diesel hydrotreater specification-reactors

of 34

HINDUSTAN PETROLEUM CORPORATION LTD.

MUMBAI

DIESEL HYDROTREATER

TITLE: JOB SPECIFICATION – REACTORS

DOCUMENT NO. : 44LK-5100-00-V.02-0114-A4

Rev No.

Issue Date

Pages Rev Description Prepared By

Checked By

Approved By

0 14.08.2008 34 ISSUED FOR ENQUIRY SNK CR HSC

1 19.12.2008 34 Revised as marked and issued SNK CR HSC

Jacobs

HPCL-MUMBAI Job specification of 34

44LK-5100 For Reactors Rev 1

Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008

44LK-5100-00-V.02-0114-A4-Job specification-Reactors

TABLE OF CONTENTS 1.0 Scope of supply 2.0 General

3.0 Design

4.0 Reactor construction 5.0 Inspection and testing

6.0 Chemical analysis

7.0 Test specimens 8.0 Painting

9.0 Guarantees 10.0 Instructions to vendor for quality requirements

11.0 Instructions to vendor 12.0 Unit rates for addition/deletion

13.0 Vendor data requirements 14.0 Specification for welding consumables for reactor

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


1.0 Scope of supply

1.1 Reactor body �� Reactor with all nozzles, with skirt and anchor chairs �� Skirt with access openings with cover, skirt vents and forged ‘Y’ section near bottom

dished end and skirt junction �� Top removable spool piece with reduction flange, pipe, elbow and flange along with

gaskets and fasteners, filler & blind flange as applicable �� Blind covers for catalyst outlet nozzle along with gaskets, stopper arrangement

including plastic stopper and fasteners �� Companion flange for quench nozzle along with gaskets and fasteners �� Companion flange for outlet collector nozzle along with gaskets and fasteners

�� Blind flanges for all thermowell nozzles through which thermo couples are inserted �� All items specifically not covered above and also not covered in Owner’s scope but

required for completing the work in all respects 1.2 Internals �� Inlet diffuser / Inlet pipe / Inlet Basket, as applicable and specified in data sheets �� Rough liquid distribution tray along with support beams and support rings �� Vapour / liquid distribution tray along with support beams and support rings

�� Liquid collection tray along with support beams and support rings �� Quench distributor �� Mixing chamber

�� Skin thermo couples including supports �� Internals excluding Catalyst bed and Ceramic balls �� Catalyst support grid tray and support beams along with all internals as required

�� Continuous support rings for supports grids to be provided as integral part of forged

shells in case shell are considered from forged materials

In case certain shell courses are considered from plate materials, shell courses with support rings shall be can be considered as forged shells with integral support rings

�� Complete thermowell assembly and accessories along with supports �� Thermocouples for thermowells including support pads etc as required �� Internal fasteners

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


�� Outlet collector near bottom head �� Rope packing, wire rope caulking, graphite gaskets and any other sealing objects �� All internals shall be match marked and assembled at shop. Subsequently Reactor

shall be delivered with these internals duly installed at vendor’s shop. �� All items specifically not covered above and also not covered in Owner’s scope but

required for completing the work in all respects 1.3 Accessories �� Name plate with bracket (Standard + ASME code stamping name plate) �� Cage type Insulation supports

�� Lifting cover on top of top man hole and tailing lug on skirt anchor chair �� Cleats for Fireproofing on skirt �� Washers for anchor chairs �� Ladder rungs inside the skirt �� Anchor bolts

1.4 Miscellaneous

�� Earthing cleats �� Seal blankets and rope packing �� Blind flanges, bolting and gaskets for hydrotest

�� Shipping steel skid �� Bolt tightening device with accessories for inlet and outlet nozzles �� All accessories for welding, preheating, ISR, PWHT etc. as required at shop

�� Blind covers for all nozzles including bolting and gaskets for shipping �� Nitrogen blanketing during shipment �� Template for Reactor anchor chair 1.5 Spare parts 1 For mandatory, Erection & Commissioning spares refer spares list attached elsewhere in the

tender / amendment document.

