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TECHNICAL SPECIFICATIONS

AUTOCLAVE DOOR WITH FLANGE AND SUSPENSION SYSTEM FOR

MARK II AUTOCLAVE

(Autoclave shell is not in the scope of supply. )

As per the enclosed drawings (Mark II-Door-000-001- 5 sheets)

1. SCOPE OF WORK :

The total job shall be handled by the supplier on a turnkey basis. Further, the job

shall be carried out under the supervision of NAL approved Third Party Inspection

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Major tasks involved are as follows :

a) Preparation of manufacturing drawings, design calculations based on the NAL

supplied drawings and calculations.

b) Getting approval of drawings and design from Third Party.

c) Fabrication of torispherical dish door with lock ring flange

d) Inspection, testing, marking and supply of records as per IS-2825/ASME,

Sec.VIII, Div., 1 under the supervision of third party inspection agency and in

accordance with the “Factory acceptance tests ”

e) Transporting of Door to NAL, Bangalore

1. Integrating the fabricated door with the NAL supplied Crab and Autoclave shell

along with supporting structure.

2. Installation, integration and commissioning of the whole system at NAL.

3. Since Hydrostatic test cannot be carried out, a Pneumatic test has to be conducted

as per the code at NAL after commissioning. The required pressure and gauges

for the test will be provided by NAL.

3. MAJOR COMPONENTS OF AUTOCLAVE DOOR :

A) Torispherical dished door with lock ring flange.

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B) Door suspension system

4. BRIEF DESCRIPTION OF MAJOR COMPONENTS :

A. AUTOCLAVE DOOR:

Specifications:

a) Design code: The autoclave Door is designed, fabricated, tested and certified in

accordance with Indian standard code for unfired pressure vessel IS 2825.

1969/ ASME Sec VIII Div. I Edd 2004+ Add 2005 and will be certified by

third party inspection agency. The design and drawings will be provided by

NAL.

b) Working temperature : 250 º C

c) Working pressure : 7 barg approx. 7.14 kg/cm2 g

d) Design pressure : 7.854 kg/cm2 g

e) Design temperature : 250 º C

f) Internal dia. of the door : 2960 mm

g) Length of the cylindrical shell : 1500 mm

h) Thickness of the shell : 20 mm

i) Corrosion allowance : 1.5 mm (included in shell thickness)

j) Class of vessel : Class I

k) Material of shell & dishes : 5A 516 Gr.70

l) Pnuematic test pressure : 1.25 x design pressure

= 9. kgs/cm2 g

m) Internal volume : 17 m3 (approx.)

n) Empty weight : 6.5 tons (approx.)

Note: All the nozzles should be supplied with blind flanges duly fixed with necessary

gaskets and bolts.

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B. DOOR DISH :

It is deep dished and flanged (torispherical) dish with 16% knuckle radius as per IS 4049

Part (11) – 1979.

Specification:

Internal diameter: 2960 mm

Dish thickness: 25mm

Thinning allowance: 3 mm (included in dish thickness)

Corrosion allowance: 1.5mm (included in dish thickness)

Tolerance on out side circumference: ± 6mm (as per IS 4049 Port II – 1979 table 5)

Notes: i)The whole assembly has to be stress relieved..

ii) The difference between the maximum and minimum inside diameters of the

Straight flange shall not exceed one percent of the nominal diameter.

iii) Sharp grooves, lamination and other surface cracks shall be completely

removed by the grinding.

1) The flange shall be fabricated by cold / hot rolling or seamless forging.

The welded ring should be stress relieved before machining. It has to be

normalized subsequent to hot rolling or during the last process of hot

rolling. It is uniformly heated to temperature within the normalizing range.

Test coupons should be taken and tested for mechanical properties.

2. Minimum No. of weld joints should be used and in no case, the joints shall be

more than three.

3. The lock ring flange has to be machined precisely as per the drawing, as it has to

align with shell lock ring flange. Any variation in circularity, teeth dimensions

and teeth pitch will seriously affect the lock ring operation and it may not be

possible to lock the door at all.

4. The door lock ring has 24 teeth cut equally on the circumference of the lock ring.

This lock ring is stationary

iii) Door Suspension System: The door is suspended using fork screw supported

on thrust bearing with knuckle joint. This has to be integrated with crab and

supporting structure supplied by NAL.

