MRpart2.pdf

  

ENGINEERING CELL PROJECT DEPARTMENT- RHQ TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS

RHQ-EC-ML-SP-0006 REV 00 PAGE 21 OF 30

   

  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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TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS

REV 00 PAGE 22 OF 30

   

 

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. 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 -

 

   

5.8  

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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TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS

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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 mockup 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 size Thickness temp. (mm) Specimen)

   

Charpy V impact value for full specimen at minimum design metal (Min. Av. of 3 specimens/Min. of 1

SA-515/516,Gr.55 & 60

  50  

  5.12

17/13 20/16 20/16 34/27

SA-515/516,Gr.65&70 20/16 27/22 34/27 47/38

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 coating steel columns & vessels

(-) 15 to 100 One coat of Epoxy Phenolic Total DFT : 10 microns 101 to 400

DM Water Service a) External Surface   b)

Internal Surface

All Temp   All temp

2 coats of heat resistant silicon paint suitable upto 400 Deg C of 20 microns per coat Total DFT : 40 microns 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 nonsupported 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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((IOCL/M&I/MECH/P/14). 5. Technical specification for Stainless Steel Plates (IOCL/M&I/MECH/P/16).

   

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TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS 

PRESSURE VESSELS

     

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PAGE 1 OF 9

  

 

ENGINEERING CELL PROJECT DEPARTMENT- RHQ

RHQ-EC-ML-0026 REV 00

 

TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS 

Abbreviations:

BIS BS BHN DP STAAD MDMT TPlA ASME AWS CS GAD ID LSTK MOC MR OD PQT PQR PL PMC SS TIG WPS

Bureau of Indian Standards British Standards Brinell Hardness Number Dye Penetration Structural analysis and design computer program Minimum Design Metal Temperature Third Party Inspection Agency American Society of Mechanical Engineers American Welding Society Carbon Steel General Arrangement Drawings Internal Diameter Lumpsum Turnkey Material of Construction Material Requisition Outside Diameter Procedure qualification test Procedure qualification record Process Licensor Project Management Consultant Stainless Steel Tungsten Inert Gas Welding Procedure specification

     

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ENGINEERING CELL PROJECT DEPARTMENT- RHQ

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TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS 

PAGE 3 OF 9

CONTENTS

SL. NO. 1.0 2.0 3.0 4.0

DESCRIPTION SCOPE CODES, SPECIFICATIONS AND REGULATIONS DESIGN BASIS MATERIALS

     

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TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS 

PAGE 4 OF 9

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 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 Vendor s h a l l submit all design parameters of vessels as per specified. Annexure-H.

2.0

CODES, SPECIFICATIONS AND REGULATIONS

2.1

Design Codes

2.2

for material, design,

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/cm 2 (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.

Material Specifications, Materials to be used shall conform to a) ASME Section II. b) Indian Standard Specification of equivalent grade.

     

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TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS 

2.3

PAGE 5 OF 9

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 relevant Indian Standards unless otherwise specified.

3.0

DESIGN BASIS

3.1

Minimum Wall Thickness

with

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

3.2

PAGE 6 OF 9

designed accordingly.

d)

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

e)

For stainless steel columns/towers- 5 mm.

and

high

alloy

steel

Corrosion allowance, if any, shall be added to minimum thickness. " 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/cm 2 (g), the design pressure shall be equal to operating pressure plus 5% (minimum 7 Kg/cm 2 ).

3.3

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•

Design Temperature Design temperature shall be calculated otherwise specified elsewhere in the package:

as

per

the

following

unless

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 lowest operating temperature.

     

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TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS 

c)

3.4

PAGE 7 OF 9

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

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 Shall be t h e v a l u e s specified in the design code.

components etc.

3.5.2 The allowable stresses for structural members a n d anchor b o l t s shall be as 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 nd 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 used shall conform t o latest issue additional requirements mentioned herein. a)

of specification SA-20 w i t h

Only normalized plates free from injurious defects w i t h workman like finish shall be used. Reconditioning/repair of plates by welding shall not

     

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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 based on heat analysis shall be satisfied.

requirements for carbon

equivalents (Ceq)

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 for supplementary requirements of S19 & S21 of specification SA-20. 4.1.2

4.1.4

or

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.

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.

     

400 of 615

  

 

ENGINEERING CELL PROJECT DEPARTMENT- RHQ

RHQ-EC-ML-0026 REV 00

 

TECHNICAL SPECIFICATIONS FOR PRESSURE VESSELS 

b)

PAGE 9 OF 9

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.