1.6 Vendor’s scope of supply �� Complete design of the equipment including FE analysis and strength calculations

and approval

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


�� Preparation of General Arrangement drawings, detail drawings including part list,

internals and arrangement for thermocouple drawings and obtaining approval from Jacobs and AE

�� Procurement of internals shall be from Licensor’s approved vendors only �� Fabrication and assembly of all internals on shop floor including PWHT

�� In case of PWHT, vendor shall ensure that 2 nos. of extra heat treatment cycles will be made available to client for future repairs

�� Assembly of all internals at shop including fixing of all temporary supports, wedges,

clamps after checking required fitting and gap. Reactor shall be delivered with Internals duly assembled

�� Fixing and assembly of internals at shop �� Fabrication at shop, completing the reactor in shop in all respects as specified in the

requisition �� Conducting all NDE tests as per this specification / Licensor’s specifications / code

requirements �� Stage wise inspection as per ASME stamp requirements �� Surface preparation and 1

st coat of painting on outside surfaces

�� ASME code stamping, Preparation and certification of MDR by a Registered

Professional Engineer (PE) as per code requirements. User’s Design specification (UDS) duly certified by PE will be supplied by Jacobs

�� Transportation of Reactor to site in single piece as a separate price for all Indian

vendors and in case of foreign vendors transportation shall be to Mumbai port

�� Hydro-testing, cleaning, drying �� All activities not specifically mentioned but required to complete the reactors in all

respects as per drawings, Licensor specifications, codes, Standards and instructions of authorized inspector

1.7 Owner’s scope of supply (see 1.9) �� Foundation �� Catalyst, Ceramic balls

�� Insulation and Fire proofing �� Permanent platforms and ladders �� Unloading of equipment at site

1.8 All the technical queries and technical documents pertaining to Reactors of Mumbai Refinery shall be addressed to Jacobs Engineering India Pvt. Ltd.

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


Method of communication shall be as per details mentioned elsewhere in the commercial

section of enquiry documents. 1.9 In case of LEPCC tender, vendor shall be treated as LEPCC Contractor. Scope

mentioned above as Owner’s scope shall be treated as part of LEPCC contractor 1.10 In case of LEPCC, if Reactor MOC & design conditions do not call for certain requirements

specified in this specification, Contractor shall bring the same to Jacobs notice and get due clarifications.

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


2.0 GENERAL 2.1 Reactors shall be designed, fabricated, inspected, tested, certified and documented in

accordance with the ASME Sec VIII, Div 1 or 2 code, Edition 2007 and additional requirements stipulated herein. Any other applicable code / standard shall also be of latest edition. Any ambiguity or contradiction shall be resolved considering the most stringent in the following order:

i. Licensor’s standards

ii. Licensor’s drawings

iii. Requirements of this specification

iv. Design codes

2.2 Reactor shell shall be welded construction from forged shell components. In case vendor

proposes to use plate shells, shell portion at internal support ring shall be of forged material 2.3 End closures shall be 2:1 ellipsoidal type formed in single piece or hemi spherical. 2.4 Each Reactor shall be ASME code stamped. Stage wise and final inspection of each

Reactor and its components shall be carried out by one of the following inspection agencies: i. Lloyds Register of Shipping and Industrial Services (LRIS) ii. CEIL iii. DNV iv. TUV India Private Ltd. v. TUV South Asia Private Ltd. vi. HSB All materials including those used for internals shall be procured with stage wise inspections

by TPI at mills. The cost of TPI and code stamping shall be borne by the vendor. 2.5 Design shall be checked for testing the Reactors in vertical condition on foundation as site 2.6 Thickness shown in the Mechanical data sheets is minimum and indicative. Thickness shall

be recalculated by vendor and if required by stress analysis vendor shall use higher thickness without any cost implication to client. Thus complete design responsibility will be in vendor’s scope.

2.7 Details of anchor chair shall be preferably as per Jacob standards. Base ring thickness as

shown in the sketch, compression ring thickness, gussets thickness shall be recalculated by vendor and if required higher thickness shall be used.

2.8 Reactor shall be transported in single piece with internals duly installed. Vendor shall confirm the shell thickness and head thickness. Vendor shall indicate Reactor’s empty weight, operating weight, weight of internals

separately along with their offer at bid stage itself. 2.9 Foundation loads indicating Empty weight, Operating weight, Hydro test weight, Wind

moment & seismic moment in empty, operating & Hydro (with 50% of wind only) shall be furnished within 4 weeks from the date of LOI. (Not Applicable in case of LEPCC)

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


3.0 DESIGN 3.1 User’s Design Specification (UDS) Vendor shall prepare User’s Design Specification based on Licensor’s drawings and all

specifications and get certified by a registered professional engineer as per code requirements.