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Note: The RF pad and Knuckle joint has to be welded on to the shell after checking

the alignment with the Autoclave shell at NAL.

J. DESIGN AND DRAWINGS :

NAL will provide the design calculations and drawings.

K. MATERIALS :

The material for all the pressure holding components of autoclave shall be SA 516, Gr.

70. The material for door flange is SA 105.

. Pipe / Nozzle necks shall be in general carbon steel confirming to 5A53/SA 106.

Forgings for flanges, etc. shall confirm to SA 105. Bolting material for pressure

connections such as blind flanges etc., shall be of SA 193. Gr. B7 bolt and SA 194 Gr.

2H for nut.

Note: All the materials used in the Autoclave shell, should have valid material test

certificate. No material should be used without the test certificate. All these test

certificates should be submitted to NAL.

L. FABRICATION :

The vessel fabricated under these specifications shall be fusion welded using the metallic

arc process. All the welding qualifications, manufacture and workmanship shall be

in accordance with the general requirements of section II - Fabrication and welding

of IS 2825-1969/ ASME Sec VIII Div. I Edd 2004+ Add 2005. All the inspection,

testing, marking and records should be carried out as per section III of IS 2825 –

1969 /ASME Sec VIII Div. I Edd 2004+ Add 2005.

The plate edges shall be scarfed by any method that will produce a reasonably smooth

surface suitable for welding. Drags, tears, accumulations of slag, excessive roughness

and dirt shall be removed. Vessel shall be designed using largest sheet courses consistent

with optimum economics based on amount of welding. The weld joints shall be so

located as to clear openings and shall be as per code. All attachments, nozzle pipes,

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nozzle flanges, reinforcing pads, gaskets, fasteners, accessories shall be as per the

requirement and shall be provided by the supplier. All the flange openings, threaded

nozzles should be supplied with suitable blank flanges and plugs with necessary gasket

and bolting.

Dimensions of nozzles flanges shall be as per ASME B 16.5 unless otherwise stated.

All temporary attachments made to the shell to facilitate erection shall be removed and

any noticeable projections of weld metal shall be chopped from plate. The plates must

not be gauged or storm in the process of removing the attachments. No hole shall be

made in the shell plate for erection purposes.

Post weld heat treatment shall be carried out as per the code requirement.

J. INSTALLATION , INTEGRATION AND COMMISSIONING :

. The required material handling equipment, tools, shackles, unloading from the trailer

and mounting in the pit is supplier’s responsibility. The supplier is responsible for any

damage during transportation, installation and commissioning.

K. INSPECTION AND TESTING :

The third party inspection agency shall be the prime inspection agency for the job. In

addition, NAL representatives will also carry out period inspection / review. All the

inspection and testing shall be carried out in accordance with code requirements.

The supplier shall prepare a “Quality plan” indicating the inspection stages and category

of inspection such as HP (Hold point – means no further work can proceed until

acceptance is given by inspection agency), WP (witness point – means notification to

Inspection Agency. Work can proceed to the next stage if inspection agency not present)

and RD (Review of Documents – means review of inspection related documents by

inspection Agency). The supplier shall prepare quality records for all the stages of

inspection. The quality plan shall be approved by inspection agency and NAL. Approval

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of the inspection agency shall not relieve the supplier of his responsibilities for

mechanical manufacturing, workman ship, guarantee and proper execution of work.

Welding procedure qualification and qualification of welders shall be carried out as per

IS 2825-1969 (Indian Standard Code for unfired pressure vessels) Section II. The

supplier shall make his own arrangements of such tests at his own cost in the presence of

clients / inspecting agency. No welding shall be permitted without approval of welding

procedure and welders qualification test by the inspecting agency.

Radiographic examination of welds and repairs of welds of required places shall be

carried out as per code and applicable appendix. Liquid penetrant test wherever required

shall be carried out as per code.

All welding and inspection should be accessible to inspector for examination. For this

purpose, the supplier shall agree with the inspector, the procedure and make available all

devices necessary for proper examination. The supplier shall supply all equipments,

blind flanges, fasteners and gaskets required for testing / hydro testing.