     

401 of 615

ENGINEERING CELL PROJECT DEPARTMENT- RHQ TECHNICAL SPECIFICATIONS FOR ANCHOR BOLT/ TEMPLATE

RHQ-EC-ML-SP-0020 REV 00 PAGE 1 OF 10



ANCHORBOLT/TEMPLATE

339 of 615

ENGINEERING CELL PROJECT DEPARTMENT- RHQ

RHQ-EC-ML-SP-0020

TECHNICAL SPECIFICATIONS FOR ANCHOR BOLT/ TEMPLATE 

Abbreviations:

BIS BS BHN DP STAAD MDMT TPlA ASME AWS CS GAD ID LSTK MOC MR OD PQT PQR PL PMC SS TIG WPS

Bureau of Indian Standards British Standards Brinell Hardness Number Dye Penetration Structural analysis and design computer program Minimum Design Metal Temperature Third Party Inspection Agency American Society of Mechanical Engineers American Welding Society Carbon Steel General Arrangement Drawings Internal Diameter Lumpsum Turnkey Material of Construction Material Requisition Outside Diameter Procedure qualification test Procedure qualification record Process Licensor Project Management Consultant Stainless Steel Tungsten Inert Gas Welding Procedure specification

340 of 615

REV 00 PAGE 2 OF 10

ENGINEERING CELL PROJECT DEPARTMENT- RHQ

RHQ-EC-ML-SP-0020

TECHNICAL SPECIFICATIONS FOR ANCHOR BOLT/ TEMPLATE

REV 00 PAGE 3 OF 10



CONTENTS

CLAUSE NO

1.0 2.0 3.0 4.0

DESCRIPTION

SCOPE GENERAL FABRICATION INSPECTION ATTACHMENTSANCHOR DETAILS FIGURES 1,2&3

3

4o 61f

BOLT

PAGE NO

TEMPLATE

4 4 6 7 9

ENGINEERING CELL PROJECT DEPARTMENT- RHQ TECHNICAL SPECIFICATIONS FOR ANCHOR BOLT/ TEMPLATE

RHQ-EC-ML-SP-0020 REV 00 PAGE 4 OF 10



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.

342 of 615

ENGINEERING CELL PROJECT DEPARTMENT- RHQ

RHQ-EC-ML-SP-0020 REV 00

TECHNICAL SPECIFICATIONS FOR ANCHOR BOLT/ TEMPLATE

PAGE 5 OF 10

 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

M24

Width of Jig Plate

Diameter of Bolt Holes

Minimum Thickness of Plate

B (mm)

d (mm)

T (mm)

120

25.5

10

343 of 615

ENGINEERING CELL PROJECT DEPARTMENT- RHQ

RHQ-EC-ML-SP-0020 REV 00

TECHNICAL SPECIFICATIONS FOR ANCHOR BOLT/ TEMPLATE

PAGE 6 OF 10

 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

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

Bolt Holes

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:

344 of 615

ENGINEERING CELL PROJECT DEPARTMENT- RHQ

RHQ-EC-ML-SP-0020

TECHNICAL SPECIFICATIONS FOR ANCHOR BOLT/ TEMPLATE

REV 00 PAGE 7 OF 10

 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).

345 of 615

ENGINEERING CELL PROJECT DEPARTMENT- RHQ TECHNICAL SPECIFICATIONS FOR ANCHOR BOLT/ TEMPLATE

RHQ-EC-ML-SP-0020 REV 00 PAGE 8 OF 10

 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).

346 of 615

ENGINEERING CELL PROJECT DEPARTMENT- RHQ

RHQ-EC-ML-SP-0020 REV 00

TECHNICAL SPECIFICATIONS FOR ANCHOR BOLT/ TEMPLATE

PAGE 9 OF 10

 VESSEL 0^

90°

90° EQUIPMENT ITEM NO.

B

20

90°

20

t

B

50

d BOLT HOLE

90°

50

d BOLT HOLE

20

20

90°

90°

'H' TO BE AS PER ANCHOR BOLT CHAIR PLUS 40mm GROUT. PIPE DISTANCE PIECES

T

T

H

T

TEMPLATE ON THE FOUNDATION

FULL WIDTH GUSSETS

FIG. 1 PLATE TYPE TEMPLATE

FIG. 2 STIFFENER TYPE TEMPLATE

347 of 615

ENGINEERING CELL PROJECT DEPARTMENT- RHQ

RHQ-EC-ML-SP-0020 REV 00

TECHNICAL SPECIFICATIONS FOR ANCHOR BOLT/ TEMPLATE

PAGE 10 OF 10



FLAT BAR

ANGLE MEMBER

B

PLATE TYPE

B

A A STIFFENER TYPE

VIEW "A-A"

VIEW "B-B" DIVIDED CONSTRUCTION TYPE FIG. 3

348 of 615

Project N°

Unit

Doc. Type

Mat. Code

Serial N°

Rev.

Page

068107C001

000

STC

0490

001

0

1/45

UNIT

: DHDT

PROJECT

: BS-IV PROJECT.

LOCATION

: IOCL, BARAUNI REFINERY.

OWNER

EPCM TECHNIP INDIA LTD.

INDIAN OIL CORPORATION

NOIDA, INDIA.

LIMITED.

CONSTRUCTION STANDARDS PRESSURE VESSELS Document Category

Document Review Status (by Client)

(Use “X” Mark)

Approval

Review

Information

Pages modified under this revision: none.

