MRpart2.pdf

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ENGINEERING CELL PROJECT

DEPARTMENT- RHQ RHQ-EC-ML-SP-0006 REV 00 PAGE 21 OF 30 TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS

f. The length of skirt shall be within plus or minus 1/4 inch (6mm) of the specified length. g. Nozzle elevations shall be within plus or minus 3/8 inch (10mm) and orientation shall

be within plus or minus 1/4 inch (6mm) of the specified location. The nozzle projection shall be within plus or minus 1/8 inch (3mm) of the specified value.

h. The maximum horizontal or vertical deflection of the machined faces of nozzles from the design plane shall be 1/2 degree or 1/32 inch (0.8mm), whichever is greater.

i. Man way elevation, orientation and projection shall be within plus or minus 1/2 inch (13mm) from the specified values. Tilt shall be within plus or minus 1/4 inch (6mm) of perpendicular nozzle axis.

j. The maximum deviation of internal tray supports from a level (horizontal) reference plane shall be plus or minus 3/8 inch (10mm).

k. The maximum variation in spacing between supports for adjacent tray shall not exceed 1/16 inch (1.6mm) per foot (300mm), with a maximum of 1/8-inch (3mm).

l. The maximum variance (distance between high and low points) in individual tray supports with respect to the level plan shall be 0.3 percent of the nominal inside diameter of the vessel, with a maximum of

1/4 inch (6mm).

m. The tray supports plane shall not vary more than 1 degree from normal to the vessel centerline.

3.0 SCOPE OF SUPPLY AND SERVICES

3.1 Scope of Supply

Bidder's scope of supply shall include the pressure vessels as specified in the attached data sheets, complete with all internals and appertunances as

applicable.

4.0 VENDOR DATA SHEET

Bidder shall comply with the enclosed "Vendor Data Requirements" list for drawing and documents to be submitted to Purchaser with the bid and after placement of order.

5.0 INSPECTION AND TESTING

5.1 The pressure vessels shall be subject to stagewise and final inspection at Bidder's shop by Purchaser. The same shall be offered prior to any primer coating.

5.2 Inspection shall be carried out based on IOCL’s quality assurance plan after agrement between purchaser and the vendor.

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5.3 Prior to the final inspection of vessels, all slag, loose scale, dirt, grit, weld spatter, paint, oil and other foreign matter are to be removed in order that the inspection can be conducted in a thorough manner.

5.4 The approval of the work by the purchaser's inspector and his release of the vessels for shipment shall in no way release the manufacturer from, or relieve the manufacturer of, any responsibility for carrying out all of the provisions of this specification and the fulfilment of the guarantee; nor does the purchaser by such approval and release, assume any responsibility whatever for such provisions and guarantee.

5.5 Manway and hand hole cover hinges and hinge bolts shall be in place before the vessel is tested. The hinge bolts shall fit so they can be turned freely by hand. Covers shall be swung open to insure that no binding occurs.

5.6 Welded attachments provided with vent holes shall be tested by pneumatic or hydrostatic pressure prior to post weld head treatment and final hydrostatic test.

5.7 Vessels shall be shop hydrostatically tested in the horizontal position and shall be supported adequately to prevent local stresses in the shell from exceeding 90% the yield strength of the material.

5.8 For vessels or sections of vessels where butt welded seams are 100% radiographed, all other pressure containing welds and all attachment welds to pressure containing parts shall be examined as follows -

a) Welded joints covered by reinforcing pads shall be 100% radiographed prior to installation of the reinforcing pad.

b) Support skirt and lifting lug welds, and pressure containing welds other than butt joint, shall be examined by the ultrasonic method using either the straight beam or shear wave mode. Alternative inspection methods such as in-process magnetic particle examination, may be substituted if approved by the Purchaser.

c) All attachment welds to pressure containing parts on materials other than P1, Groups

1 and 2, shall be examined by the magnetic particle method. If the material is non- magnetic, the liquid penetrant inspection method shall be used in place of the

magnetic particle method.

Accessible welds subject to PWHT shall be inspected after PWHT. All locations of temporary attachment welds on materials other than P1, Group 1 and 2, shall be similarly inspected.

5.9 Hardness of hot formed sections, base metal, weld metal and the related heat affected zone (HAZ) of all welds shall not exceed 225 Brinell for P-1, P-3, P-4 and P-10 materials, before PWHT.

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The vessels fabricator shall check the weld hardness of the initial production weld for each welding process, filler metal, and technique used. If the clearances are such that it is not possible to check the production weld, a mock-up with identical conditions shall be used.

5.10 For vertical vessel supports skirts, the finished skirt-to-shell weld shall be examined by the magnetic particle method after any required postweld heat treatment (PWHT). For field welded skirts, the top skirt course of alloy material shall be "safe-ended" with a carbon steel extension prior to any required PWHT, Skirt butt welds shall be inspected by spot radiography. Atleast one radiograph shall be made for every two girth seams, and

one for every two vertical seams.

5.11 Charpy impact tests shall be carried out for deposited weld metal from electroslag, electrogas, and other single pass butt welds through the full thickness of the material. Tests shall be made on weld production impact test plates (run-off tabs). Required impact values shall be as given below -

Reference Charpy V impact value for full size Thickness specimen at minimum design metal

temp. (mm) (Min. Av. of 3 specimens/Min. of 1 Specimen)

SA-515/516,Gr.55 & 60 SA-515/516,Gr.65&70 <= 17/13 20/16 10 to 25 20/16 27/22 25 to 50 20/16 34/27 > 50 34/27 47/38

5.12 For stainless steel vessels, the quality of water to be used for hydrotesting shall have a maximum value of 25 ppm chloride. For C.S. Vessels, the testing medium (water) shall be at a temperature of more than 20 Deg C. Sea water shall not be used for testing.

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5.13 Bidder shall give minimum 15 days clear notice of shop inspection and testing to Purchaser.

6.0 NAME PLATE

Each vessel shall be provided with a name plate of stainless material, bearing the trade name of the manufacturer. This plate shall be permanently fixed and carry all the relevant process informations, capacity and empty weight of the vessel.

Name plates shall be permanently visible. On hot insulated vessels this plate shall be fashioned on a small support so as to protrude beyond vessel insulation.

7.0 PAINTING AND PROTECTION

7.1 Surface cleaning and painting

7.1.1 All completed equipment shall be cleaned internally and externally to remove scale, dirt, sand, water and foreign matter

7.1.2 The surface preparation of outside surface of vessels / columns shall be done by blast cleaning only.

On completion of operation, the blasted surface shall be clean, dry and free from any mill cale, rust, rust scale and foreign matter. Primer or first coat of paint shall be applied with spray / brush as per the manufacturer’s recommendations and preferably within 4 hours of surface prepraration. Blast cleaning shall not be done outdooe in bad weather without adequate protection or when there is dew on the metal surface which is to be cleaned or when humidity exceeds 85 %.