3.2 Manufacturer’s Design Report (MDR) MDR shall be prepared by the vendor in accordance with code requirements and shall be

certified by a registered Professional Engineer. Cost shall be borne by vendor. MDR shall include, as a minimum, the following:

− Calculation for shell and formed head thickness as per code including fatigue analysis as per Div 2, as applicable

− Strength calculations for skirt, anchor chair

− Strength calculations for top lifting cover, tailing lug

− Temperature distribution across shell/ head thickness, attachments, shell, head and skirt

junction

− All loads for foundation

Stresses at following portions of the vessel at steady state condition are to be analysed

using the computer program in accordance with code, considering all the loadings, thermal conditions and their configurations.

Vendor shall give description of computer program along with assumptions and carry out

complete analysis and furnish computer output results. Computer programs shall have third party validation or in case of in-house program hand calculations shall be submitted.

• Analysis of shell and head away from discontinuity for loadings including thermal

• Complete stress analysis of each nozzle at all discontinuities

• Bottom head to outlet nozzle, shell to bottom head and skirt junction

• Internal supports to shell/head junction

• Manway to head, shell to top head

• Shell to quench nozzle / Outlet nozzle junction

• Complete analysis for lifting (with fixed internals) considering all loads and impact factor

of 2.0

• Check for cyclic loading criteria as per Div 2

3.3 Some important requirements for local stress analysis are highlighted below: Finite Element Analysis for local stress analysis at discontinuities shall be carried out using

three dimensional (3D) solid elements or axisymmetric solid elements (if applicable) whenever any component (vessel, nozzle etc.) at the intersection has a ratio of minimum mean radius of curvature to thickness less than 10.0

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


In the FEM model, the length of any component from the intersection shall be sufficiently large (normally not less than three times of square roof of RT, where R is mean radius of curvature and T is the thickness of the component) so that the effect of junction discontinuity dies down completely within the modelled portion and the effect of assumed boundary conditions does not influence the results at the region of discontinuity.

Appropriate boundary conditions shall be prescribed so that the stresses at or near the

boundary are reasonably close to the state of stress in the absence of the discontinuity. The elements used in the discretisation of the FEM model shall be well shaped. The aspect

ratio of an element near the intersection shall not exceed 5. The maximum value of aspect ratio of an element in the entire model shall be limited to 6.

Categorization of stresses shall be done as per code and checked against allowable values. Sections for linearisation, if used, shall pass through the thickness of shell /head/nozzle

walls. Stress intensity checks must be carried out at sections at the maximum stress locations in the intersecting components.

Peak stress intensity exceeding three times the basic allowable stress intensity (Sm) shall

be checked against its allowable value Sa as per Clause 4.135 of appendix - 4 of ASME Sec.VIII Div.2.

Maximum allowable compressive stress for skirt of reactors shall be calculated as per ASME

Sec VIII Div 1. The stress analysis report shall include: a) A brief description of the program used for the analysis to understand the applicability,

input, output and validation of the software. b) Copy of any literature referred in the report c) Basic inputs (geometrical parameters, loading etc.) for each model d) Lengths of the modelled portions for different components at the junction e) Prescribed boundary conditions in each model f) Points of application of the external loading (nozzle loads, seismic load etc.) and

basis/source of external loading considered for analysis. g) Description (with supporting literature) of any equivalent mathematical model used for

the application of loads h) Type (s) of elements used in analysis i) A report on checking for aspect ratio and skewed angle for the elements j) Colour plots of stress contours or any other items, wherever applicable. Black and white

plots are not acceptable. k) Summary of stress intensities (membrane, bending and total) at critical locations /

sections for all individual load cases separately (e.g. pressure load, individual nozzle load components, thermal load, seismic load) as well as for all relevant load combinations

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


The locations of these stresses must be clearly shown in the model mentioning the corresponding element / node numbers.

l) Establishment of the local nature of discontinuity stress by indicating the maximum

extent of spread in terms of square root of RT m) Codal stress intensity checks for all categories of stresses for all relevant load

combinations A stress analysis report which ignores the above requirements is liable to be rejected. 3.3.1 In case of Div 2 Reactors, FE analysis shall be carried out for the following :

− Top head to shell / Nozzle Junction

− Bottom head to skirt / shell and Nozzle orientation

− Catalyst support ring to shell

− Top head to shell / nozzle junction during lifting

3.4 Calculation of the thermal gradient along the height of skirt under steady state conditions

with the inside of the vessel at operating temperature and with the vessel insulated as specified in Licensor’s specifications and drawings. Reactors shall be insulated as per Process licensor’s requirements.