0

20/10/2015

Rev

Date DD/MM/YY

Issued for Information

RTS

KD

RR

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

Project N°

Unit

Doc. Type

Mat. Code

Serial N°

Rev.

Page

068107C001

000

STC

0490

001

0

2/45

CONSTRUCTION STANDARDS FOR PRESSURE VESSELS

TABLE OF CONTENTS REVISION

DOCUMENT NUMBER 068107C001-000-STC-0490-01 068107C001-000-STC-0490-02 Sheet 1/3 068107C001-000-STC-0490-02 Sheet 2/3 068107C001-000-STC-0490-02 Sheet 3/3 068107C001-000-STC-0490-03 068107C001-000-STC-0490-04 Sheet 1/2 068107C001-000-STC-0490-04 Sheet 2/2 068107C001-000-STC-0490-05 Sheet 1/2 068107C001-000-STC-0490-05 Sheet 2/2 068107C001-000-STC-0490-06 068107C001-000-STC-0490-07 068107C001-000-STC-0490-08 Sheet 1/3 068107C001-000-STC-0490-08 Sheet 2/3 068107C001-000-STC-0490-08 Sheet 3/3

0 0 0 0 0 0 0 0 0 0 0 0 0 0

068107C001-000-STC-0490-09 068107C001-000-STC-0490-10 068107C001-000-STC-0490-11 068107C001-000-STC-0490-12 068107C001-000-STC-0490-13 068107C001-000-STC-0490-14 068107C001-000-STC-0490-15 Sheet 1/4 068107C001-000-STC-0490-15 Sheet 2/4

0 0 0 0 0 0 0 0

068107C001-000-STC-0490-15 Sheet 3/4

0

068107C001-000-STC-0490-15 Sheet 4/4

0

068107C001-000-STC-0490-16 Sheet 1/2 068107C001-000-STC-0490-16 Sheet 2/2

0 0

068107C001-000-STC-0490-17 068107C001-000-STC-0490-18 068107C001-000-STC-0490-19 068107C001-000-STC-0490-20 Sheet 1/3 068107C001-000-STC-0490-20 Sheet 2/3 068107C001-000-STC-0490-20 Sheet 3/3 068107C001-000-STC-0490-21 Sheet 1/2 068107C001-000-STC-0490-21 Sheet 2/2 068107C001-000-STC-0490-22 Sheet 1/3 068107C001-000-STC-0490-22 Sheet 2/3 068107C001-000-STC-0490-22 Sheet 3/3 068107C001-000-STC-0490-23 Sheet 1/2 068107C001-000-STC-0490-23 Sheet 2/2 068107C001-000-STC-0490-24 Sheet 1/2 068107C001-000-STC-0490-24 Sheet 2/2 068107C001-000-STC-0490-25 068107C001-000-STC-0490-25

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

DESCRIPTION

MANUFACTURER NAME PLATE SKIRT – ACCESS HOLE & VENTS SKIRT SUPPORT – ANCHOR CHAIRS SKIRT SUPPORT – ATTACHMENT NAME PLATES MOUNTING BRACKET SUPPORT BRACKETS SUPPORT CONTINUOUS RING TOLERANCES FOR VERTICAL EQUIPMENTS TOLERANCES FOR VERTICAL EQUIPMENTS MANHOLES COVER SUPPORTS MANHOLES & HANDHOLE HINGES HOT INSULATION SUPPORT HOT INSULATION SUPPORT HOT INSULATION SUPPORT FOR VERTICAL VESSELS WITH INSULATION INSTALLED IN HORIZONTAL POSITION FIREPROOF SUPPORTS LIFTING TRUNNIONS LIFTING LUGS TAILING LUG DETAIL EARTHING LUGS TEMPLATES TYPICAL NOZZLE DETAILS - REINFORCEMENTS TYPICAL NOZZLE DETAILS – PLATE FLANGES FOR INTERNAL PIPE DISTRIBUTORS TYPICAL NOZZLE DETAILS – PROJECTION OF NOZZLES ON PLATFORM TYPICAL NOZZLE DETAILS – PROJECTION OF NOZZLES ON SHELL TYPICAL DETAILS - VARIOUS TYPICAL DETAILS – VARIOUS SUPPORT FOR INTERNAL PIPE DISTRIBUTORS VORTEX BREAKERS SUPPORT SADDLES TYPE A & B (DIA. < 3000mm) SUPPORT SADDLES TYPE C (DIA. > 3000mm) SUPPORT SADDLES FOR STACKED UNITS TYPE “A” SUPPORT SADDLES FOR STACKED UNITS TYPE “B” WEDGES FOR STACKED UNITS TOLERANCES FOR HORIZONTAL EQUIPMENTS TOLERANCES FOR HORIZONTAL EQUIPMENTS SUPPORT LEGS FOR VERTICAL VESSELS SUPPORT LEGS FOR VERTICAL VESSELS SUPPORT LEGS FOR VERTICAL VESSELS COLD INSULATION SUPPORTS COLD INSULATION SUPPORTS LIFTING LUG FOR HORIZONTAL VESSELS LIFTING LUG FOR HORIZONTAL VESSELS NOZZLE SCHEDULE FOR CS/SS/CLAD TEST PROCEDURE

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

25

Project N°

Unit

Doc. Type

Mat. Code

Serial N°

Rev.