The finish of surface preparation of steel surface requiring painting shall conform to SA 2.5 of Swedish Standard SIS-05-5900. The anchor profile shall be in general 15 to 50 microns. However, for F-12 system of painting, anchor profile shall be 10 to 15 microns.

The two types of blast cleaning methods are as given below :

7.1.2.1 Air Blast Cleaning

The surface shall be blast cleaned using one of the abrasives : sand chilled cast iron or malleable iron and steel at pressure of 7 Kg / Sq.cm at appropriate distance and angle depending on nozzle size; maintaining constant velocity and pressure. Chilled cast iron, malleable iron and steel shall be in the form of shot or grit of size not greater than 0.055“ maximum in case of steel and malleable iron and 0.04 “ maximum in case of chilled iron. Compressed air shall be free from moisture and oil. The blasting nozzles shall be venturi style with Tungsten Carbide or Boron Carbide as the materials for liners. Nozzle orifice from 3/16” to 3/4”.

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7.1.2.2 Water Blast Cleaning

Environmental, health and safety problems associated with abrasive blast cleaning limit the application of air blasting in many installations. In such cases, water blasting shall be resorted to.

Water blast cleaning can be applied with or without abrasive and high pressure water blasting. The water used shall be inhibited with sodium chromate / phosphate. the blast cleaned surface shall be washed thoroughly with detergents and wiped with solvent and dried with compressed air. For effective cleaning, sand is used as an abrasive. The operation shall be carried out as per SSPC guidelines for water blast cleaning.

7.1.3 Austenitic stainless steel, high alloy steel and non-ferrous materials shall be kept free of paints

7.1.4 All flanged faces and other machined surfaces shall be greased or protected with rust preventive coating.

7.1.5 The shades of successive coats shall be kept different in order to ensure visual inspection of application of each coat.

7.2 Painting

Except for machined surfaces, all exterior surfaces of the vessels and columns, including skirts and integral supports shall be painted as given below to prevent rust, corrosion or damage during transit and storage before erection and final painting. This paint system mentioned hereunder shall be applicable for all environments after satisfactory surface preparation.

System Description Operating Paint System Temp Range ( Deg C)

Uninsulated Carbon and Low Alloy Steel Columns & Vessels

- above ground & underground

(-) 25 to 400 One coat of Inorganic Zinc Silicate coating

Total DFT : 65 to 75 microns

Insulated carbon and low alloy (-) 15 to 100 One coat of Epoxy Phenolic coating

steel columns & vessels Total DFT : 10 microns DM Water Service

101 to 400 2 coats of heat resistant silicon paint suitable upto 400 Deg C of 20 microns per coat

Total DFT : 40 microns a) External Surface b) Internal Surface All Temp All temp

As per applicable system above

2 coats of Epoxy Zinc phosphate primer (35 microns / coat) plus 2 coats of Epoxy high built coating (100 microns / coat)

Total DFT : 270 microns

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7.3 After the vessels are shop tested, all exposed machined surfaces shall be suitably protected by an approved type of protective compound. All nozzle openings shall be covered by wooden or metal closures prior to despatch.

7.4 Marking

In addition to General Purchase Conditions, the following requirements shall also be complied with.

7.4.1 All loose components such as studs, nuts, washers, gaskets, etc., shall be packed in crates and shall be marked for the project, consignee, consigner, job no., item no., order no., gross

& net weight, dimensions, etc.

7.4.2 Additional indications such as North / East / South / West along with the centre of gravity shall be clearly marked with white paint.

7.4.3 Vessels which have been post weld heat teated or have an applied lining, eg. lead, glass, rubber, etc., shall have a suitable warning printed on the visible portion on the outside on the

outside of the vessel.

7.4.4 Specific marking with white paint for slinging shall be provided for all heavy lifts weighing 5 tonnes and above.

7.4.5 A copy of the packing list shall accompany the material enclosed in a water tight envelope fastened inside a shell connection with an identifying arrow sign “Documents” applied with indelible paint.

7.4.6 If it is necessary to separate the unit into different parts for transportation all components and sub-assemblies shall be carefully identified and match marked to prevent aby error in assembly.

8.0 PACKING & SHIPMENT

8.1 Pre-fabricated sections shall be protected by temporary stiffeners at each non-supported end.

Edges of plates or sections to be welded shall also be protected. Flange faces on all nozzles and couplings shall be protected by blanks. Tapped orifices shall have threaded plugs.

8.2 Equipment shall be carefully packed so as not to be damaged in any way during transport.

Fragile or machined parts in particular, shall be especially protected, not only against rust but also against shocks of any nature.

8.3 All parts shall be carefully cleaned. Unless otherwise indicated vessels shall be delivered unpainted.

8.4 If it is necessary to separate a unit into different parts for transport reasons, all parts shall be carefully identified or match marked to prevent any error in assembly.

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8.5 Large diameter vessels of small thickness shall be provided with an adequate number of struts, positioned inside the vessel to prevent ovalization effect while being handled. These struts shall not be removed until after vessel is placed in postion at jobsite.

8.6 Vessels, unless provided with their own steel saddles for entire protection, shall be provided with suitable wooden saddles with steel saddles with steel ties and tension rods. The minimum height of the saddle shall correspond to the maximum projected length of the connected attachments, plus an additional clearance of 45 mm. Saddle spacing shall depend on the length of the equipment.

8.7 After removal of plugs and checking of flange faces, vessels shall be shipped to the field with gaskets used for shop hydraulic tests. Final gaskets shall be shipped properly protected in a separate container.

Solid metal joints used for shipment, together with the corresponding flange faces, shall be specially covered with a coat of grease or varnish.

9.0 GUARANTEE

Bidder shall guarantee the pressure vessels supplied in respect of design, materials and fabrication in accordance with the terms of General Purchase Conditions.

10.0 SITE FABRICATION & ERECTION

10.1 Where the shape or size of the vessel makes it impossible to ship it in one piece, the fabricator shall ship minimum number of shop fabricated sections suitable for shipment. Assembly and testing shall be completed by the vessel fabricator at site in horizontal position (for erection by others) in strict

accordance with the provisions of the applicable order / specification.

10.2 Where the size or shape of vessel makes it impossible to erect it in single piece, the fabricator shall ship minimum number of shop fabricated sections suitable for erection.Erection, assembly and testing shall be completed by vessel fabricator at site in vertical position in strict accordance with the provisions of the applicable order / specification.

10.3 In either of the above two cases, the following additional requirements shall apply :

10.3.1 All pieces shall be shop fit up into sections and each section fit to the adjacent one by the fabricator and all pieces match marked thereafter.

10.3.2 The width of the permissible gap furing fitup shall be in accordance with the approved shop drawings and welding procedures.

