exchangers. 14 15

Hardness test of gasket is required only in case of solid metal gasket. PT may be substituted for MT, if MT is impractical.



02 ES 019/ 94


PAGE 12 OF 18

INSP.& TEST REQMT. FOR CLASS – C1 ( C.S FOR LOW TEMP. SERVICE < 50kg/cm2g ) parts

Pressure parts

RT - Radiographic UT - Ultrasonic ET - Eddy Current MT - Magnetic Particle PT - Liquid Penetrant


@ - Required


C

D

@

@

@

@

@ @

@ @

@ @

@ @

@

@

@

@

@


@

@

@


@ @ @ @ @(

@ @ @ @ @(

@

@

@

@

@

@

@(

@ @ @

@(2)

@

@

@

@

gaskets (12)

@

forgings @

plates @

@

d inspn

T

@

Production weld test Prewel-

Inspection on the weld Complet ed eqpt.

E

@


Materials

inspection & test as per relevant matl, code high temp, tensile test at design impact test (1) hardness test UT(3) ET MT PT transfer of identification marks (4) transverse tensile test all-weld metal tensile test high temp, tensile test at design bending test impact test hardness test macro test micro test trasverse tensile test all-weld metal tensile lest high temp, tensile test at design bending test impact test hardness test macro test micro test Weld prepararion (5)


B

pipes & fittings

A

COMPLETED EQUIPMENT

NOMENCLAURE

@

@

@ @ @ @(6) @(8) @ @

@

@

@ @ @ @

Notes: 1

Impact test is not required for tubes when design temp. is between –100C to -29BC.

2

Applied to parts of which materials are same as or equivalent to shell/head.

3

UT required for: (a) all plates of a nominal thickness 50mm & over (b) all forgings (except for std. Nozzle flanges) with nominal thk of 100mm & over.

4

Transfer of identification marks are required if materials are cut into piece.

5

Required to be supplemented by MT or PT, if accessible, when thk. Is 25mm & over.

6

RT required for category-D if readily radiographed (for butt welds only).

7

UT required for category-A, B & D when shell thk. Is 50mm & over (for shall/heads).

8

Applied to full penetration welds where nominal size of nozzle exceeds 150mm NB, when UT for category-D is specified.

9

MT required for category-A & B when shell thk. is 25mm and over.

10

MT required for all welds before PWHT & after hydrostatic test when shell thk. Is 50mm & over.

11

Gas leakage test required for reinforcement pads, sleeve liners, shell side of h.exch. & nozzle of stacked heat exchangers

12

Hardness test of gasket is required only in case of solid metal gaskets.

13

PT may be substituted for MT, if MT is impractical.


02 ES 019/ 94



PAGE 13 OF 18

INSP.& TEST REQD.FOR CLASS – C2 (C.S FOR LOW TEMP. SERVICE>=50kg/cm2g) parts

@ @(

@ @

@ @(

foundation bolts

@ @

gaskets (12)

@


@ @

@

@

@

d inspn

B

C

D

@

@

@

@ @

@ @

@ @

E

@( 2(4) @

@ @

@

@ @ @

@

@

@

@

@


@

@

@


@ @ @ @ @

@ @ @ @ @

@ @ @ @(7) @(8) @ @

1 2 3 4 5 6 7 8 9 10

11 12 13

T

@(2)


Inspection on the weld Complete d eqpt. Notes:

A

@


UT(2) ET MT PT transfer of identification marks (5) transverse tensile test all-weld metal tensile test high temp, tensile test at design bending test impact test m hardness test macro test micro test trasverse tensile test all-weld metal tensile lest high temp,tensile test at design bending test impact test hardness test macro test micro test Weld prepararion (6)

@ @

Accessories Parts welded to shell / head Internals not welded

inspection & test as per relevant matl, code high temp, tensile test at design impact test (1) hardness test

pipes & fittings


Materials


Pressure parts

plates forgings

@ - Required

COMPLETED EQUIPMENT

NOMENCLAURE

@ @

@ @ @ @ 11

Impact test is not required for tubes when min: design temp. is more than between –100C to -29BC Applied to parts of which materials are same as or equivalent to shell/head. UT not required for all std. nozzles flanges. UT or ET Required for tubes. Transfer of identification marks are required if materials are cut into pieces. Required to be supplemented by MT or PT if accessible. RT required for category- D if readily radiographed (for butt welds only). U T required category-A & B and D when shell thk. is 50mm and over(for shell/heads) Applied to full penetration welds where nominal size of nozzle exceeds 150 NB, when UT for Category-D is specified. MT required for all welds before PWHT and after hydrostatic test.

Gas leakage test required for reinforcement , Pads, sleeve liners shell side of heat exch. and nozzle of stacked heat exchangers Hardness test of gasket is required only in case of solid metal gasket PT may be substituted for MT, if MT is impractical



02 ES 019/ 94


PAGE 14 OF 18

INSP.& TEST REQMT. FOR CLASS – D (L.ALLOY FOR LOW TEMP. SERVICE) parts


Pressure parts


@ - Required


D

@

@

@

@

@ @

@ @

@ @

@ @

@

@

@

@

@


@

@

@


@ @ @ @ @(

@ @ @ @ @(

@ @

@

@

@

@ @(1 @ @

@

@

forgings @

plates @

@

@

d inspn

T

@

@(2)

@

@

@

Production weld test Prewel-

Inspection on the weld Complet ed eqpt.

E

@


Materials

inspection & test as per relevant matl, code high temp, tensile test at design impact test (1) hardness test UT(3) ET MT PT transfer of identification marks (4) transverse tensile test all-weld metal tensile test high temp, tensile test at design bending test impact test hardness test macro test micro test trasverse tensile test all-weld metal tensile lest high temp, tensile test at design bending test impact test hardness test macro test micro test Weld prepararion (5)

gaskets (12)

C

bolts & nuts

B

pipes & fittings Heat exchanger tubes

A

COMPLETED EQUIPMENT

NOMENCLAURE

@

@

@ @ @ @(6) @(8) @ @

@

@

@ @ @ @ 11

Notes: 1 2 3 4 5 6 7 8 9 10 11 12 13

Impact test is not required for tubes when design temp. is between –100C to -29BC. Applied to parts of which materials are same as or equivalent to shell/head. UT required for: (a) all plates of a nominal thickness 50mm & over (b) all forgings (except for std. Nozzle flanges) with nominal thk of 100mm & over. Transfer of identification marks are required if materials are cut into pieces. Required to be supplemented by MT or PT, if accessible, when thk. Is 25mm & over. RT required for category-D if readily radiographed (for butt welds only). UT required for category-A, B & D when shell thk. is 50mm & over (for shall/heads). Applied to full penetration welds where nominal size of nozzle exceeds 150mm NB, when UT for category-D is specified. MT required for category-A & B when shell thk. is 25mm and over. MT required for all welds before PWHT & after hydrostatic test when shell thk. Is 50mm & over. Gas leakage test required for reinforcement pads, sleeve liners, shell side of h.exch. & nozzle of stacked heat exchangers. Hardness test of gasket is required only in case of solid metal gaskets. PT may be substituted for MT, if MT is impractical