Page

068107C001

000

STC

0690

001

0

1/21

UNIT

: DHDT

PROJECT

: BS-IV PROJECT.

LOCATION

: IOCL, BARAUNI REFINERY.

OWNER

EPCM TECHNIP INDIA LTD.

INDIAN OIL CORPORATION

NOIDA, INDIA.

LIMITED.

CONSTRUCTION STANDARDS HEAT EXCHANGERS Document Category

Document Review Status (by Client)

(Use “X” Mark)

Approval

Review

Information

Pages modified under this revision: none.

0

20/10/2015

Rev

Date DD/MM/YY

Issued for Information

RTS

KD

RR

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

Project N°

Unit

Doc. Type

Mat. Code

Serial N°

Rev.

Page

068107C001

000

STC

0690

001

0

2/21

CONSTRUCTION STANDARDS FOR HEAT EXCHANGERS

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

068107C001-000-STC-0690-24 Sheet 2/4

0

068107C001-000-STC-0690-24 Sheet 3/4

0

ASME NAME PLATE FOR HEAT EXCHANGERS (LAYOUT) ASME NAME PLATE FOR HEAT EXCHANGERS (SUPPORT BRACKET) ASME NAME PLATE FOR HEAT EXCHANGERS (NOTES)

068107C001-000-STC-0690-24 Sheet 4/4

0

068107C001-000-STC-0690-31

0

ASME NAME PLATE FOR HEAT EXCHANGERS (INSTRUCTION FOR DATA FILLING) 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

068107C001-000-STC-0690-43

0

BRIGGS PLUGS FOR COUPLING

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 UNIT

PROJECT

: BSIV PROJECT, BARAUNI.

LOCATION

: IOCL, BARAUNI REFINERY.

LIST OF DEVIATIONS BREECH LOCK EXCHANGERS REQUISITION NO: 068107C001-702-MR-0610-01-Rev.A SL NO

DOCUMENT NO / CLAUSE NO

SPECIFICATION / REQUIREMENT

DEVIATION

Note: 1. Deviation Listed in this Format only shall be considered. 2. Vendor shall validate the Deviation List with Company Seals & Signature

REASON FOR DEVIATION

INSPECTION AND TEST PLAN FOR SHELL & TUBE HEAT EXCHANGERS

CONFIDENTIAL PROPERTY OF TECHNIP INDIA LIMITED

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

SHEET: 1 OF 3

Manufacturer

Third Party Inspetion Agency

Technip India Limited

INSPECTION BY

H

H

Weld Map/WPS/PQR/WPQ

H

R/W

Purchase Requisition/Approved drgs

NDT Scheme

H

R

OR

Purchase Requisition/Applicable Code

Purchase Requisition/Applicable Code

NDT/Job Procedures

H

R

OR

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.

Weld Set-ups

Visual & Dimensional Inspection including NDT (if any) of Weld Setups & 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 Purchase Requisition / (As applicable ) Approved Procedure / Approved Drawings

Applicable code / Approved Procedure / Approved drgs

Inspection Report

H

W

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

11

Radiographic Examination of Welds

Review of Radiographic Films

Approved drgs / ASME Sec V ASME VIII Div1 / Approved Procedure

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

UT Report

H

R

OR

TYPE OF CHECK

REFERENCE DOCUMENT ACCEPTANCE CRITERIA

VERIFYING DOCUMENT

REMARKS RECORD

STAGE DESCRIPTION

Client

SL. NO.

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 1

Pre-inspection Meeting

Pre-inspection Meeting

Technip India Doc.:General Quality Control Requirements, MR

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

3

NDT Scheme

Review of NDT Scheme

Purchase Requisition/Approved drgs

4

NDT & Job Procedures

Review of NDT & Job Procedures

5

Material Identification

6

ASME Sec VIII Div1

OR

OR W for new Procedures

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 ) OR R- For Exsiting procedure W-For New Procedure

INSPECTION AND TEST PLAN FOR SHELL & TUBE HEAT EXCHANGERS

CONFIDENTIAL PROPERTY OF TECHNIP INDIA LIMITED

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

SHEET: 2 OF 3

Manufacturer

Third Party Inspetion Agency

Technip India Limited

INSPECTION BY

13

Positive Material Identification ( As Applicable )

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

Applicable material code/ Purchase Requisition

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

Inspection Report

H

W

OR

15

Tube Sheet Machining & drilling

Dimensional , Hole Dia & Alignment Check

Approved Drgs

Purchase Requisition / Approved Drawings

Inspection Report

H

W

OR

16

Pneumatic Test of tube to tube sheet Joint Pneumatic Test of tube to tube sheet Approved Drawings , ASME Joint after First Run Sec VIII Div1

Approved Drawings , ASME Sec VIII Div1

Inspection Report

H

W

OR

17

Inspection of Tube to Tubesheet joint Expansion

Tube to tube sheet check up

Approved Drgs / Approved Mock Up procedure

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.