10.3.3 Suitable erection lugs and locating pins shall be provided by the fabricator to ensure proper fitup of the equipment.

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10.3.4 All radiographic requirements for welds completed in the shop shall be made by the fabricator before the part of the section leaves the shop.

11.0 DIMENSIONAL TOLERANCES FOR PRESSURE VESSELS

Dimensional tolerances for pressure vessels shall be as listed below except when specified otherwise in the vessel data sheet :

11.1 Outside surface of shell cylinder may be out of alignment/straightness not more than 6 mm in any 6 metre of cylinder length, subject to a maximum of 20 mm in the total length.

11.2 The maximum permissible offset for longitudinal joints shall be 6 mm and for circumferential joints 12 mm.

11.3 Out-of-roundness (ovality) of vessel shell shall be as per ASME Code, with the additional limitation that for vessels with internal trays any diameter may not vary more than +/- 0.5 percent from the nominal diameter, with a maximum variation in diameter from nominal of 12 mm.

11.4 Outside circumference of shell shall be within the following limits : +/- 10 mm for noimnal diameter 1200 mm and under.

+/- 12 mm for noimnal diameter 1200 mm through 2400 mm. +/- 20 mm for noimnal diameter above 2400 mm.

11.5 Tolerance for overall length of vessel, not including the skirt, shall be +/-5 mm per 3 metre subject to a maximum of 15 mm.

11.6 The skirt length for vertical vessels shall be held within a tolerance of +/- 6 mm.

11.7 The tolerance for nozzle location shall be +/- 10 mm for elevation, +/- 6 mm for orientation, and +/- 3 mm for projection.

11.8 The tolerance for manways shall be +/- 12 mm for elevation, orientation and projection, and 6 mm for tilt.

11.9 Elevations from reference plane may vary to the extent of +/- 12 mm for manholes, +/- 6 mm for nozzles, and +/- 5 mm for internal supports except that locations or manholes and nozzles near trays shall not vary more than +/- 5 mm from the tray.

11.10 Tolerance for centre to centre distance between any pair of instrument connections shall be+/- 1mm.

11.11 The maximum horizontal or vertical perfection of the machined surfaces of the gaskets contact faces of nozzles shall be +/- 2 Degree or 0.6 mm whichever is greater.

11.12 The tolerance for the maximum variance (distance between high and low points) in individual tray supports with respect to the level plane shall be within +/- 5 mm of the specified elevation from datum. Variation in spacing between adjacent internal trays/supports be within 0.30 percent of the nominal inside

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diameter, with a maximum of 6 mm.

11.13 The maximum tolerance from a true base for internal tray supports shall be +/- 10 mm.

11.14 The tolerance for maximum variation of tray supports with respect to the vessel shell shall not exceed 1 Deg. from normal.

11.15 Tolerance for distance between horizontal vessel centre line and bottom of saddle supports shall be +/- 3 mm.

11.16 Centre to centre distance between saddle supports and saddle bolt holes may vary +/- 3 mm.

11.17 Skirt base ring out of squareness shall be within +/-3 mm for 2500 mm OD and under, and +/-6 mm for larger diameters.

11.18 The base ring bolt circle diameter and the distance between two consecutive anchor bolt holes may vary +/- 5 mm.

11.19 Tolerance for distance between any pair of adjacement structural attachments shall be +/- 3 mm.

12.0 DATA FOLDER

The manufacturer shall prepare six copies of data folders and two copies in soft form (CD form) as required in the purchase order. The folder shall contain the following information, duly certified by the Inspector :

a) Manufacturer’s code certificate

b) Sketches of the vessel showing as-built dimensions and the plates used with their cast and test numbers.

c) Material test and analysis certificates.

d) Welding procedure qualification reports.. e) Welder qualification reports. f) Radiograhic results

g) Ultrasonic, Magnetic particle, dye-penetrant test results (if applicable) h) Hardness, corrosion and leak test record (if applicable)

i) Record charts showing complete heat treatment cycle (if applicable) j) Production test coupon results (if applicable)

k) Charpy V notch test results (if applicable)

l) Record chart of pressure test (hydrostatic and / or pneumatic) m) Rubbing of name plate

n) Any other documentation as required in the purchase requisition / order.

13.0 Following should be attached as Annexure (as per tender specific requirement):

1. Supplementary Specification for Handling/Cleaning of Stainless Steel and Nickel alloys (IOCL/M&I/MECH/E/S/13).

2. Supplementary Specification for Carbon Steel Vessels (IOCL/M&I/MECH/E/S/04). 3. Supplementary Specification for Structural Quality Plates for Tanks &

Vessels (IOCL/M&I/MECH/E/S/12).

4. Technical specification for Boiler Quality Carbon Steel Plates

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DEPARTMENT- RHQ RHQ-EC-ML-SP-0006 REV 00 PAGE 30 OF 30 TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS ((IOCL/M&I/MECH/P/14).

5. Technical specification for Stainless Steel Plates (IOCL/M&I/MECH/P/16).

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DEPARTMENT- RHQ RHQ-EC-ML-0026 REV 00 PAGE 1 OF 9 TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS

PRESSURE VESSELS

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DEPARTMENT- RHQ RHQ-EC-ML-0026 REV 00 PAGE 2 OF 9 TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS Abbreviations:

BIS Bureau of Indian Standards

BS British Standards

BHN Brinell Hardness Number

DP Dye Penetration

STAAD Structural analysis and design computer program MDMT Minimum Design Metal Temperature

TPlA Third Party Inspection Agency

ASME American Society of Mechanical Engineers

AWS American Welding Society

CS Carbon Steel

GAD General Arrangement Drawings

ID Internal Diameter

LSTK Lumpsum Turnkey

MOC Material of Construction

MR Material Requisition

OD Outside Diameter

PQT Procedure qualification test

PQR Procedure qualification record

PL Process Licensor

PMC Project Management Consultant

SS Stainless Steel

TIG Tungsten Inert Gas

WPS Welding Procedure specification

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DEPARTMENT- RHQ RHQ-EC-ML-0026 REV 00 PAGE 3 OF 9 TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS CONTENTS

SL. NO. DESCRIPTION PAGE NO.

1.0 SCOPE 4

2.0 CODES, SPECIFICATIONS AND REGULATIONS 4

3.0 DESIGN BASIS 5

4.0 MATERIALS 7

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DEPARTMENT- RHQ RHQ-EC-ML-0026 REV 00 PAGE 4 OF 9 TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS 1.0 SCOPE

1.1 This specification covers g e n e r a l r e q u i r e m e n t s for material, design, f a b r i c a t i o n , erection a n d testing of pressure vessels.

1.2 Vessel S i z i n g /Design shall b e in vendor’s scope u n l e s s o t h e r w i s e specified. Vendor s h a l l submit all design parameters of vessels as per Annexure-H.