02 ES 019/ 94



PAGE 15 OF 18

INSP.& TEST REQD.FOR CLASS – S (AUSTENITIC STAINLESS STEEL VESSEL ) parts

@

@

@

@

@

A

B

C

D

@

@

@

@

@

@

@

@

E

T

@

@

Complete d eqpt.


d inspn

Prewel



@ @

gaskets (12)

@

foundation bolts

@ @

@

Accessories Parts welded to shell / head Internals not welded

UT ET MT PT transfer of identification marks (1) transverse tensile test all-weld metal tensile test high temp, tensile test at design bending test impact test hardness test macro test micro test trasverse tensile test all-weld metal tensile lest high temp,tensile test at design bending test impact test hardness test macro test micro test Weld prepararion


@ @

Materials

inspection & test as per relevant matl, code high temp, tensile test at design impact test hardness test

pipes & fittings

forgings

Pressure parts

plates



COMPLETED EQUIPMENT

NOMENCLAURE

@

@

@


@

@

@

after back gauging (2) visual inspection of weld RT [if soeafied) UT MT PT(4) (5) hardness test visual inspection dimensional inspection hydrostatic lest leakage test

@ @ @

@ @ @

@

@ @ @ @(3)

@

@

@

@

@

@

@

@ @ @ @(6)

Notes: 1 2 3 4 5 6

Transfer of identification marks are required if materials are cut into two or more pieces. Required to be supplemented by PT, if accessible, when thk. Is more than 25 mm. PT required for category-D if readily radiographed (for butt welds only). Required PT for the internal surfaces of all welds in contact with the fluids (regardless of thk.) & for nozzle welds, when the vessel is required to be 100% radiographed. In addition to (4) above required PT for all internal & external weld surface when shell thk. Is 19 mm. Gas/air leakage test is required for reinf. pads, sleeve type liners shell side of heat exch. and nozzle connections for stacked exchangers.



02 ES 019/ 94


PAGE 16 OF 18

INSP.& TEST REQMT.CLASS – SC (AUSTENITIC STAINLESS STEEL CLAD VESSEL) parts

@

@

(9)

@ @(2 @(4) @ @

@

@

@

A

B

C

D

E

T

10

10

10

10

10

10

10

10

10

10

10

10

COMPLETED EQUIPMENT

Solid stainless steel matl.(9)

@

Internals not welded foundation bolts

Weld overlay clad matl.

Accessories

@

@ @ @

@ (6) @ (7) @ (8) @ 11 @ 11 @ 11

(9)

d inspn

Complet ed eqpt.


Prewel-



Materials

inspection & test for base material Chemical anal. For cladding matl. Tensile test after cladding Shear test after cladding (3) Bending test after caldding UT(5) PT Welding procedure quali. test transfer of identification marks transverse tensile test all-weld metal tensile test high temp, tensile test at design bending test impact test (4) hardness test macro test micro test trasverse tensile test all-weld metal tensile lest high temp, tensile test at design bending test impact test hardness test macro test micro test Weld prepararion

Hot rolled clad plates (1)


Pressure parts Explo. Clad mat. forgings

@ - Required


Parts welded to pressure parts

NOMENCLAURE

fit-up for butt weld after back gauging visual inspection of weld RT UT MT PT hardness test visual inspection dimensional inspection hydrostatic lest leakage test

@ @ @ @ 12

Notes: 1 2 3 4 5 6 7 8 9 10 11 12

The cladding material thick. Shall not be included in the design calculations. Tensile test required for base material. Shear bond strength test may be substituted for shear test, if shear test is not available. Shear test required if base material is of (a) carbon steel with a nominal thk. Of more than 38mm or (b) low alloy steel plate. To be examined by UT for testing bind between base material & cladding. UT required only for tube sheet& channel cover. PT required on finished surface of weld overlay cladding. Welding procedure qualification test required for overlay weld. Inspection & test of solid stainless steel material shall be as per class-S. Inspection & test for base material shall be as per the respective class of base material. Additional PT shall be done for clad welds as shown in Fig. 1 (step-1: PT after the first layer. step-2: PT on the completed surface.) Transfer of identification marks are required if materials are cut into pieces. Gas leakage test required for reinforcement pads, sleeve liners, shell side of heat exch. & nozzles of stacked heat exchangers.



02 ES 019/ 94


PAGE 17 OF 18

INSPECTION AND TEST REQUIREMENT CLASS – M (MUTI-LAYER VESSEL) parts

Materials

inspection & test as per relevant matl, code high temp impact test impact test hardness test

10 10 @ @ 10

G

H I

J

@

@

@ @ @

@ @ @ @

@ @ @

@ @ @ @ @ @ @ @ @

K E T

10

@ @ @ @ @

@ @ @

@ @

@9 9 @9 @9 @9 @9 @9 @9 @

@ @ @


@

@ @ @

after back gauging (2) visual inspection of weld RT(if soeafied) UT MT (6) (7) PT hardness test visual inspection dimensional inspection hydrostatic lest leakage test

@ @ @

Dd


Inspection on the weld Complete d eqpt.

F

COMPLETED EQUIPMENT

Parts welded to shell / head Internals not welded

Shell layers

Inner shell

Gaskets

Heat exchanger tubes Bolts & nuts

Forgings

10 10 10

Accessories


UT ET MT PT transfer of identification marks (1) transverse tensile test all-weld metal tensile test high temp, tensile test dsg.(8) bending test impact test (4) hardness test macro test micro test trasverse tensile test all-weld metal tensile lest high temp,tensile test at design bending test impact test hardness test macro test micro test Weld prepararion (2)

1 0

Pipes & fittings

Pressure parts

plates



foundation bolts

NOMENCLAURE

@ @ @

@ @ @ @ @ @ @ @ @ @ @3 @ @ @ @3 @ @5 @ @ @ @ @ @ @

@ @ @ @11

Notes: 1 2 3 4 5 6 7 8 9 10 11 12

Transfer of identification marks are required if materials are cut into pieces. Required to be supplemented by MT or PT if accessible. RT or UT required specifically if required by applicable code. RT required for category-J if readily radiographed (for butt joints). MT required for category-F after PWHT, if done. MT required for step welded joints of category-G.I & J during assembling & fabrication. MT required for he exposed surface of all welds before & after hydrostatic test. High temp. tensile test required when designed as per AD-Merkblatter or BS-5500 & the design temp. is 100BC or more Production weld test required for vessel designed to high stress code. Inspection & test for material in solid wall section shall be in accordance with vessel class A2, B2, C2 respectively depending on the material & the design condition. Leackage test required when specified in this spec. for reinforcement pads, sleeve type liners, shall side of exchangers & nozzle of stacked exchangers. PT may be substituted for MT, if MT is impractical.