3.5 Calculation for reinforcement of all nozzles, man ways and other shell or head penetrations

shall be as per code. Excess thickness available in head / shell shall not be considered for reinforcement

calculations. Area required to be compensated for reinforcement shall be based on nominal thickness used.

All nozzles shall be Self-reinforced nozzles and when forged shell is used, SR nozzles shall

be part of the main shell forging 3.6 All flanges shall be designed / checked as per ASME Section VIII Div. 1 Appendix 2 and

blind flanges as per UG-34 of ASME Sec. VIII Div. 1. Flanges conforming to ASME B 16.5/ASME B 16.47 series B shall be used for process nozzles.

Specially designed flanges, violating standard flange parameters for reducing their weights

shall not be permitted. All flanges shall also be checked for actual piping loads as and when the flexibility analysis reports of connected piping systems are available.

3.7 Wind and seismic requirements Wind loads shall be as per IS 875 (including latest amendment) considering the following

parameters: Basic wind speed = Vb = As per IS 875 Probability factor = K1 = 1.0 Height & terrain factor = K2 = As per IS 875 as applicable for Class A/B/C with terrain category of 3 1 Topography factor = K3 = 1.0

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


Force coefficient = Cf = 0.7 (for cylindrical construction) Contingency factor of 1.1 shall be used on basic wind pressure

3.8 Seismic design shall be as per latest edition of IS 1893 including all relevant parts 3.9 Design loadings While designing the reactors following system of loading conditions shall be adopted. Erection Condition a) Weight of reactor excluding all removable internals, insulation, fireproofing. b) Full wind load or earthquake load whichever is governing. 2.10 Testing Condition a) Test pressure (Based on maximum allowable pressure in New and Cold condition) to

be measured at top most position b) Weight of water c) Weight of reactor less all removable internals, insulation, fire proofing d) 50% wind load 3.11 Normal Operation Condition a) Design Pressure at design temperature. b) Operating weight of fluid c) Dead weight of reactors including all internals, insulation, fire proofing, piping,

catalyst, etc d) Wind or earthquake load whichever is governing e) Piping reaction forces f) Impact loads including fluctuating pressure and temperature 3.12 Regeneration Condition a) Pressure and temperature specified in assembly drawings. b) Operating weight of fluid c) Dead weight of reactors including all internals, insulation, fire proofing, piping,

catalyst, etc d) Wind or earthquake load whichever is governing. e) Piping reaction forces 3.13 Piping loads

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


Refer 4401LK5100-00-V.02-0113-A4 Nozzle loadings on high pressure vessels for

piping loads 3.14 Materials Refer Mechanical data sheet / Licensor data sheet for details. Materials for internals shall be

as per process data sheet Approximately top 1000 mm (2000 mm in case of design temp > 400

0C) of skirt height shall

be of same materials as shell base materials and same shall be connected to Y section. Remaining portion shall be of SA 516 Gr 70. 1

The butt weld joint between the dished end and Y ring should be easily accessible

when reactor is on foundation for conducting UT tests, if required, after erection. 3.15 Chemical tests Chemical analysis shall be conducted by the instrument Texas Nuclear Analyser Model 9277

or equivalent. 3.16 Weld metal All welding consumables, as a minimum shall meet Licensor’s specification requirements. 3.17 Mechanical Test All mechanical tests shall be established after simulation of actual heat treatments of test

specimens in accordance with Mandatory requirements of code ASME Sec. VIII Div.2. Two additional PWHT cycles to allow future repairs shall also be considered. Vendor

shall check the actual cycles and confirm that this is feasible. The test results including details of heat treatment shall be reported and documented. The

mechanical tests shall include tensile, impact, step cooling etc. 3.19 Tensile Tests Base Metal a) Tensile test at room temperature and hot tensile test shall be conducted on each shell

ring, head forging and Y-section forged ring with the following requirements: • Two sets (min.) from each block location, one being near the heat-treated

surface, other being representative of ½ T locations. The specimen shall be taken tangential to the forging.