2.0 CODES, SPECIFICATIONS AND REGULATIONS 2.1 Design Codes

a) Vessels with design pressure 1.0 Kg/Cm2 (g) and less than 210 Kg/cm2 (g) shall be designed, fabricated, inspected and tested as per ASME Code Sec. VIII Div.1. (Latest)

b) All v e s s e l s with design pressure 210 K g /cm2 (g) shall be designed, fabricated, inspected and tested as per ASME Code Sec. VIII Div.2. (latest)

c) Vessels full of liquid and/or with design pressure < 1.0 Kg/cm2(g) shall be designed, fabricated, inspected and tested as per ASME Code Sec. VIII Div.1 - Practice.

d) Mechanical design of self-supporting tall column shall be carried out as per guidelines given in Annexure-IV.

2.2 Material Specifications,

Materials to be used shall conform to a) ASME Section II.

b) Indian Standard Specification of equivalent grade.

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DEPARTMENT- RHQ RHQ-EC-ML-0026 REV 00 PAGE 5 OF 9 TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS 2.3 Statutory Regulations

a) National laws & regulations together with local bye-laws for the country or state where vessel(s) is (are) to be erected must be complied with. Approval of design and drawings from statutory authorities shall be Vendor's responsibility.

b) Wind and earthquake loads shall be calculated in accordance with relevant Indian Standards unless otherwise specified.

3.0 DESIGN BASIS

3.1 Minimum Wall Thickness

Vessel shell and heads shall have minimum wall thicknesses calculated with design pressure and temperature, in accordance with codes, but in no case, shall the thickness be less than that determined by following formulas:

a) For carbon and low alloy steel vessels - 6mm (Including corrosion allowance not exceeding 3.0 mm), but not less than that calculated as per following:

FOR DIAMETERS LESS THAN 2400 mm

Wall thickness= Dia./1000 + 1.5 + Corrosion Allowance FOR DIAMETERS 2400 mm AND ABOVE

Wall thickness= Dia./ 1000 + 2.5 +Corrosion Allowance All dimensions are in mm.

b) For stainless steel vessels and high alloy steel vessels - 3 mm, but not less than that calculated as per following for diameter more than 1500mm. Wall thickness (mm) = Dia./ 1000+ 2.5 Corrosion allowance,

if any, shall be added to minimum thickness.

c) If the vessel height (H) from base of skirt to top tangent line is greater than 5 times diameter (D) then vessel shall be considered as column

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and shall be designed accordingly.

d) For carbon and low alloy steel columns/towers- 8mm (including corrosion allowance not exceeding 3.0 mm)

e) For stainless steel and high alloy steel columns/towers- 5 mm.

Corrosion allowance, if any, shall be added to minimum thickness. "

3.2 Design Pressure

Design pressure shall be calculated as per the following unless otherwise specified elsewhere in the package:

a) When operating pressure is upto 70 Kg/cm2 (g) the design pressure shall be equal to maximum operating pressure at top of vessel or highest point in vessel plus 10% (minimum of 1.0 Kg/cm2) more than operating pressure.

When operating pressure is over 70 Kg/cm2(g), the design pressure shall be equal to operating pressure plus 5% (minimum 7 Kg/cm2).

b) Design pressure at any lower point is to be determined by adding the maximum operating liquid head and any gradient within the vessel.

c) Vessel operating under vacuum (or partial vacuum) shall be designed for differential external pressure of 1.055 Kg/cm2•

3.3 Design Temperature

Design temperature shall be calculated as per the following unless otherwise specified elsewhere in the package:

a) For vessels operating at 0° C and over, the design temperature shall be operating temperature plus 15° C. However design temperature shall not be less than 65° C.

b) For vessel operating below 0° C, design temperature shall be lowest operating temperature.

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c) Minimum Design Metal Temperature (MDMT) shall be lower of minimum atmospheric temperature and minimum temperature envisaged during operation.

3.4 Corrosion Allowance

Minimum corrosion allowance for carbon steel vessels shall be 3.0 mm unless otherwise specified elsewhere in the package.

3.5 Allowable Stresses

3.5.1 Basic allowable stresses for s h e l l , heads a n d o t h e r components etc. Shall be t h e v a l u e s specified in the design code.

3.5.2 The allowable stresses for structural members a n d anchor b o l t s shall be a s specified in Indian Standard IS:800.

3.6 Wind and Seismic Loads

3.6.1 Wind load shall be calculated as per Indian Standard I S 875 site specific wi n d data if attached with the bid package. ·

3.6.2 Earthquake forces shall be calculated in accordance with Indian Standard I S : 1893 or it shall be based on meteorological and seismic data of the site, if attached with the bid package.

4.0 MATERIALS

Materials of various parts of equipment shall be selected a s per Table given in Annexure – III for general industrial condition/services.

4.1 Specifications of Carbon Steel Plates

4.1.1 Chemical Analysis

Plates us ed shall conform t o latest issue of specification SA-20 w i t h additional requirements mentioned herein.

a) Only n o r m a l i z e d plates free from injurious defects w i t h workman like finish shall b e used. Reconditioning/repair of plates by welding shall not

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DEPARTMENT- RHQ RHQ-EC-ML-0026 REV 00 PAGE 8 OF 9 TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS be permitted.

b) One product analysis of each heat shall be carried out and reported. Chemical analysis shall be as per applicable specifications with carbon content not exceeding 0.23%.

I

Additionally, one o f following requirements for carbon equivalents (Ceq) based on heat

analysis shall be satisfied.

Ceq = C + Mn/6 0.42 ...(1)

Ceq = C + Mn/6+ (Cr + Mo + V)/5+(Cu+Ni)/15 0.43 ...(2)

Equation -(1) shall be used when applicable material specify C and Mn o nly.

Equation-(2) is applicable f o r restricted chemistry r e q u i r e m e n t s or for supplementary requirements of S19 & S21 of specification SA-20.

4.1.2 Ultrasonic Examinations of Plates

a) Plates having thickness 16 mm to 50 mm (both inclusive) shall be examined ultrasonically as per specification SA-435.

b) For thickness above 50 mm, ultrasonic examinations shall be carried out as per specification SA-578 and shall have acceptance standard of level-B.

c) For quenched and tempered steel plates, ultrasonic examination shall be carried out after the specified heat treatment.

4.1.4 Charpy V-notch impact testing as per S5 of specification SA-20 to be carried out at design temperature for low temperature services.

4.1.5 Plates needed for IBR vessels shall meet the requirements of IBR(Indian Boiler Regulations).

4.1.6 Plates above 50 mm in thickness shall meet following additional requirements. a) Vacuum treatment as per supplementary requirement S1 of specification SA-20.

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b) Charpy V-notch test as per the supplementary requirement S5 of specification SA-20. c) Material meant to be used for design temperature warmer than 0° C.

Test temperature minus 29° C.