02 ES 019/ 94

INSPECTION AND TESTING OF VESSELS AND HEAT EXCHANGERS INSP.& TEST REQMT. FOR CLASS – T

@

@

@

@

@

@

@

Parts welded to shell / head Internals not welded foundation bolts

Bottom plates

gaskets

bolts & nuts

Pipes and fittings

forgings

@


Accessorie s

@

@

A

B

C

D

E

@

@

@

@

@ @

@

@

@

@ @

@ @

@

@ @

@

@

@

@

@

@

@ @ @

@ @ @

@

@ @ @ @(5)

@

@

@

@

d inspn

Prewel-



Materials

inspection & test as per relevant matl, code high temp, tensile test at design impact test (1) hardness test UT(2) ET MT PT transfer of identification marks (3) transverse tensile test all-weld metal tensile test high temp, tensile test at design bending test impact test (4) hardness test macro test micro test trasverse tensile test all-weld metal tensile lest high temp, tensile test at design bending test impact test hardness test macro test micro test Weld prepararion (4)_

Major parts

plates


( STROAGE TANKS)

Eqpt. parts

NOMENCLAURE

PAGE 18 OF 18

COMPLETED EQUIPMENT




after back gauging (4) visual inspection of weld RT (f soeafied) UT MT (6,7,8) PT hardness test Vacuum box test visual inspection dimensional inspection hydrostatic lest leakage test

@

Complet ed eqpt.

@

Notes: 1 Impact test required for plates and forging materials (except for standard nozzle flanges) of the following parts when thickness is l00 mm and over. 2 UT required for: (a) all plates of a nominal thickness 75mm and over. (b) all forgings (except for Std.Nozzle flanges) with nominal thickness of 100 mm and over. 3 Transfer of identification marks are required if materials are cut into pieces. 4 Required to be supplemented by MT or PT, if accessible, when thk. is 50mm and over. 5 RT required for category-D if readily radiographed (for butt welds only) 6 MT required for category-A & B when shell thk. is 38mm and over 7 MT required for category-C & D that cannot be radiographed, where full radiography is specified. 8 MT required for category –E when shell thk. Is 50mm and over. 9 PT may be substituted for MT, if MT is impractical. .


@ @ @ @ @

02ES023/97


PAINTING PAGE

1 OF

CONTENTS: 1.0.0. SCOPE 2.0.0. MATERIALS 3.0.0. SURFACE PREPARATION 4.0.0. STORAGE OF PAINTING MATERIALS 5.0.0. MIXING AND THINNING 6.0.0. PAINTING 7.0.0. SAFETY 8.0.0. INSPECTION 9.0.0. GUARANTEE 10.0.0. CODIFICATION OF PAINTING MATERIALS 11.0.0. SCHEME OF PAINTING 12.0.0. COLOUR CODING & MATERIAL FOR PIPING TABLES

PRPD.BY:- RS

CHKD.BY:- GPN

APPRD. BY:- KV


ISSUED ON:- 23.07.97

13

02ES023/97


PAINTING

1.0.0. SCOPE

a)

1.1.0. This specification covers the requirements for surface preparation, painting and painting materials for equipment, structures and piping (including those painted/primed at shop and those painted at Field/Site.

b) c) d) e) f) g) h) i)

1.2.0. Requirement of painting for any item shall be as specified in any of the following documents. a) b) c) d)

Equipment Data Sheet Piping line schedule Design Basis for items Painting schedule

package

1.3.0. The purpose of painting described in this specification is generally for protection against corrosion. 1.4.0. Painting for other reasons shall be as indicated in the respective equipment data sheets or painting schedule. 1.5.0. The following surfaces exposed to atmosphere are covered by this specification, which are not provided by any other form of covering/coating. a)

b) c) d)

PAGE 2 OF

Pressure vessels, Tanks, Heat Exchangers and other process equipment with Carbon steel and low alloy steel as material of construction. Machinery items including motors. Steel structures Carbon and low alloy steel piping

1.6.0. The following items shall not be painted unless otherwise specifically required by respective equipment Data Sheets/Painting schedule

j)

13

Non ferrous surfaces, stainless steel and High Alloy steel surfaces. Glass, tile or ceramic surfaces Name plates and identification tags Valve stems Machined contact surfaces Galvanised surfaces Insulation covers Plastics Underground / buried piping and equipments which are provided with special type of protective coatings. Surfaces / Items which are excluded from painting due to specific reasons.

1.7.0. This specification also covers painting of “Markings” and color-coding of carbon steel, low/high alloy steel, stainless steel, galvanized iron and insulated pipes. 2.0.0. MATERIALS 2.1.0. All painting materials shall be of good quality as covered by respective IS or other international specifications 2.2.0. Special paints and painting materials shall have proven quality and shall meet the requirements laid down in the respective data sheets for equipment and piping. 2.3.0. All painting materials shall not have passed the date of expiry or shelf life as recommended by manufacturer. 3.0.0

SURFACE PREPARATION

3.1.0

All surfaces to be painted shall be free from rust, oil, grease, dust, stain, moisture or any other foreign material/contamination, as per IS 1477 Part I.


02ES023/97

PAINTING

ENGINEERING SPECIFICATION Surfaces to be completely dry.

be

deg.C or when the relative humidity of air exceeds 90%.

3.3.0

Oil, grease, stains and other similar contaminants shall be completely removed by using proper solvents and removers, After cleaning, the surfaces shall be free from even traces of contaminants and solvents/removers.

3.9.3. Blasting operations shall not be carried out during rain, snow, or strong winds.

3.5.0

shall

13

3.2.0

3.4.0

painted

PAGE 3 OF

Dust shall be removed by air blowing or vacuum cleaning. Hard and caked dust, mud, mill scale and rust shall be removed by mechanical means like wire brushing, sand blasting , shot blasting or grit blasting.

3.6.0

Wet surfaces shall be dried by blowing warm air.

3.7.0

All surfaces cleaned by different methods shall be painted immediately with out allowing the clean surfaces to gather dust, rust and other external substances.

3.8.0

During the course of painting if it is found that the surfaces are contaminated due to any reason, the same shall be cleaned by any of the methods described earlier, before further proceeding with painting.