Approved Drgs. / Approved Inspection Report Mock up Procedure / Purchase Requisition Purchase Requisition Inspection Report /Approved Drgs.

H

W

OR

19

Bundle Insertion

Bundle insertion

Approved Drgs.

Smooth going of bundle inside Inspection Report the shell

H

W

OR

20

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

Final Dimensional & Completeness of Approved Drgs. Assebly

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

Internal Records

H

R

OR

24

Hydrotest

Tube side Hydro test Shell side Hydrotest

Approved Drg/ Approved Procedure

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

Inspection Report

H

W

OR

TYPE OF CHECK

REFERENCE DOCUMENT ACCEPTANCE CRITERIA

VERIFYING DOCUMENT

REMARKS RECORD

STAGE DESCRIPTION

Client

SL. NO.

INSPECTION AND TEST PLAN FOR SHELL & TUBE HEAT EXCHANGERS

CONFIDENTIAL PROPERTY OF TECHNIP INDIA LIMITED

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

SHEET: 3 OF 3

Manufacturer

Third Party Inspetion Agency

Technip India Limited

INSPECTION BY

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

TYPE OF CHECK

REFERENCE DOCUMENT ACCEPTANCE CRITERIA

VERIFYING DOCUMENT

REMARKS RECORD

STAGE DESCRIPTION

Client

SL. NO.

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

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)

05.10.2015

0

PDK

SSJ

VKY

SLSK

Issued For Enquiry

DATE

REV

PREP

CHD

APP

PM

DESCRIPTION

NOTE: For items not covered in the above list, the vendor list shall be approved by NOTE: For items not covered in the above list, the vendor list shall be approved by IOCL/ Technip prior to placement of order by Supplier. Supplier shall list down the proposed OWNER / PMC prior to placement of order by CONTRACTOR. CONTRACTOR shall list suppliers / vendors for such items and submit the same for IOCL/ Technip review / approval along down the proposed suppliers / vendors for such items and submit the same for OWNER / with necessary documents / credentials. Non-acceptance of a particular proposed vendor due to any PMC’s review / approval along with necessary documents / credentials. Non-acceptance reasons whatsoever shall not be a cause of schedule and cost implication. of a particular proposed vendor due to any reasons whatsoever shall not be a cause of schedule and cost implication.

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PROJECT

: BS-IV PROJECT

LOCATION

: IOCL, BARAUNI REFINERY

OWNER

EPCM TECHNIP INDIA LTD.

INDIAN OIL CORPORATION

NOIDA, INDIA.

LIMITED.

JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS Document Category

Document Review Status (by Client)

(Use “X” Mark)

Approval

Review

Information

Pages modified under this revision: none.

A

09/10/2015

Rev

Date DD/MM/YY

Issued for Review

RTS

KD / BTS

RR

STATUS

WRITTEN BY (name & visa)

CHECKED BY (name & visa)

APPROVED BY (name & visa)

DOCUMENT REVISIONS

This document developed by TECHNIP IINDIA LTD 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

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JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

TABLE OF CONTENTS PAGE NO. 1. 

PURPOSE

3 

2. 

SCOPE

3 

3. 

CONFLICTS & DEVIATIONS

3 

4. 

DEFINITIONS:

3 

5. 

ABBREVIATIONS:

4 

6. 

CODES & STANDARDS

4 

7. 

BASIS OF DESIGN / ASSEMBLY / METHODOLOGY

5 

8. 

ACCESSORIES:

16 

9. 

INSPECTION AND TESTING:

16 

10. 

PREPARATION FOR SHIPMENT:

17 

11. 

GUARANTEES

18 

12. 

VENDOR DATA REQUIREMENT:

18 

13. 

VENDOR DOCUMENT / DATA FORMAT

19 

14. 

MINIMUM NOZZLE LOADING

20 

This document developed by TECHNIP IINDIA LTD 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

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JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

1.

PURPOSE

1.1

The purpose of this specification is to define minimum design & fabrication requirements for Shell & Tube Heat Exchangers.

2.

SCOPE

2.1

It is intention of this specification that the Bidder provides the most economical exchanger based on his standard equipment design & fabrication method provided the Bidder complies with the requirements of the specified design code, TEMA standards, and this specification.

3.

CONFLICTS & DEVIATIONS In case of contradiction between codes, specifications & standards or other documents relating to an enquiry or order, the following order of precedence shall apply: a) b) c) d) e) f) g)

Design & construction code, including national/ or local regulations. Purchase order and subsequent change order. Data sheets & drawings This specification Other project specification & standards Client Specification & Standards Other national & international standards

Note that if the requirements of b) through h) are more stringent than a), then these shall govern. Should conflicts occur it shall be responsibility of Bidder to call Owner / Consultant attention to the conflict and request a ruling or interpretation from Owner / Consultant. While the order of governing order of precedence is given, the Bidder shall not assume any instruction without reference to Owner / Consultant. 4.