Acceptance Criteria - As per Table A 2.15 of specification SA-20. Orientation of test bar Transverse to the direction of rolling.

d) Simulated heat treatment of mechanical test coupon as per clause 4.1.3 of this specification.

4.2 Specification of Stainless Steel Plates/Pipe/Forging

Plates used shall conform to latest issue of specification SA-480 with additional requirements mentioned herein.

a) All plates shall be hot rolled, annealed, pickled and shall have No.1 finish on both sides with reference to specification SA-480. In addition, all stabilized grade of SS (SS 321, SS 347 etc.) shall be given stabilization heat treatment.

b) Unless otherwise specified plates, pipes, forgings and fittings representative of each heat shall be subjected to inter granular corrosion tests as per ASTM A 262 practice E.

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ENGINEERING CELL PROJECT DEPARTMENT- RHQ RHQ-EC-ML-SP-0020 REV 00 PAGE 1 OF 10 TECHNICAL SPECIFICATIONS FOR

ANCHOR BOLT/ TEMPLATE

ANCHORBOLT/TEMPLATE

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Abbreviations:

BIS Bureau of Indian Standards BS British Standards

BHN Brinell Hardness Number DP Dye Penetration

STAAD Structural analysis and design computer program MDMT Minimum Design Metal Temperature

TPlA Third Party Inspection Agency

ASME American Society of Mechanical Engineers AWS American Welding Society

CS Carbon Steel

GAD General Arrangement Drawings ID Internal Diameter

LSTK Lumpsum Turnkey MOC Material of Construction MR Material Requisition OD Outside Diameter

PQT Procedure qualification test

PQR Procedure qualification record

PL Process Licensor

PMC Project Management Consultant SS Stainless Steel

TIG Tungsten Inert Gas

WPS Welding Procedure specification

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CONTENTS

CLAUSE NO DESCRIPTION PAGE NO

1.0 SCOPE 4

2.0 GENERAL 4

3.0 FABRICATION 6

4.0 INSPECTION 7

ATTACHMENTS- ANCHOR BOLT TEMPLATE DETAILS FIGURES 1,2&3

9

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1.0 SCOPE

1.1 This Specification covers the requirements for the fabrication of anchor bolt templates to be used for the setting out of anchor bolts for the foundations of skirted vertical vessels having more than four anchor bolts.

1.2 The anchor bolt template shall have a companion gauge plate to be used for drilling anchor bolt holes in the base plate of the vessel skirt.

2.0 GENERAL

2.1 Types of Anchor Bolt Templates

The following two types of anchor bolt templates shall be used and they shall be selected based on the shape and size of the pressure vessels.

2.1.1 Plate Type

Plate type anchor bolt templates shall be made from a single steel plate shown in figure 1. This type shall be used for vessels with skirts having single ring type base plates.

2.1.2 Stiffener Type

Stiffener type anchor bolt template shall consist of upper and bottom plates with stiffeners and pipe spacers fabricated as shown in figure 2. This type shall be used for skirts having double ring type base plates with compression rings.

Stiffener type anchor bolt templates shall be constructed in one piece for base plates having a 3000 mm or smaller anchor bolt circle diameter, and two or three pieces for larger anchor bolt circles, for ease of transportation.

Preparation

The anchor bolt template shall be delivered to site in advance of the shipment of the vessel and prior to the commencement of the foundation installation. Delivery date will be as stated in the vessel purchase order.

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The preferred fabrication method is to machine the holes in the vessel base plates and anchor bolt template together in a single operation thus minimising the risk of accumulated manufacturing errors. For this method a gauge plate will not be required.

If the anchor bolt template has to be fabricated prior to the fabrication of the vessel skirt base ring, for scheduled delivery reasons, then a gauge plate shall be manufactured.

The gauge plate shall be made at the same time as the anchor bolt template and the holes machined in both components in a single operation.

2.2 Gauge Plate

The gauge plate shall be made from carbon steel plate having a minimum thickness of 6 mm.

Gauge plate dimensions shall be the same as those of the anchor bolt template and divided construction shall not be permitted.

Gauge plate markings shall be in accordance with section 4.4.

The gauge plate shall be kept with care at the fabricator’s shop until completion of vessel inspections.

Gauge plates shall be reinforced with flat bars to prevent deformation if necessary.

DIMENSIONS OF ANCHOR BOLT TEMPLATES

2.3 Plate Type

The dimensions of plate type anchor bolt templates shall conform to Table 1.

TABLE 1 - DIMENSIONS OF PLATE TYPE (Units mm) Nominal Size of Anchor Bolt Width of Jig Plate Diameter of Bolt Holes Minimum Thickness of Plate B (mm) d (mm) T (mm) M24 120 25.5 10 343 of 615

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2.4 Stiffener Type

The dimensions of stiffener type anchor bolt templates shall conform to Table 2.The height (H) of the anchor bolt template shall be the same as the height of the skirt bolt chair Tower Base Support Lugs for Anchor Bolts plus 40mm grout.

TABLE 2 - DIMENSIONS OF STIFFENER TYPE

Nominal Size of Anchor Bolt Width of Jig Plate Diameter of Bolt Holes Minimum Thickness of Plate Distance Pieces (Std Pipe) B (mm) d (mm) T (mm) Inch M30 130 32 10 1½ M36 150 38 10 2 M42 160 44 10 2½ M48 180 50 10 2½ M56 180 58 10 3 M64 200 66 10 3 3.0 FABRICATION 3.1 Material

Material of the anchor bolt template and gauge plate shall be ASTM A283, A36 or equal.

3.2 Reinforcement

Anchor bolt templates shall be reinforced with steel angles, flat bars or other steel members to prevent deformation, as shown in Figure 3.

3.3 Form Correction

Should any strains / distortions be caused in anchor bolt templates, they shall be corrected to exact specified form.

3.4 Marking

The top surface only of the anchor bolt templates and gauge plate shall be painted black then the following shall be marked on the top surface of the anchor bolt template and gauge plate:

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a) Equipment number.

b) Orientation in degrees at 0, 90, 180, and 270 degrees.

c) Match marks at connection points of divided construction type. Equipment number shall be marked with both die stamp and white paint. Orientation and match markings shall be made with both die stamp and white paint.

Orientation notches cut perpendicularly, as shown in Figures 1 & 2. 3.5 Bolt Holes

The holes of anchor bolts on both anchor bolt template and skirt base plate shall be drilled exactly by tracing of the holes from the gauge plate.

For divided construction type of anchor bolt template, the holes shall be made in the fully assembled condition after sectioning.

3.6 Assembly

Anchor bolt template assembly joints shall be made with the use of reamer bolts or cotter pins to ensure accurate assembly.