3.9.4. Blasting medium viz. Slag, grit, or shot shall be completely dry and shall be free from any sort of contaminants like dust, oil, grease etc. 3.9.5. Blasting air shall be completely dry and shall have minimum pressure of 3.5 kg/cm2 . 3.10.0 Surfaces which are not suitable for blast-cleaning or could not be blastcleaned due to practical reasons shall be thoroughly wire brushed to exhibit a pronounced metallic sheen, equivalent to St 3 as per IS 9954. 3.10.1 Absence of compressed air, slag/shot/grit and/or blasting equipment and accessories shall not be a reason for not carrying out blast cleaning. 4.0.0. STORAGE MATERAILS

OF

PAINTING

4.1.0. Paints, varnishes, thinner, additives and other volatile substances shall be stored in a flame proof enclosure, away from heat.

3.9.0

All surfaces to be painted after sand, grit or shot blasting shall exhibit almost clean white metal and shall have surface finish of SA 2 ½ as per IS 9954.

4.2.0. Fire extinguishers or sand and water for emergency fire fighting operations shall be provided near storage area at easily accessible place for use, in case of fire.

3.9.1

Blast cleaned surfaces shall be primed within 2 hrs, after blasting, before rerusting starts and before contamination.

4.3.0. Warning Boards and signs shall be exhibited around the storage area.

3.9.2. Blast cleaning shall not be carried out when temperatures are less than 20


02ES023/97


PAINTING

5.0.0. MIXING AND THINNING 5.1.0

Mixing and thinning of paints shall be carried out as per manufacturer’s recommendations.

5.2.0

Mixing and thinning operations shall be carried out in well ventilated rooms.

5.3.0

Only that quantity of paint which is sufficient to cover the required area within the specified painting time, shall be mixed at a time.

5.4.0

Mixed paints shall be used with in the time span as recommended by manufacturer. Mixed paints, for which standing time specified has elapsed, shall not be used.

5.5.0

5.6.0

Ready-mixed paints containers shall be opened only at the time of painting. Containers shall be closed air tight after drawing paint from it. Ready-mixed paints shall be stirred well before drawing from the storage container as well as during painting operations.

5.7.0

Ready-mixed paints shall be thinned only if absolutely necessary by using thinners commended by manufacturer.

5.8.0

Balance of ready-mixed paints shall not be poured back into the main container after use, but shall be kept in a separate air tight container.

6.0.0

PAINTING

6.1.0

General Requirements.

6.1.1

Painting of equipment, piping and structurals shall be carried out at shop or site as prescribed in the respective eqpt. data sheets, piping line schedule or structural detail drawing.

. 6.1.2

PAGE 4 OF

13

Painting shall not be carried out on surfaces not prepared and not meeting the requirements of clause 3.0.0.

6.1.3

Painting shall be carried out only under favourable conditions. Painting shall not be carried out in dusty and draught conditions in damp areas and during rainy seasons or cold atmosphere.

6.1.4

During painting, adjacent equipments or surfaces shall be protected from paint sprays, splashes or drips.

6.1.5

Painting shall be carried out only by using brushes, rollers, air/airless spray.

6.1.6

Caution boards indicating ‘wet paint’ shall be posted after painting is over and kept till the curing time is completed.

6.1.7

For painting of multiple coating, each coat shall be applied only after sufficient curing time has elapsed after the previous coat, as recommended by manufacturer.

6.1.8

All painted surfaces shall have a uniform and smooth regular finish. The surfaces shall be free from foreign particles, brush marks, bristles, ridges, waves, laps wrinkles etc. If such surface defects occur, the same shall be removed by using abrasive paper/cloth and re-painted.

6.1.9

Surfaces inaccessible after assembly shall be painted to requirement before assembly.

6.1.10 Any imperfect or damaged layer/coat shall be repaired before subsequent coating. 6.1.11 At places where welding is to be carried out at field after assembly, a space of 100 to 200 mm width shall be left unpainted on both sides of the welding joint.


02ES023/97


PAINTING

6.1.12 Field welded areas shall be thoroughly cleaned as required in clause 3.0.0 and painted in the same manner as the remaining area. 6.2.0

Shop Painting/Priming.

6.2.1

Shop painting/priming shall be carried out as specified in the respective data sheets/line schedule etc. and shall meet all the requirements of this specification.

6.3.0

Painting at Field /Site.

6.3.1

Field/site painting shall be carried out as specified in the data sheets/painting schedule and shall meet all the requirements of this specification for painting.

6.3.2

Where equipments/piping/structures have already received shop painting/priming, the painted/primed surfaces shall be thoroughly cleaned and inspected for any damage or defects. Such damages or defects shall be repaired before starting the filed/site painting.

7.2.0. Open flames and exposed elements or sources of ignition of any kind shall be prohibited in the area where painting materials are stored and painting operations are carried out. 7.3.0. ‘Warning’ or ‘Caution’ boards indicating chances of fire shall be displaced around the paint storage and painting areas.

13

7.4.0

Electrical fittings and appliances shall be spark proof and shall not cause a fire in the painting storage and painting areas.

7.5.0

Cleaning agents with flash point less than 400 C shall be used.

7.6.0

Adequate ventilation shall be ensured during painting and storage of paints.

7.7.0

Painting workmen shall wear face masks, gloves and protective clothing during painting and mixing operations. In addition, workmen engaged in blasting operations shall be earmuffs also.

7.8.0

Area where painting is carried out, as well as materials are stored shall be clean, After work, the areas shall be cleared of all scaffoldings, balance materials etc. in order to prevent fire hazards and hinder fire fighting operations.

7.9.0

Painting materials shall be stored and painting and blasting operations shall be carried out only in areas where fire fighting equipments/vehicles and personnel evacuation vehicles can have easy access. In areas where such easy access is not available suitable precautions are to be ensured.

8.0.0

INSPECTION

7.0.0. SAFETY 7.1.0. Sufficient safety precautions shall be taken to ensure protection of Personnel, equipments, piping structures and buildings in the vicinity, where painting materials are stored and painting and blasting operations are carried out.

PAGE 5 OF

8.1.0. All painting materials and related items shall be inspected to check the suitability of the same for the specified purposes. 8.2.0. Painting surfaces are to be inspected after cleaning operation, to ensure that the surfaces are fit for painting. 8.3.0. Finished surfaces shall be checked for uniformity in colour, finish and appearance as well as for defects.