DEFINITIONS:

4.1

The BIDDER shall comply with the applicable federal, state or local codes, regulations, ordinances & rules. Unless defined otherwise these shall be those applying to the country or state where the equipment is to be installed.

4.2

Owner / Consultant right of inspection shall not take the place of the required testing based on the material specification quoted by the Bidder, nor shall they relieve the Bidder of any responsibility for any testing which should be done as a result of design requirements. A final cleanliness inspection shall be performed on all the piping and appurtenances furnished by the Bidder including the exchanger internals.

4.3

The definitions of key terms used in the specification are as follows: OWNER: Indian Oil Corporation Limited, Barauni (IOCL) CONSULTANT: Technip India Pvt. Ltd. (TP) BIDDER: The firm contracted to supply the equipment to the Owner/Consultant.

This document developed by TECHNIP IINDIA LTD 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

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JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

5.

ABBREVIATIONS: ASME BS NDE TEMA IBR WRC EEMUA CS SS LAS HAS NACE HP WP RI RD W.P PWHT NPS NPT ASNT TPIA HCN LPG EDMS CP

American Society of Mechanical Engineers British Standard Non-Destructive Examination Tubular Exchanger Manufacturer’s Association Indian Boiler Regulation Welding Research Council Engineering Equipment Manufacturers & Users Association Carbon Steel Stainless Steel Low Alloy Steel High Alloy Steel National Association of Corrosion Engineers Hold Point Witness Point Random Inspection Review Document Working Pressure Post Weld Heat Treatment Nominal Pipe Size Nominal Pipe Thread American Society of Non Destructive Testing Third Party Inspection Agency Hydrogen Cyanide Liquid Pressurized Gas Electronic Document submittal guidelines Cathodic Protection

6.

CODES & STANDARDS

6.1

The following documents are referred to herein and form a part of the specification. Unless otherwise specified the editions of codes & standards which apply shall be those current at the date stated in the Material Requisition, including all revisions and addenda up to and including that date. ASME Section VIII, Div. 1 Rules for Construction of Pressure Vessels ASME Section VIII, Div. 2 Alternative Rules for Construction of Pressure Vessel ASME Section V Non-Destructive Examination ASME Section IX Welding & Brazing Qualifications ASME Section II Materials IBR Indian Boiler Regulations TEMA Tubular Exchanger Manufacturers Association API 660 Eighth Edition Shell & Tube Exchanger for General Refinery Service IS-875 (Part 3) Code of Practice for Wind Load Design IS-1893 Part 1 & 4 Criteria for Design of earthquake resistant structure ASME B16.5 Pipe Flanges & Flange Fittings

This document developed by TECHNIP IINDIA LTD 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

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ASME B16.47 ASTM A263 ASTM A264 ASTM A265 ASTM A435 ASTM A388 NACE MR 0103 NACE MR 0175 NACE RP0472-2008 Welding Research Council Bulletin No. 107/297 EEMUA 143

Large Diameter Pipe Flanges Specification for Corrosion Resisting Chromium Steel Clad Plate, Sheet & Strip Specification for Chromium Nickel Steel Clad Plate, Sheet & Strip Specification for Nickel & Nickel Base Alloy Clad Steel Plate Straight Beam Ultrasonic Examination of Steel Plate Practice of Ultrasonic Examination of Heavy Steel Forgings Material Resistant to Sulphide Stress Cracking in Corrosive Petroleum Refinery Environments Standard Material Requirements, Sulphide stress cracking resistant metallic materials for oilfield equipment’s Method & controls to prevent in service environmental cracking of carbon steel weldments in corrosive petroleum refining environments Local Stresses in Spherical & Cylindrical Shells due to external loading Recommendation for Tube end welding: Tubular Heat Transfer equipment Part 1 – Ferrous Material

7.

BASIS OF DESIGN / ASSEMBLY / METHODOLOGY

7.1

General

7.1.1

Design pressures, design temperature, operating conditions, fluid properties, pressure drops & fouling factors shall be specified on the exchanger data sheet.

7.1.2

The BIDDER shall provide full mechanical design & guarantee. If specified in the Material Requisition, the BIDDER shall verify the thermal design and state in his proposal that he will supply complete mechanical, thermal, hydraulic & vibration guarantees.

7.1.3

When exchanger Thermal design is provided by OWNER/CONSULTANT, it shall be BIDDER’s responsibility to confirm the exchanger geometry provided. Shell diameter specified in BIDDER proposal shall be their calculated value. Price adjustments after the order for increased shell diameters will not be allowed.

7.1.4

All bolting of girth flanges & nozzle flanges shall be TEMA metric. Nuts shall be heavy series.

7.1.5

All tapped holes shall be in accordance with NPT standards.