4.0 INSPECTION

4.1 General

All anchor bolt templates and gauge plates shall be inspected at the fabricator’s shop in accordance with the following requirements:

a) Dimensional inspection.

b) Visual inspection, including match markings and clarity.

c) Deviation check of bolt holes by placing gauge plate on the anchor bolt template (max. deviation 1mm).

4.2 Dimensional Check

Dimensional check shall cover the following dimensions:

a) Bolt circle diameter (±2 mm for BCD of 2100 and under, ±4 mm for over 2100 mm).

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b) Bolt circle pitch (±3 mm). c) Bolt hole diameter (+1/-0 mm). d) Orientation notches (±1.5 mm).

e) Height of jig “H” as shown in Figure 2 (±4 mm).

f) Alignment of bolt holes between upper and bottom plate from stiffener type jig plates (±2 mm in any plane).

(28)

90° 90° 90° 20 20 50 90° 90° 90° 20 50 TEMPLATE ON THE FOUNDATION

FIG. 1 PLATE TYPE TEMPLATE

T

B

T

FIG. 2 STIFFENER TYPE TEMPLATE PIPE DISTANCE

PIECES FULL WIDTHGUSSETS 'H' TO BE AS PER ANCHOR BOLT CHAIR PLUS 40mm GROUT.

H

VESSEL 0^

B

t

d BOLT HOLE _{d BOLT HOLE}

EQUIPMENT ITEM NO.

20

(29)

ANGLE MEMBER FLAT BAR PLATE TYPE A A VIEW "A-A" B B VIEW "B-B"

DIVIDED CONSTRUCTION TYPE

FIG. 3 STIFFENER TYPE

(30)

Project N° Unit Doc. Type Mat. Code Serial N° Rev. Page 068107C001 000 STC 0490 001 0 1/45

Pages modified under this revision: none.

0 20/10/2015 Issued for Information RTS KD RR Rev Date

DD/MM/YY STATUS

WRITTEN BY (name & visa)

CHECKED BY (name & visa)

APPROVED BY (name & visa)

DOCUMENT REVISIONS

TECHNIP India Limited. This document and the information it contains are property of Indian Oil Corporation Ltd... It shall not be used for any purpose other than for which it was supplied.

CONFIDENTIAL – Not to disclose without Authorization

UNIT : DHDT

PROJECT : BS-IV PROJECT.

LOCATION : IOCL, BARAUNI REFINERY.

CONSTRUCTION STANDARDS PRESSURE

VESSELS

Document Category Document Review Status (by Client)

(Use “X” Mark)

Approval Review

Information

OWNER EPCM

INDIAN OIL CORPORATION LIMITED.

TECHNIP INDIA LTD. NOIDA, INDIA.

(31)

Project N° Unit Doc. Type Mat. Code Serial N° Rev. Page 068107C001 000 STC 0490 001 0 2/45 CONSTRUCTION STANDARDS FOR PRESSURE VESSELS

TECHNIP India Limited. This document and the information it contains are property of Indian Oil Corporation Ltd.. It shall not be used for any purpose other than for which it was supplied.

TABLE OF CONTENTS

DOCUMENT NUMBER REVISION DESCRIPTION

068107C001-000-STC-0490-01 0 MANUFACTURER NAME PLATE

068107C001-000-STC-0490-02 Sheet 1/3 0 SKIRT – ACCESS HOLE & VENTS 068107C001-000-STC-0490-02 Sheet 2/3 0 SKIRT SUPPORT – ANCHOR CHAIRS 068107C001-000-STC-0490-02 Sheet 3/3 0 SKIRT SUPPORT – ATTACHMENT

068107C001-000-STC-0490-03 0 NAME PLATES MOUNTING BRACKET

068107C001-000-STC-0490-04 Sheet 1/2 0 SUPPORT BRACKETS

068107C001-000-STC-0490-04 Sheet 2/2 0 SUPPORT CONTINUOUS RING

068107C001-000-STC-0490-05 Sheet 1/2 0 TOLERANCES FOR VERTICAL EQUIPMENTS 068107C001-000-STC-0490-05 Sheet 2/2 0 TOLERANCES FOR VERTICAL EQUIPMENTS

068107C001-000-STC-0490-06 0 MANHOLES COVER SUPPORTS

068107C001-000-STC-0490-07 0 MANHOLES & HANDHOLE HINGES 068107C001-000-STC-0490-08 Sheet 1/3 0 HOT INSULATION SUPPORT

068107C001-000-STC-0490-08 Sheet 2/3 0 HOT INSULATION SUPPORT

068107C001-000-STC-0490-08 Sheet 3/3 0 HOT INSULATION SUPPORT FOR VERTICAL VESSELS WITH INSULATION INSTALLED IN HORIZONTAL POSITION

068107C001-000-STC-0490-09 0 FIREPROOF SUPPORTS

068107C001-000-STC-0490-10 0 LIFTING TRUNNIONS

068107C001-000-STC-0490-11 0 LIFTING LUGS

068107C001-000-STC-0490-12 0 TAILING LUG DETAIL

068107C001-000-STC-0490-13 0 EARTHING LUGS

068107C001-000-STC-0490-14 0 TEMPLATES

068107C001-000-STC-0490-15 Sheet 1/4 0 TYPICAL NOZZLE DETAILS - REINFORCEMENTS 068107C001-000-STC-0490-15 Sheet 2/4 0 TYPICAL NOZZLE DETAILS – PLATE FLANGES FOR

INTERNAL PIPE DISTRIBUTORS

068107C001-000-STC-0490-15 Sheet 3/4 0 TYPICAL NOZZLE DETAILS – PROJECTION OF NOZZLES ON PLATFORM

068107C001-000-STC-0490-15 Sheet 4/4 0 TYPICAL NOZZLE DETAILS – PROJECTION OF NOZZLES ON SHELL

068107C001-000-STC-0490-16 Sheet 1/2 0 TYPICAL DETAILS - VARIOUS

068107C001-000-STC-0490-16 Sheet 2/2 0 TYPICAL DETAILS – VARIOUS SUPPORT FOR INTERNAL PIPE DISTRIBUTORS

068107C001-000-STC-0490-17 0 VORTEX BREAKERS

068107C001-000-STC-0490-18 0 SUPPORT SADDLES TYPE A & B (DIA. < 3000mm) 068107C001-000-STC-0490-19 0 SUPPORT SADDLES TYPE C (DIA. > 3000mm)

068107C001-000-STC-0490-20 Sheet 1/3 0 SUPPORT SADDLES FOR STACKED UNITS TYPE “A” 068107C001-000-STC-0490-20 Sheet 2/3 0 SUPPORT SADDLES FOR STACKED UNITS TYPE “B” 068107C001-000-STC-0490-20 Sheet 3/3 0 WEDGES FOR STACKED UNITS