02ES023/97

PAINTING


8.4.0. Thickness of each coat of paint shall be checked after curing time. The total thickness of multiple coats shall be as specified in the data sheets/piping line schedules/painting schedules. 8.5.0. Paint thickness gauge shall be either mechanical or electronic. The gauges shall be calibrated regularly. Defective gauges shall not be used. 8.6.0. Absence of paint thickness gauge shall not be made for each eqpt/line/structure separately. 8.7.0. A detailed quality / inspection report shall be made for each eqpt / line / structure separately 9.0.0. GUARANTEE Guarantee shall cover materials and workmanship. 10.0.0. CODIFICATION MATERIALS

OF

PAINTING

10.1.0. Primers A.01 A.02 A.03 A.04 A.05 A.06

Synthetic Zinc Phosphate Primer Epoxy based Zinc Phosphate Primer Epoxy based Zinc Rich Primer Alkyd High Build Zinc Phosphate Primer Inorganic Zinc Silicate Primer Chlorinated Rubber based High Build Zinc Phosphate Primer

10.2.0. Finish Paints B.01 B.02 B.03 B.04 B.05

Epoxy Resin based Enamel Epoxy Resin based Micaceous Iron Oxide Paint Epoxy Resin based High Build Paint Coal Tar Epoxy Resin based Paint Chlorinated Rubber Paint

PAGE 6 OF

13

C.01

Nontoxic Inert Coating for drinking water tanks C.02 Acid Alkali and Heat Resisting Coating 10.4.0. Heat Resistant Paints D.01 D.02

Dual Pack Aluminium Paint (upto 250o C) Single Pack High Temperature Silicon Aluminium Paint (upto 600o C)

10.5.0. Polyurethane Coating. (For low temp. application) E.01 E.02

Two-Pack Polyurethane Holding Primer High Build Polyurethane Coating

10.6.0. General Purpose Paints F.01 F.02 F.03

Synthetic Resin based Enamel Chemical Resistant Enamel Alkyd, Antiskid Abrasion Resistant Synthetic Floor Paint

10.7.0. Special Applications G.01 G.02 G.03

Bituminous Mastic Coating Asphalt doping as per IS 10987 App-B Thermocolour Paint

10.8.0 As an alternative, in place of one coat of E.01 – Two pack Polyurethane Holding Primer, one coat of Epoxy Zinc Phosphate Primer A02 (20 microns) followed by one coat of High Build Epoxy containing Micaceous Iron oxide-Bo2 (20 microns) shall be applied before applying finish paint E02-High build Polyurethane coating. 11.0.0 SCHEME OF PAINTING 11.1.0. Scheme of painting of equipment, piping, structures and other items shall conform to class 1, class II or class III as specified in the equipment data sheet/ piping line schedule/ painting schedule/ structural drawings. 11.2.0 Representation of painting

10.3.0. Bituminous Coating FACT ENGINEERING AND DESIGN ORGANISATION

02ES023/97

PAINTING


Requirement of painting of an item shall be indicated in respective drawings/ data sheets/ line schedule/ painting schedule as follows. Indicate primer or finish or both as requiredfollowed by subclass indicated in Table 1, Table 2 or table 3 as the case may be. Eg Primer Finish Primer & Finish Primer Primer & finish Primer Finish Primer & Finish

Class I

(1)L

Class I

(1)L

Class I

(2)M

Class II

(2)O

Class II

(3)O/P

Class III

(1)

Class III

(1)

Class III

(3)

PAGE 7 OF

13

12.0.0 COLOUR CODING AND MARKING FOR PIPING 12.1.0 In addition to the requirements of painting as per 11.0 the finish painting of the piping shall have the specified colors as per Table 4 – Color coding for pipes, for purposes of identification of service. 12.2.0 All pipes and pipe lines covered under 1.7 shall be provided with “Markings” such as color bands, hazard markings, line identification markings, flow arrow markings etc. at specified locations/intervals and dimensions as indicated in Table 5 – Marking of pipes.

*******************


02ES023/97

PAINTING


PAGE 8 OF

13

TABLE 1 – CLASS I – Pressure Vessels, Heat Exchangers, Reactors, Towers, Tanks and Piping Sl. No.

SERVICE CONDITIONS

OPERAT ING TEMP.

PAINT SUBCLASS

Type

1

UN INSULATED NON CORROSSIVE ATMOSPHERE UN INSULATED CORROSSIVE ATMOSPHERE INSULATED CORROSSIVE ATMOSPHERE

=/< 15 =/< 65 =/< 125 =/< 400

(1) L (1) N (1) M (1) H

=/< 15 =/< 65 =/< 125 =/< 400 =/< 15 =/< 65 =/< 125 =/< 400 INSULATED =/< 15 CORROSSIVE =/< 65 ATMOSPHERE =/< 125 =/< 400 SUPPORTS =/< 15 FOR ALL =/< 65 EQPTS.(INSUL =/< 125 ATED/UN =/< 400 INSULATED) EQPT. AND =/< 15 STRUCTRURE =/< 65 S SUBJECTED =/< 125 TO SALINE =/< 400 ATMOSPHERE UN INSULATED

2

3

4

5

6

PRIMER *DFT

Type

E.01 A.01 D.01 D.02

No.of coats 1 2 2 2

*DFT

E.02 F.01 D.01 D.02

No.of coats 2 2 2 2

30 20 20 20

(2) L (2) N (2) M (2) H (3) L (3) N (3) M (3) H (4) L (4) N (4) M (4) H (5) L (5) N (5) M (5) H

E.1 A.06 A.02 D.02 E.01 A.04 D.01 D.02 E.01 A.06 D.01 D.02 E.01 A.01 D.01 D.02

1 2 2 2 1 2 2 2 1 1 1 1 1 2 2 2

30 20 20 20 30 25 20 20 30 30 30 30 30 20 20 20

E.02 B.05 B.02 D.02 E.02 F.01 D.01 D.02

2 2 2 2 2 2 2 2

20 20 20 20 30 20 20 20

(6) L (6) N (6) M (6) H

E.01 A.06 A.02 D.02

1 2 2 2

30 20 20 20

E.02 B.05 B.01 D.02

2 2 2 2

30 30 30 20

* DFT – Dry film Thickness per coat microns Notation: L – N – M– H –

FINISH

Low Temperature Normal Temperature Moderate Temperature High Temperature

:


30 20 20 20

02ES023/97

PAINTING


PAGE 9 OF

13

TABLE 2 – CLASS II – OTHER EQUIPMENTS PRIMER PAINT SUB CLASS

Sl. No. TYPE OF ITEM

1

2 3 4 5

6

7

8 9 10

11

Chimneys,Stacks, Furnaces,heaters (fired and unfired)operating Temp upto450o C D.M.Water Storage Tanks Fresh Water/fire Water Storage Tanks Drinking Water Storage Tanks Acid/alkali Storage Tanks Storage Tanks/Vessels for Petroleum Products Floating Roof Tanks:Inside of shell, top of bottom plate,topside and underside of deck, inside of pontoon Underside of Bottom Plate of Tanks Underground Tanks (buried) Below Ground (submersible) Tanks Secondary Reformer&Simila r Eqpt.(Thermo colour paint) *DFT : ** : Notation:

FINISH

Type

No.of coats

*DFT

Type

No.of coats

*DFT

Outside

(1)

A.05

2

25

D.02

2

20

Outside Inside Outside

(2)O (2)P (3)O

A.01 A.03 A.01

2 2 2

20 35 20

F.01 B.03 F.01

2 2 2

25 35 25

Inside Outside Outside

(3)P (4)O (4)P

A.03 A.01 A.01

2 2 2

35 20 20

B.04 F.01 C.01

2 2 3

75 25 20

Outside

(5)

A.04

2

30

C.02

3

25

Outside

(6)O

A.04

2

50

D.01

2

25

Inside

(6)P

A.02

2

30

B.03

2

75

Outside

(7)O

A.04

2

50

D.01

2

25

(7)P

A.02

2

30

B.03

2

75

(7)Q

A.01

2

25

(8)

A.01

1

20

G.01

1

80

Outside

(9)

A.01

1

20

G.02

Outside

(10)

A.06

2

35

B.05

3

35

(11)

G.03

2

**

G.03

1

**

Dry Film Thickness per coat microns As per Manufacturer’s recommendations O- Outside P-Product Side Q-Specified Side


02ES023/97


PAINTING

PAGE 10 OF

13

TABLE 3 – CLASS III – MISCELLANEOUS

Sl. TYPE OF ITEM No.