• Same shall be applicable for nozzle forgings and cover forgings. One set of

specimen each shall be taken at a depth of ½ T. b) Two tensile tests at room temperature and hot tensile test on each plate shall be

conducted. Coupons shall be taken transverse to the direction of final rolling. c) One through thickness tensile test shall be carried out from each plate as per

specification ASTM A-770. Minimum reduction in area shall not be less than 35%.

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


As specified in code, hot tensile tests shall be for information only and not for rejection. In case of large variation in tested results and code specified values, vendor shall take suitable precautionary steps with respect to quality of ordered materials.

3.20 All weld metal tensile tests at room temperature as well as high temperature tests shall meet

the minimum requirement of the base metal. 3.21 Impact tests Base metal and Production test coupons a) Charpy V-notch Impact test shall be carried out at temperature of – 30ºC. Average of

three impact values shall not be less than the values specified for specific materials as per code.

b) Charpy V-notch impact test specimens shall be taken transverse to the direction of

primary rolling and shall be taken at ½ T. For forgings Charpy V-notch bars shall be taken transverse to direction of greatest elongation during forging and shall be taken at ½ T.

Forging test specimens shall be taken from actual forgings. For weld metal Charpy V-

notch bars shall be taken from centre of material at ½ T, in addition to code required bars within 1/16” of the surface. For HAZ Charpy V-notch bars shall be at ½ T and for all materials except specified above shall be as per code requirement.

c) Impact energy versus temperature (transition) curves shall be developed for each

heat of plate and/ or forging (small nozzle forgings shall be tested on a lot basis) and for weldments (all weld coupon) consisting of each batch or heat of welding consumables, covered electrodes, and wire–flux combinations for each weld process used in production welds.

i) A minimum of six sets of three impact tests of fully heat-treated material (of

material subjected to the same heat treatment as the completed reactor) shall be performed. Sample location of the three specimens shall be as specified by ASME code.

(ii) The six sets of impact tests shall be performed at different temperatures but

shall include the minimum test temperature specified for the equipment. The generated transition curve shall clearly define the transition zone and the upper shelf. The maximum test temperature shall correspond to the upper shelf energy level.

3.22 Step cool tests (Temper Embrittement tests) Step cool test to determine temper embrittlement resistance shall be carried out at mill in

accordance with procedure approved by Process Licensor and reviewed by Jacobs/client. a) Step cool tests shall be performed at mill on a fully heat treated samples from each

heat of plate and /or forging (small nozzle forgings may be tested on a lot basis) and for weldments (all weld coupon) consisting of each batch or heat of welding consumables, covered electrodes and wire-flux combinations for each weld process used in production welds in a reputed lab.

b) Impact tests of each Step Cool Test sample shall be performed and transition curve

shall be developed as per Licensor specification as per code requirements

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


Acceptance criteria for step cooling shall be included in procedure for step cooling treatment for components like base metal, base metal HAZ and weld metal.

3.23 Hardness Hardness of forgings and plates shall meet requirements of Process Licensor’s project

specification. Refer Jacob specifications for hardness limitation on (after PWHT) on weld metal, HAZ and base metal. Hardness measurement shall be conducted by portable hardness tester type EQUOTIP or equivalent.

3.24 Weld overlay Weld overlay cladding on reactor wherever required shall be in two layers only. Fabricator

shall guarantee 3 mm thickness of undiluted type 347 SS weld overlay out of total weld deposit thickness. First layer of weld overlay shall be obtained by 309 L for reactors.

Fabricator proposing single layer of weld overlay shall have done the same for at least 2

reactors of similar material and these shall also be in operation. Fabricator shall furnish details for the same. However, weld overlay applied to flange face and support ring surface shall be of minimum 2 layers.