No cracks should be present on the autoclave shell or at the welding zones. An

examination for cracks will be performed by NAL before accepting the autoclave and the

autoclave supplier shall be responsible for all repairs during the warranty period.

L. PAINTING :

The painting of vessel shall be carried out after inspection, and examination for cracks.

All surfaces to be painted shall have surface preparation to clean out oil, grease, weld

sediments and rust. Thereafter, the interior of the shell, door should be sand blasted to a

white metal finish and painted with two coats of inorganic zinc chromate primer. This

shall be followed by two topcoats of high temperature aluminium paint of reputed make

(Suitable for 350 Deg C). Both paints shall be suitable for the elevated temperatures of

the shell. Application of paints shall be in accordance with the paint manufacturer’s

recommendations.

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The external surface of the vessel shall also be given same treatment. The exterior of the

shell and dishes should also be sand blasted to a white metal finish after cleaning out oil,

grease and rust. The prepared surface should be given with two coats of inorganic zinc

chromate primer of reputed make. No painting is required on the external surface of the

shell.

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TERMS AND CONDITIONS

1) DOCUMENTS, MANUALS, DRAWINGS AND INSPECTION REPORTS

The supplier shall submit 3 copies each of fabrication drawings, test certificates of

materials, inspection reports, manufacturer’s test records certified by approved inspection

agency and 3 sets of “As built” drawings for the vessel and other accessories if any.

NAL is an ISO 9001- 2000 certified organisation and therefore it is mandatory that all

documents shall confirm to ISO standards.

2) WARRANTY

The equipment supplied by the supplier (including bought out items) must be guaranteed

for raw materials and workmanship for a period of 18 months after being put in

operation at NAL and accepted by NAL. The firm has to submit the 10% of the order

value as a performance Bank guarantee for the guarantee period.

During the warranty period, all the defective parts should be replaced by the contractor to

NAL’s satisfaction, free of cost.

3. DELIVERY

The delivery period is 4 months from the date of purchase order. The firm has to include

time schedule bar chart clearly indicating the various events such as.

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4) QUALITY & WORKMANSHIP

The quality and workmanship shall comply with the specifications in all respects and to

the satisfaction of NAL. The firm should get the autoclave shell certified by approved

inspection agency.

5) DESIGN MODIFICATIONS, IMPROVEMENTS

NAL reserves the right to change the design at any stage of fabrication of autoclave shell.

But these changes will not be on over all dimensions of the shell. Generally changes may

be of minor in nature and to meet any assembly problems if it occurs. The supplier

should not modify any approved drawing without written permission from NAL.

6) SECURITY OF TECHNICAL DATA

All the technical specifications, drawings supplied by NAL is proprietary drawings of

NAL should be kept confidential. These documents should not be distributed. No

copies or excerpts should be made without the prior written consent of NAL.

7) PACKING, SHIPPING AND OFF – LOADING AT SITE

The contractor shall at his own expenses arrange for the system to be crated suitably

depending on the mode of transport.

The system shall be carefully and securely packed so as best to avoid damage during

transit. All the cases should contain packing slips detailing the contents.

. The off loading of equipment at NAL, and positioning at the final place of

commissioning is the responsibility of the supplier.

8) INSURANCE

The supplier shall arrange the insurance for loading, transit, off-loading, storage, erection

and commissioning in respect of the equipment to cover all risks up to the commissioning

stage. In the event of any damage (or) loss of equipment or spares, the supplier shall take

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appropriate action to replace or repair such equipment / spares and lodge their claim on

the insurance company.

9) LIQUIDATED DAMAGES

Time is of essence of this contract and this work has to be executed on a turn-key basis

and completed in all respect including commissioning within a stipulated time. In the

even of delay in the scheduled commissioning date, the liquidated damages will be

recovered as per the rules in force.

BRIEF OUTLINE OF ACCEPTANCE TESTS

1) NAL approved third party inspection agency shall be the inspecting agency for

the job at the manufacturer’s works.

2) All the fabrication work carried out at manufacturer’s works shall be inspected by

the inspecting agency as per the approved quality plan to meet the requirements of

IS 2825/ASME, Sec VIII, Div.1 code for unfired pressure vessels

3) Pneumatic testing has to be conducted at NAL as hydro testing cannot be carried

out. .

4) Sand blasting and painting as per the specification.