1

Steel structures, Platform Supports

PAINTING SUB Type CLASS

PRIMER No. of *DFT coats

FINISH Type

No.of coats

*DFT

(1)

A.04

2

20

B.01

2

25

2

Chequered Plate,Floorplanks&Gang ways

(2)

A.04

2

20

F.03

2

25

3

Handrails Posts,Railings,Ladders and Stairways

(3)

A.04

2

20

B.01

2

25

* DFT – Dry Film Thickness per coat microns


02ES023/97


PAINTING

PAGE 11 OF

13

TABLE 4 – COLOUR CODING FOR PIPES Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Identification Ground / Finish Colour Instrument Air0 Sky Blue Service Air Sky Blue Plant Air Sky Blue Cooling Water Sea Green Service Water Sea Green Demineralised Water Sea Green Boiler Feed Water Sea Green Steam Condensate Sea Green Boiler Blow Down Sea Green Turbine condensate Sea Green Process Condensate Sea Green Low Pressure Steam Silver Grey Medium Pressure Steam Silver Grey High Pressure Steam Silver Grey Very High Pressure Silver Grey Steam Naphta Liquid Light Brown Naphta Vapour Light Brown Fuel Oil Light Brown Antifoam Solution Black Phosphate Black Hydrazinc Black Waste Water Black Oily Water Black Ammonia Liquid Dark Violet Ammonia Water Dark Violet Ammonia gas Dark Violet MDEA Solution Dark Violet Process Vent Canary Yellow Carbondioxide Canary Yellow Hydrogen Canary Yellow Nitrogen Canary Yellow LPG Canary Yellow Fuel gas Canary Yellow Process Gas Canary Yellow Synthesis Gas Canary Yellow Effluent Black Drinking Water Sea Green Service

Colour Band - 1

Colour Band - 2

White Light Brown French Blue French Blue French Blue Light Orange Light Brown White White Black Light Orange Light Brown Signal Red Signal Red

Signal Red French Blue Signal red French Blue

French Blue French Blue White Sea Green Signal Red Signal Red Sea Green White French Blue French Blue French Blue Black Light Grey Light Grey Signal Red Black French Blue Light Brown Sea green White Sea Green Light Orange

White Sea Green Signal Red Sea Green Canary Yellow White Signal Red Signal Red -


02ES023/97

PAINTING


PAGE 12 OF

13

TABLE 5 – MARKING FOR PIPES 1.0. GROUND COLOUR UNIT OF MEASUREMENT Insulated Line – all (excludes buried line) 1.1. Un-insulated Lines–Stainless : Ground colour for a length Per Marking as per para 6.0 Steel,GI ,Alloy steels & of 2 meters below including pipe supports Other non-ferrous pipelines (excludes buried line) ___________________________________________________________________________ 1.2. Un-insulated carbon steel : Ground colour applied Run length in Meters along Lines (excluded buried throughout entire length centreline including Markings Lines) as per Para 6.0 below & pipe supports ___________________________________________________________________________ 2.0. COLOUR BANDS MARKINGS Colour band(s)and its width,Band 2 downstream of Band 1(ie.after band 1 along the direction of flow) Pipe size NB (D-pipe size in inches) 80 NB and below Above 80 NB(3”) up to 100 NB(4””) Above 100 NB(4”) up to 300 NB(12”) Above 300 NB(12”)

Band 1 mm 75 D x 25 D X 20 D x 15

B and 2 mm ¼ of Band 1 (Rounded to nearest mm)

the

HAZARD Diagonal strips of Black and golden Yellow as per IS2379 superimposed on MARKINGS the ground color. If color bands exists,the hazard marking shall be painted Downstream of the bands (ie. after bands in the direction of flow) 3.0.

LINE IDENTIFICATION MARKINGS

Color shall be Black or White to contrast with the color on which they are painted. It shall consist of Line No., Line size, Fluid code & Pipeline Spec. No. The lettering dimensions Shall be as per IS2379.

4.0.

FLOW ARROW MARKINGS

Color shall be Black or White to contrast with the color on which they are painted. The dimension of the arrow shall be as follows and is based on the size of the pipeline.

d

a c

b

a b c d

150NB & below 65 30 95 20


200NB & above 90 50 125 30

02ES023/97

ENGINEERING SPECIFICATION 5.0.

PAINTING

PAGE 13 OF

13

LOCATION OF MARKINGS Marking includes 2M long ground color, color band(s), hazardous marking, Line No. & flow direction arrow which shall be located at the following points with proper visibility as per IS2379. a. b. c. d. e.

Battery Limit Points Either side of walls & dyke walls For long yard piping – at 30M interval Inter-section on pipe bridge Any other location indicated by the Engineer-in-charge at site

6.0.

PIPE SUPPORTS

6.1.

This includes base springs, hanger springs, shoes and trunnions etc. and excludes pipe bridge structures, platform, equipment support structures and such structures which do not actually support the pipeline.

6.2.

The painting of pipe supports forms part of the pipelines and a separate rate will not operate.

6.3.

The

painting specification for pipe supports shall be same as that for pipe ground colour.

****************


02ES041/94


ANCHOR BOLT

PAGE 1 OF 2

CONTENTS

PRPD.BY:- PSK

1.0.0

SCOPE

2.0.0

CODES AND STANDARDS

3.0.0

MATERIAL

4.0.0

IDENTIFICATION MARKS

5.0.0

INSPECTION

6.0.0

PACKING AND FORWARDING

7.0.0

VENDOR DOCUMENTS

8.0.0

GUARANTEE

CHKD.BY:- GPN

APPRD. BY:- KKR


ISSUED ON:- Oct `94

02ES041/94


ANCHOR BOLT

1.0.0 SCOPE 1.1.0 This specification covers the requirement for manufacture, inspection, testing and supply of anchor bolts for static equipment. 1.2.0 The vendor shall quote for all the items in the anchor bolt schedule. The requirement given in the schedule is indicative only. The purchaser reserves the right to delete/increase/decrease the number of bolts in each category. The quoted rates shall be firm even after such change in scope. The final requirement will be intimated during the time of placing the order. 2.0.0 CODES AND STANDARDS 2.1.0 Bolt shall be Metric sizes as per the anchor bolt schedule and threads shall be as per IS 4218. 2.2.0 The threads shall be 2 pitch series for bolts below M24 size and 3 pitch series of sizes M24 and above. 3.0.0 MATERIAL 3.1.0 The material of construction of bolt shall be as specified in the anchor bolt designation. Anchor bolt designation is as explained below.