068107C001-000-STC-0490-21 Sheet 1/2 0 TOLERANCES FOR HORIZONTAL EQUIPMENTS 068107C001-000-STC-0490-21 Sheet 2/2 0 TOLERANCES FOR HORIZONTAL EQUIPMENTS 068107C001-000-STC-0490-22 Sheet 1/3 0 SUPPORT LEGS FOR VERTICAL VESSELS 068107C001-000-STC-0490-22 Sheet 2/3 0 SUPPORT LEGS FOR VERTICAL VESSELS 068107C001-000-STC-0490-22 Sheet 3/3 0 SUPPORT LEGS FOR VERTICAL VESSELS 068107C001-000-STC-0490-23 Sheet 1/2 0 COLD INSULATION SUPPORTS

068107C001-000-STC-0490-23 Sheet 2/2 0 COLD INSULATION SUPPORTS

068107C001-000-STC-0490-24 Sheet 1/2 0 LIFTING LUG FOR HORIZONTAL VESSELS 068107C001-000-STC-0490-24 Sheet 2/2 0 LIFTING LUG FOR HORIZONTAL VESSELS

068107C001-000-STC-0490-25 0 NOZZLE SCHEDULE FOR CS/SS/CLAD

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Project N° Unit Doc. Type Mat. Code Serial N° Rev. Page 068107C001 000 STC 0690 001 0 1/21

Pages modified under this revision: none.

0 20/10/2015 Issued for Information RTS KD RR Rev Date

DD/MM/YY STATUS

WRITTEN BY (name & visa)

CHECKED BY (name & visa)

APPROVED BY (name & visa)

DOCUMENT REVISIONS

TECHNIP India Limited. This document and the information it contains are property of Indian Oil Corporation Ltd. It shall not be used for any purpose other than for which it was supplied.

UNIT : DHDT

PROJECT : BS-IV PROJECT.

CONSTRUCTION STANDARDS HEAT

EXCHANGERS

Document Category Document Review Status (by Client)

(Use “X” Mark)

Approval Review

Information

OWNER EPCM

INDIAN OIL CORPORATION LIMITED.

TECHNIP INDIA LTD. NOIDA, INDIA.

(76)

Project N° Unit Doc. Type Mat. Code Serial N° Rev. Page 068107C001 000 STC 0690 001 0 2/21

CONSTRUCTION STANDARDS FOR HEAT EXCHANGERS

TECHNIP India Limited. This document and the information it contains are property of Indian Oil Corporation Ltd. It shall not be used for any purpose other than for which it was supplied.

TABLE OF CONTENTS

DOCUMENT NUMBER REVISION DESCRIPTION

068107C001-000-STC-0690-01 Sheet 1/2 0 SUPPORT SADDLES FOR HEAT EXCHANGER 068107C001-000-STC-0690-01 Sheet 2/2 0 SUPPORT SADDLES FOR HEAT EXCHANGER 068107C001-000-STC-0690-02 Sheet 1/3 0 HEAT EXCHANGER ACCESSORIES

068107C001-000-STC-0690-02 Sheet 2/3 0 HEAT EXCHANGER ACCESSORIES 068107C001-000-STC-0690-02 Sheet 3/3 0 HEAT EXCHANGER ACCESSORIES 068107C001-000-STC-0690-03 Sheet 1/2 0 STACKED EXCHANGER SUPPORT 068107C001-000-STC-0690-03 Sheet 2/2 0 STACKED EXCHANGER SUPPORT

068107C001-000-STC-0690-04 0 BRACKET SUPPORT FOR VERTICAL EXCHANGER 068107C001-000-STC-0690-11 Sheet 1/2 0 SET OF WEDGE FOR STACKED EXCHANGER

068107C001-000-STC-0690-11 Sheet 2/2 0 SET OF WEDGE FOR STACKED EXCHANGER 068107C001-000-STC-0690-24 Sheet 1/4 0 ASME NAME PLATE FOR HEAT EXCHANGERS

(LAYOUT)

068107C001-000-STC-0690-24 Sheet 2/4 0 ASME NAME PLATE FOR HEAT EXCHANGERS (SUPPORT BRACKET)

068107C001-000-STC-0690-24 Sheet 3/4 0 ASME NAME PLATE FOR HEAT EXCHANGERS (NOTES) 068107C001-000-STC-0690-24 Sheet 4/4 0 ASME NAME PLATE FOR HEAT EXCHANGERS

(INSTRUCTION FOR DATA FILLING)

068107C001-000-STC-0690-31 0 TUBE HOLE GROOVING

068107C001-000-STC-0690-32 0 TUBE WELDING ON TUBESHEET

068107C001-000-STC-0690-41 0 COUPLING FOR TAPPED CONNECTION

068107C001-000-STC-0690-42 0 COMPOSITE COUPLING

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UNIT _{: DHDT UNIT}

PROJECT : BSIV PROJECT, BARAUNI.

LIST OF DEVIATIONS

BREECH LOCK EXCHANGERS

REQUISITION NO: 068107C001-702-MR-0610-01-Rev.A

SL NO DOCUMENT NO / CLAUSE NO SPECIFICATION / REQUIREMENT DEVIATION REASON FOR DEVIATION Note: -

1. Deviation Listed in this Format only shall be considered.

(97)

SHEET: 1 OF 3 CLIENT : Indian Oil Corporation Limited, Barauni Refinery PROJECT : EPCM Services for BS-IV Project at Barauni Refinery

DOC NO :068107C001-702-ITP-0610-001 Rev 0

Ma nuf a c tur e r T h ir d P a rt y I n sp eti o n A g en cy Te c hni p I ndi a Li m it e d C lie n t

1 Pre-inspection Meeting Pre-inspection Meeting Technip India Doc.:General Quality Control Requirements, MR

H H OR

2 Welding Book Review of Weld Map/WPS/PQR/WPQ Establishment of new WPS/WPQ Approved Drawings/ASME Sec IX Approved Drawings/ASME Sec IX

Weld Map/WPS/PQR/WPQ H R/W OR W for new Procedures

3 NDT Scheme Review of NDT Scheme Purchase

Requisition/Approved drgs

Purchase

Requisition/Approved drgs

NDT Scheme H R OR

4 NDT & Job Procedures Review of NDT & Job Procedures Purchase

Requisition/Applicable Code

Purchase

Requisition/Applicable Code

NDT/Job Procedures H R OR

5 Material Identification Review of MTC / Check Test Report Approved Drgs Approved Drgs / Applicable Code

Inspection Report H W / R*

OR 1) Material to be procured from approved vendors as per Purchase Requisition 2) Technical delivery conditions to be submitted for review.

3) R* - For Non Pressure parts & Structurals.