7.1.6

Lifting lugs shall be designed for twice the weight of the components to be lifted.

7.1.7

Whenever, differential pressure design is specified, it shall be applicable to tube bundle (i.e. tube sheet, tubes & floating head) unless otherwise specified.

This document developed by TECHNIP IINDIA LTD 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

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JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

7.1.8

A WARNING sign, stating the maximum differential design pressure and the maximum differential test pressure, shall be located next to the nameplate.

7.1.9

Use of hydraulic bolt tensioners shall be considered for bolts sizes above 1 ½” on girth flanges.

7.2

Tubesheet, Tubes & Tube Bundle

7.2.1 The number of tubes in any pass shall be within 10% of the average number of tubes per pass 7.2.2 Bypass seal devices are required when the radial clearance distance between the outer tube limit (OTL) and shell is greater than one tube diameter, or when a large number of tubes are dropped for impingement plates. Dummy tubes or solid bars shall be placed in void areas caused by pass ribs. Only those areas parallel to cross flow need to be considered. Sealing devices shall not be located in the inlet and outlet spaces. 7.2.3 When impingement plates are provided the bundle entrance and exit areas shall be calculated at a plane through the first row of tubes and shall include the area obstructed by the impingement plate (if any). 7.2.4 Cross baffles and support plates shall be provided with suitable notches to facilitate venting and draining of shell. Support / baffles shall not be welded to the shell & they shall be attached to tube sheet by means of tie rods. 7.2.5 Skid bars are required on removable bundles 760 mm in diameter or larger to facilitate bundle removal. Slide rails shall be provided in kettle type shells. Kettles shall also be provided with a bundle retaining device at floating end. 7.2.6 Bundles shall be withdrawn after insertion, by a distance equal to the lesser of two central baffle spaces or 1000 mm. Additionally, for stacked exchangers, the bottom bundle need to be withdrawn and checked in stacked position. Grinding of baffles to permit insertion is not acceptable. 7.2.7 Tube holes in Tubesheets shall be as per TEMA. Additionally, for stainless steel tube sheet the same shall be furnished in conformity with TEMA special close fit dimensions and tolerances as referenced in TEMA. 7.2.8 Removable bundles shall be provided with full diameter support plate. For U-tube bundles this shall be positioned at the tangent line. For floating head bundles it shall be positioned to minimize the distance from the tube sheet whilst giving adequate support within the shell flange. The baffle may be provided with a central window for fluid passage if required, when inlet and outlet nozzle are located beyond the support node. 7.2.9 U-bends shall be provided with additional supports if the TEMA maximum span length is exceeded or if vibration checks indicate such requirements. Vendor shall give guarantee for the same. 7.2.10 Eye bolts for bundle pulling shall be forged quality.

This document developed by TECHNIP IINDIA LTD 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

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7.2.11 Removable bundles shall be provided with suitable lugs for the use of a bundle puller. 7.2.12 Multi- pass tube bundles with a large temperature differential across each pass shall have the stationary tube sheet extended for bolting. 7.2.13 Perforated impingement plates shall not be used. 7.2.14 Impingement plate when used shall be continuously welded to ties rods / spacer. Stitch welding is not permitted. 7.2.15 Tubesheet thickness shall be calculated to ASME VIII Division 1 part UHX. 7.2.16 Extended tube sheet with collar bolt shall be considered for type B- stationary head exchangers and stub in type heat exchangers. 7.2.17 Design of fixed tubesheet exchangers shall take into consideration the most stringent of the following criteria in determining the need for an expansion joint: a) Normal operating conditions. b) Shell side start up, no fluid tube side. c) Tube side start up, no fluid shell side; shell at most severe ambient temperature. d) Shell side pressure failure. e) Tube side pressure failure. f) Specified turn down operating conditions. g) Hydro test. h) Steam out or other cleaning procedures when specified. Tubesheet calculations shall be based on the above conditions in both corroded and uncorroded state. 7.2.18 Tube sheets shall be made of forging only (except for non-ferrous material). Where hub type fixed Tubesheets are required, the hub shall be integrally forged with the tubesheet. Hubs made from built up weld metal are not permitted. Hub type tubesheets shall be provided for low temperature services (MDMT < -45°C) and critical services as defined in data sheets. 7.2.19 Unless otherwise noted on the data sheet, the design temperature for tubesheets shall be taken as the maximum of either the shell side or tube side design temperatures as specified on the exchanger data sheets. 7.2.20 For fixed tubesheet exchangers, tube to tubesheet joint loads shall not exceed allowance loads as defined in Appendix A2 of ASME VIII Div.1. 7.3

Tube to Tubesheet Joints

7.3.1

Expanded tube-to-tubesheet joints Tube-to-tubesheet joints shall be expanded into two grooves in the tube sheet. The length of full expansion shall be 50mm with light expansion for the remainder to within 3mm of the shell side face of the tubesheet.