PAGE 2 OF 2

4.0.0 IDENTIFICATION MARKS 4.1.0 Anchor bolts supplied shall be provided with proper identification marks indicating the bolt designation listed in the schedule. The designation shall be clearly stamped with low impression punching on the shank of each anchor bolt. In addition to this all the anchor bolts shall be individually provided with suitable leather tags with the designation printed on it. 5.0.0

INSPECTIION

5 . 1 . 0 Anchor bolts shall be subjected to inspection / acceptance by FEDO / Purchaser. 6.0.0 PACKING AND FORWARDING 6.1.0 All items shall be properly packed so as to enable easy identification of each type of bolts. The packing shall be done as per the FEDO engineering spec. 02DS022. Threadings of bolts and nuts shall be coated with suitable lubricant to prevent galling, before despatch.

Eg.M24TP3A 7.0.0 VENDOR DOCUMENTS M24 Size

TP3 A Type Material code

3.2.0 Refer FEDO standard 02DS002 for details and dimensions of various types of anchor bolts. Material code shall be as specified below. Material Part Bolt Nut

A SA 193 B7 SA 194 2H

Plates IS-2062

B IS-226 SA 194 2H

C SS-304 SS-304

IS-2062

SS-304

7.1.0

Relevant material test certificates, certificate of manufacturing and inspection shall be forwarded along with supply.

8.0.0 GUARANTEE 8.1.0 Vendor shall guarantee against defective materials and faulty workmanship for the period and terms as specified in the commercial conditions of the enquiry/order.

**********************



02ES022/94

PACKING, MARKING AND FORWARDING PAGE

1

OF

CONTENTS

PRPD.BY:- KS

1.0.0

SCOPE

2.0.0

PACKING

3.0.0

MARKING

4.0.0

GLASS LINED / FRP EQUIPMENTS

5.0.0

FORWARDING

CHKD.BY:- JR

APPRD. BY:-KKR


ISSUED ON:- Mar. 94

5

02ES022/94


PACKING, MARKING AND FORWARDING

1.1.0 SCOPE This specification covers the requirements of Packing, Marking" and Forwarding for equipment. 1.2.0 This specification shall be conjunction with such instructions as are given commercial conditions Purchase Order.

read in specific in the of the

2.0.0 PACKING 2.1.0 The manufacturer shall be responsible for packaging each item to protect it from damage or loss during handling and shipment in accordance with the Purchase Order and the following requirements. 2.1.1 All materials and methods of packing shall conform to these and any additional specifications referenced in the Purchase Order. 2.1.2 Packages shall include lifting lugs or designated lifting points. 2.1.3 Each item, crate or bag shall be durably marked with the receiving address, Purchaser's item number/equipment number and complete Purchase, order number of the contents therein. 2.1.4 Special tools shall be separately boxed, shipped and identified with the item on which they are to be used; and marked as special tools. 2.2.0 The vendor shall include a packing list in each shipment, listing the contents by assembly piece mark/Individual piece mark or by item number of each. box, crate, bag and skid. The list shall state whether the contents are complete or partial. 2.3.0 The vendor shall include with all shipments, a copy of each instruction manual and all drawings required for assembly, installation or erection of the. Equipment / parts therein.

PAGE 2

OF

5

2.3.1 These documents shall be attached preferably to the inside of the largest crate in the shipment and this crate shall be marked accordingly. 2.4.0 Vessels shall not be floated nor transported to the job site, as above deck cargo without prior written approval of the Purchaser. 2.5.0 Vessels shall be shipped in completed condition as represented by the drawings. Where clearances for transportation / shipping require alteration or elimination of vessel nozzles, clips, lugs, or other similar attachments, the fabricator shall submit drawings showing the attachments which require re-orientation or removal. No changes shall be made unless written approval has been obtained from the Purchaser. 2.6.0 Small parts of the vessel shall be shipped bagged or boxed or otherwise protected from damage or loss spare gaskets shall be shipped separately and not bolted in place between flange and cover plate. 2.7.0 The protection of end connections from corrosion, contamination and impact damage shall be as given below: 2.7.1 Threaded openings shall be plugged with hexagonal headed threaded plugs' of the same material as the connected part and sealed in with Teflon tape sealant. 2.7.2 Tell tale holes / vent holes too small to be sealed as in 2.7.1 above shall be sealed using grease compatible to the material of the part. 2.7.3 Bevelled and plain openings shall be suitably closed with solid metal wedge type protectors that fit either outside or inside the connectors. 2.7.4 In the case of overland transport all flanged openings shall be provided with bolted wooden blends with gaskets. 2.7.5 In the case of water transport all flanged openings shall be protected and made


02ES022/94



waterproof with bolted full size 10 gauge minimum thickness steel covers and sponge rubber cord 6 mm mini mum diameter gaskets. Bolting shall be equally spaced, machine bolts. Flanges shall be furnished with one bolt for every other bolthole, subject to a minimum of four bolts. 2.7.6 When special rust preventive measures are required for the inside surface of vessels, these will be indicated a the job specifications. All equipment, however, if transported by sea shall have VPI filling inside the outside coated with suitable corrosion inhibiter.

3.2.0 Markings shall be done in white colour paint after rust prevention painting has been done and shall be protected by lacquer coating against contamination and separation of the markings. 3.3.0 The width of the marking line shall be 3 mm. 3.4.0 The location of markings shall, unless otherwise specified be as per Fig.1 and Fig.2. 3.5.0 The centre of gravity shall be clearly indicated together with the lifting weight as given in Fig.3. 3.6.0 The equipment number shall be marked at one conspicuous place as indicated in Fig.1. 3.7.0

5

3.9.1

If so requested, the manufacturer shall submit analysis of marking material to FEDO / Purchaser. Submittal shall demonstrate (by chemical analysis and history of user) that the material meets the requirements specified herein.

3.10.0

Plates, assembled pieces, internals, clips, lugs or other similar attachments which are either removable or are to be assembled by others shall be marked with piece numbers for identification in assembly and match marked as required.