6 Weld Set-ups Visual & Dimensional Inspection including NDT (if any) of Weld Set-ups & PTC

Approved Drawings/NDT Scheme

Approved Drawings/NDT Procedures

Weld Set-up Reports H W/R OR

7 Visual Examination & NDT of Welds Visual Examination of Welds Purchase Requisition / Approved Drawings

No visible defects smooth weld finish

Inspection Report H W OR

8 NDT of Welds Review of Radiographic Films/Witness of other NDT

Approved drgs / NDT Scheme Approved NDT Procedures NDE reports H W/R OR

9 Forming Visual , Dimensional , Heat Treatment (As applicable )

Purchase Requisition / Approved Procedure / Approved Drawings

Applicable code / Approved Procedure / Approved drgs

Inspection Report H W OR Min Thk & Profile to be verified By TPI. Cold Formed D/End up to 16 mm to be stress relieved & More than 16 mm to be Normalised for CS Vessel & Normalised & Tempered for LAS vessel. SS D/End to be solution annealed. PT to be done on knuckle portion ( I/S & O/S )

10 Mock-up test for Tube to tube sheet joint Mock-up test for Tube to tube sheet joint

Review & approval for confirmity of qualification requirment

ASME Sec-VIII Div-01/ Purchase Requisition

Approved Test Report H R/W OR R- For Exsiting procedure W-For New Procedure

11 Radiographic Examination of Welds Review of Radiographic Films Approved drgs / ASME Sec V / Approved Procedure

ASME VIII Div1 NDE report H R OR Extent as per approved drawings. Films to be reviewed by TPI

12 UT of all pressure part welds UT of all pressure part welds Approved Drg, PR, UT Procedure

ASME Sec VIII Div1 UT Report H R OR

REMARKS REFERENCE DOCUMENT

INSPECTION BY

RECORD

This ITP indicates the main extent & stages of inspection to be performed by TPI The same will be incorporated in Vendor's detailed QCP/ QC Procedure

STAGE DESCRIPTION TYPE OF CHECK CONFIDENTIAL PROPERTY OF

TECHNIP INDIA LIMITED

INSPECTION AND TEST PLAN FOR

SHELL & TUBE HEAT EXCHANGERS

(98)

DOC NO :068107C001-702-ITP-0610-001 Rev 0

Ma nuf a c tur e r T h ir d P a rt y I n sp eti o n A g en cy Te c hni p I ndi a Li m it e d C lie n t REMARKS REFERENCE DOCUMENT INSPECTION BY RECORD

SL. NO. ACCEPTANCE CRITERIA VERIFYING DOCUMENT

13 Positive Material Identification ( As Applicable )

PMI of all SS , Non ferrous & AS parts & Weld

Applicable material code/ Purchase Requisition

PMI report H W OR

14 Pneumatic Test of RF Pads Pneumatic Test of RF Pads Approved Drawings , ASME Sec VIII Div1

Approved Drawings , ASME Sec VIII Div1

15 Tube Sheet Machining & drilling Dimensional , Hole Dia & Alignment Check

Approved Drgs Purchase Requisition / Approved Drawings

16 Pneumatic Test of tube to tube sheet Joint Pneumatic Test of tube to tube sheet Joint after First Run

Approved Drawings , ASME Sec VIII Div1

17 Inspection of Tube to Tubesheet joint Expansion

Tube to tube sheet check up Approved Drgs / Approved Mock Up procedure

Approved Drgs. / Approved Mock up Procedure / Purchase Requisition

Inspection Report H W OR Review of Expansion records , Visual Inspection , PT of Weld.

18 Inspection of Tube Bundle and Shell before insertion

Visual & Dimensional Inspection Purchase Requisition /Approved Drgs.

Purchase Requisition /Approved Drgs.

19 Bundle Insertion Bundle insertion Approved Drgs. Smooth going of bundle inside the shell

20 Visual & Dimensional Inspection Shell, Channel, Shell Cover Assembly & Floating HD ( as applicable) beforePWHT

Final Dimensional & Completeness of Assebly

Approved Drgs. Approved Drgs. Inspection Report H W OR

21 PWHT Review of PWHT

chart/records/Hardness survey records

Approved Drawings/WPS, Approved Procedure

Applicable code, Approved Procedure

PWHT Chart/Records H R OR

22 Testing of Production Test Coupon Testing of Production test Coupon Purchase Requisition & Material dta Data sheet

Purchase Requisition & Material dta Data sheet

Inspection Test Report H W OR

23 NDT after PWHT RT, UT, MT of Welds ASME V/ Approved Procedure/ NDT Scheme

ASME Sec VIII Div.1/ Approved Procedure/ NDT scheme

Internal Records H R OR

24 Hydrotest Tube side Hydro test Shell side Hydrotest

Approved Drg/ Approved Procedure

Hydro test Certificate H W OR

25 Inspection of Welds after Hydrotest UT & PT of Welds ASME V/ Approved Procedure Approved Procedure Internal Records H W OR 26 Surface Preparation Checking of Surface after shot

blasting Purchase Requisition /Approved Drgs. Purchase Requisition /Approved Drgs. Inspection Report H R OR

27 Painting Inspection Verification of painting spec and random check of DFT

Approved Drawings/ Painting spec

Approved Drawings/Painting spec

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DOC NO :068107C001-702-ITP-0610-001 Rev 0

Ma nuf a c tur e r T h ir d P a rt y I n sp eti o n A g en cy Te c hni p I ndi a Li m it e d C lie n t REMARKS REFERENCE DOCUMENT INSPECTION BY RECORD

SL. NO. ACCEPTANCE CRITERIA VERIFYING DOCUMENT

28 Dry Out & Nitrogen Purging Check of N2 Pressure Approved Drawings/ PR/ Approved Drawings/ PR Inspection Report H R OR 29 Inspection of Spares Verification of spares Purchase Requisition/PO Purchase Requisition/PO Inspection Report/ packing List H H OR

30 Preservation & Packing Preservation & Packing Purchase Requisition/ Approved Procedure

Full compliance to Purchase Requisition

Preservation Report and Packing list

H R OR Check of lifting arrangement, cleanliness, protection, marking, name plate, packing condition and quantity

Nitrogen Purging , If spcified in drgs. 31 Inspection Record Book Review of Inspection Record Book,

NDT Records etc

Purchase Requisition Full compliance to Purchase Requisition

Inspection Book H H OR

32 Final Inspection Issue of Release Note Purchase Requisition Confirmation of completion of all required inspection

Inspection Record Book H H OR

1)Requirements of Purchase Requisition shall govern, wherever more stringent than this QAP

05.10.2015 0 PDK SSJ VKY SLSK Issued For Enquiry

DATE REV PREP CHD APP PM DESCRIPTION

LEGEND: H - HOLD POINT; W - WITNESS; IW - INITIAL WITNESS; R - REVIEW OF DOCUMENTS; S - SURVEILLANCE; OR - OFFICIAL RECORD; IR - INTERNAL RECORD;

REF.DOC.:GENERAL QUALITY CONTROL REQUIREMENTS ( Doc No.068107C001-702-PP-502)

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