This document developed by TECHNIP IINDIA LTD 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

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JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

A minimum of two grooves each 0.4mm deep and 3mm wide shall be provided at 6mm spacing in the tube-hole of the tube sheet. Thinning limited to 4-5% for stainless steel tubes and 8-10% for carbon steel tubes. Quality and extent of expansion into grooves to be checked by the following methods: Go & No-Go gauging Air leak test Hydrotest Mock-up procedure test (if required) 7.3.2

Welded tube to tubesheet joints:

(a) Tube-tubesheet welding shall comply with requirements of EEMUA- Publication No-143, with following exceptions / additions: (b) Strength welded tube-tubesheet joints shall have minimum two welds runs with different start and stop runs. (c) Duration of pressure test shall be minimum one hour. 7.3.3

Mock-up procedure test is required in any of the following condition: if code or purchase-order warrants. if fabricator has no similar established procedure. if joint-load capacity to be certified. Following shall be demonstrated during mock-up test: % thinning vs expander-settings Shear load test. Mock-up for different settings of expander for different combinations of tolerances of tube hole dia. and tube thickness variations to be carried out. Mock-up sample shall be cut along the tube axis into two halves and metal flow into groove to be checked.

7.3.4

All clad tubesheets shall have seal welded tube joint followed by expansion into 2 grooves as described in Para 7.3.1 (Expansion shall be no closer than 10mm from seal weld). This requirement shall take precedence where items with clad tubesheets also fall into one of the strength weld categories listed in para 7.3.5. Credit should not be taken for the strength of the seal weld.

7.3.5

Unless Otherwise specified, Tube to tubesheet joints shall be strength welded followed by light expansion (no closer than 10mm to the weld) for the following cases: a)

All exchangers using steam as a heating medium.

b)

All high pressure exchangers (≥ 900 # flange rating)

c)

All exchangers operating at > 300 deg C (Either steam)

This document developed by TECHNIP IINDIA LTD 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

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d)

All exchangers with a predicted temperature difference across the tubesheet of ≥ 100 deg C based on steam temperature at location of greatest difference temperature.

e)

For hydrogen service on shell side with partial pressure > 6.9 bar (a).

For tube to tubesheet joints with dissimilar materials, weld overlay on tubesheets with material suitable for process and having good weld ability with both tube and tubesheet base material should be considered. f)

Where tube hardness/ yield strength exceeds that of tube sheet.

g)

For low temperature service where MDMT is below -45 Deg C.

h)

When either shell or tube side design pressure > 50 kg/cm2 and design temperature is > 400 deg C.

7.4

Floating Heads

7.4.1

For split ring designs, split ring with recessed grooves (TEMA style A, with groove profile modified if needed) shall be generally used. Split rings which are recessed in grooves on the tubesheet periphery shall not be used in corrosive shell side services. While sizing the split ring, the following shall be carried out: a) Minimum thickness behind the groove shall be as per TEMA Fig RCB 5.141 Style A; b) In addition to the Code/TEMA calculations, Vendor to calculate the stress and deflection at the groove of the split ring, to demonstrate suitable design. In addition, to avoid cracks, backing ring recesses shall not have sharp corners.

7.4.2

Seating gasket ribs for partitions must be taken into account when designing the floating head.

7.4.3

Floating head covers shall be provided with lifting lugs welded on each side at 45 degrees from top.

7.4.4

Floating head flange and backing rings shall be made of forging only.

7.4.5

Floating head shall be through bolted type only. Tapped bolting on tubesheet is not acceptable.

7.4.6

For floating head and other internal flanges minimum bolt size shall be M20.

7.5

Shells, Shell Covers and Shell Supports

7.5.1 It is the responsibility of the BIDDER to determine the need for shell expansion joints for the conditions specified on the data sheet and/or paragraph 7.2.1.7 of this specification. 7.5.2 The minimum permissible shell cover thicknesses specified in TEMA are to be after forming, but not less than 6 mm nominal. 7.5.3 Shell supports shall be designed to withstand a vertical load including the heat exchanger weight, weight of heat exchangers stacked above, weight of water contained in the stacked heat exchangers, other specified loads, plus 15% of the above loads, without distortion to the shells.

This document developed by TECHNIP IINDIA LTD 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

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The lower shell of stacked exchangers should have box type supports. The 15% safety factor in this specification does not apply to earthquake forces. 7.5.4 The horizontal support load shall be taken as follows: The horizontal load induced by pulling a tube bundle from a heat exchanger unit without jacking screws shall be taken as 150% of the tube bundle weight. 7.5.5 Two grounding lugs (SS) shall be provided on each exchanger. On stacked exchangers, two lugs are required only on the bottom shell. The lug shall be located, approximately 150 mm above the exchanger foundation. 7.5.6 Channel sections and covers shall be provided with lifting lugs to facilitate lifting and removal of section. 7.5.7 Supports for stacked exchangers shall be provided with a shimming pack. 7.5.8 Vertical exchangers shall have provision for complete draining of the shell. 7.5.9 Vertical heat exchangers having inside diameter