3.11.0

For vessels that have been post weld heat treated, the following sign shall be painted on the vessel after heat treatment. "NO WELDING PERMITTED ON THIS VESSEL"

3.11.1

The sign shall be in letters approximately 75 mm high and of bright yellow paint. On vertical vessels, this sign shall be located on two opposite sides near the bottom tangent line and repeated at approximately every 3-mt height, but rotated 90 deg.

3.11.2

On horizontal vessels, it shall be located on both sides near the horizontal centre line.

3.12.0

In the case of bulk materials packed in bags the bags shall clearly be marked with the name of the material, batch number and shelf life if any.

3.13.0

Special storage requirements like airconditioning/ moisture control shall be clearly indicated on the case/bag and shall be clearly spelt out on an additional leaflet included with the packing list.

4.0.0

GLASS LINED / FRP EQUIPMENTS

The centre line shall be exactly marked along the punch mark.

3.8.0 Stamping on all austenitic steels and impact-tested materials shall be with 'low-stress' steel stamps having round or "U" shaped cross sections or with "interrupted-dot" die stamps. 3.9.0 Marking with paint or ink on all austenitic and high nickel alloy steel

OF

shall be with a water insoluble ink that contains no harmful subsistence eg. Metallic pigments, sulphur or chlorides, which would harmfully affect austenitic steels at ambient or elevated temperatures.

3.0.0 MARKING 3.1.0 This section covers the requirements of marking of equipment and shall be read together with Fig.1, Fig.2 and Fig.3 on page 3 of 3.

PAGE 3


02ES022/94



4.1.0 The vessel shall be cleaned inside to be free of all traces of release agents, fibres, dust or other foreign matter. 4.2.0 All nozzle and other openings shall be blanked' either with service blanks or with temporary covers suitable for protecting flange faces and protecting glass finish. 4.3.0 Care shall be taken to ensure that FRP nozzles/glass lining is not damaged during transit due to overstressing of the parts in question. 4.4.0 Care shall be taken to ensure that even after the blanking of nozzles, the vessel is vented at all times. 4.5.0 The vendor shall ensure that the vessel is not transported in such manner as will cause the vessel to be subjected to temperatures in excess of 50 deg.C. 4.6.0 To prevent overstressing of FRP vessels during handling and transportation,5. temporary stiffening/supporting devices such as spiders or saddles shall be provided when necessary. 4.7.0 If the vessel or vessel section has a transport mass in excess of 200 kg., a drawing shall be provided showing lifting positions, handling techniques and equipment required together with any other information necessary for safe handling of the vessel. 4.7.1 If lifting positions have special restrictions on angle of lift or minimum

PAGE 4

OF

5

number of positions used details shall be recorded on the drawing and a permanent notice affixed to the vessel refer ring to these restrictions. 4.8.0 When lifting lugs are not provided, the vessel shall only be lifted using webbing or rope slings passed around the girth of the vessel. Extreme' care shall be taken to ensure that the vessel is protected from local loads and abrasion. . 4.9.0

Care shall be taken when lifting to ensure that shock loads are not applied to the lugs or the vessel.

4.10.0

In the case of FRP vessels, due care shall be exercised to ensure that the packing and transportation sequence does not bring the vessel into contact with sharp protrusions.

4.11.0

Under no circumstance shall loose parts be placed inside the vessel.

5.0.0

FORWARDING

5.1.0

Forwarding/transportation of t h e equipment/parts shall be carried out as per the instructions from FEDO / Client depending on the specific project and as per conditions of contract.

5.2.0

Over dimensional carriage (ODC) shall be as per specific trans port plan showing method of' transport, route, bottlenecks on the route, limo etc. which shall be submitted to FEDO/Client for study/approval.

*********************


PROCUREMENT SPECIFICATION

PROJECT

LPG BLENDING FACILITY AT HPCL,

MANGALORE ENQUIRY NO: 8122-02-PS-001

1

1.0

DESCRIPTION

2

UNIT PRICE

*

3

Lumpsum cost for the Design, Supply, Fabrication, Painting, Testing and Transportation to site of L.P.G. Heater E 301, including Structural, as per TPS NO. 8122-02-PS-001.

PAGE 1 OF 1

4

TOTAL PRICE

5

FREIGHT EXCISE SALES TOTAL INSP. P&F CHARGE CHARGES CHARGDUTY TAX DELIVUP TO ON ES. RATE & RATE & ERED (5) IF 3rd PARTY AMOUNT AMOUNT DESTINCOST TION (5 TO NOT 10) INCLUDED 6 7 8 9 10 11

1 No.

IMPORTANT: VENDOR TO COMPLETE ALL THE COLUMNS for each item of equipment & spares separately.

10FT006/94

R0

VENDOR:

QTY

SL. NO.

8122--02-PS-001 PB

PRICE BID-SUPPLY (INDIGENOUS)

Signature Designation

Date


: :

:

8122-02-PS-001 RN1 TECHNICAL RATE FOR ADDITION / DELETION OF PROCUREMENT PAGE 1 OF 1 Rev. 0 NOZZLES SPECIFICATION TPS NO.: 8122-02-PS-001 (Space for vendor's seal &

signature)

NOZZLE NECK MATERIAL: SA 106 GR B FLANGE MATERIAL: SA105 Vendor shall fill in his rates for addition / deletion of nozzles in the following format and furnish along with the offer. 150#

SIZE

300#

600#

900#

S.No (mm NB) SORF 1

15

2

20

3

25

4

40

5

50

6

80

7

100

8

150

9

200

10

250

11

300

12

350

13

400

14

450

15

500

16

600

WNRF

BF

WNRF

BF

WNRF

BF

WNRF

BF

0

For Enquiry

SK

AAN

JK

24.09.09

Rev.

Details

By

Chkd

Apprd

Date


TECHNICAL 8122-02-PS-001 RN2 RATE FOR ADDITION / DELETION OF PROCUREMENT PAGE 1 OF 1 Rev. 1 NOZZLES SPECIFICATION TPS NO.: 8122-02-PS-001 (Space for vendor's seal &

R1

NOZZLE NECK MATERIAL: SA 106 Gr.B + Cu / Ni 70/30 cladding

R1

FLANGE MATERIAL: SA 105 + Cu / Ni 70/30 Full face cladding

signature)

Vendor shall fill in his rates for addition / deletion of nozzles in the following format and furnish along with the offer. 150#

SIZE

300#

600#

900#

S.No (mm NB) SORF 1

15

2

20

3

25

4

40

5

50

6

80

7

100

8

150

9

200

10

250

11

300

12

350

13

400

14

450

15

500

16

600

WNRF

BF

WNRF

BF

WNRF

BF

WNRF

BF

1

Revised

SK

AAN

JK

15.10.09

0

For Enquiry

SK

AAN

JK

24.09.09

Rev.

Details

By

Chkd

Apprd

Date


Technical Specification -LPG Heater

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