Final pass of weld overlay on inside corners of nozzles, corners of weld built-up support

rings and solid plate attached cleats/rings shall be done after final PWHT. 3.25 Disbonding tests Disbonding tests for weld overlay shall be carried out in line with ASTM G 146 to eliminate or

minimize future disbonding of the stainless steel weld overlay. Fresh hydrogen disbonding test is required. No past Hydrogen disbanding test qualification

is acceptable. The procedure of Hydrogen disbanding test shall be as follows: A. Cooling of Test

Specimen: Intermediate cooling rates between 450

0C/hr and 150

0C/hr

shall be achieved by blowing air in the open Autoclave. B. Exposure Conditions: The hydrogen charging conditions shall not be less than the

design Pressure and design temperature of Reactors. C. Evaluation Criteria: UT examination of test specimen are performed before and

2 weeks after exposure to hydrogen atmosphere. All discontinuities producing first reflection equal to or exceeding the calibration amplitude (80% of CRT) shall be unacceptable.

D. Acceptance criteria shall be zero percent disbanding. 3.26 Radiography during PWHT For all long seams and cir seams RT shall be carried out before PWHT and recordable UT

(TOFD) shall be carried out after PWHT, as per code case 2235. For nozzle to shall or head joints, RT shall be carried out before PWHT and manual UT after

PWHT. 3.27 Ferrite check

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


Ferrite check is to be included in vendor’s scope. Acceptable range is 3 to 8. However, in case of unforeseen problems, vendor shall target the upper limit of the FN to 8 in the applicable WPS and PQR and achieve in production values ranging up to 8 + 2.2 = 10.2 FN, in line with the tolerance range measurements of FN as per AWS 4.2 standard procedure SFA 5.9 par. A7.5 of ASME II Part C

Thorough checking of final weld deposit before final weld deposit and before final PWHT

shall be carried out for controlling FN. Two tests on each ring, two on each head, two on each girth seam, two on each nozzle and

one per sealing surface of each nozzle.

3.28 Intermediate SR and dehydrogenation heat treatment

Intermediate SR for hoop & cir seams, nozzle and shell / dish end, ring to shell joints shall be carried out and SR of complete vessel shall be carried out

2¼Cr1MoV material cracks in the welds, before final PWHT is applied, may occur due to the

combined effect of hydrogen and residual stresses, associated with the low toughness of the weld metal in the “as welded conditions”.

An intermediate stress relief at 650-670 °C on all welds which are restrained and therefore

subjected to high residual stresses, e.g. nozzle attachment welds and internal weld build up rings can be applied.

Whereas for the non-restrained welds (longitudinal and circumferential welds) a

dehydrogenation heat treatment at 350°C can be carried out to outgas hydrogen from the weld metal and to prevent risk of cracking, provided same is acceptable to Licensor

The duration of each ISR is 4 hours so as to minimize the use of tempering time allowed for

the steel. 4.0 REACTOR CONSTRUCTION Reactor construction shall be as per Licensor’s specifications 4.1 Anchor Bolt Anchor bolts shall meet Process licensor’s specification requirements and Mechanical data

sheet. 4.2 Internals Vendor shall submit experience list for both design and fabrication of internals at bid stage

itself. In case vendor is subcontracting the design and fabrication of internals, then experience for both design and fabrication of internals shall be submitted for subcontractor at bid stage itself.

Wherever Licensor’s approved vendor list is provided for internals, Reactor vendor shall

consider the same vendors and no deviation will be accepted to the vendor list unless specific approval is obtained from Licensor during pre-order (enquiry) stage itself.

In case vendor is designing the internals and only fabrication is subcontracted then vendor’s

experience of design of internals shall be submitted separately at bid stage itself a) Top surface of the support rings after overlay shall have a smooth finish and all the

internals shall have a proper fit-up.

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


Lower and upper corners of support-rings shall have generous radius before weld

overlay and after smooth grinding the final layer of weld overlay. Corners radii shall not be less than 25 mm.

b) Thickness of support rings for catalyst beds shall be as per Licensor drawings. If

required by stress analysis, thickness of rings shall be increased. c) Thickness of support rings for liquid distributor and quench mixing trays shall be as

per Licensor drawings. Thickness shall be increased if required by stress analysis. d) All internals including beams for support grids for catalyst, pipe-fittings, flanges and

grid support beams shall be as per Licensor specifications. If support beam details are not made available, vendor shall decide the same as per design calculations

e) All internals like liquid distribution trays, quench mixing trays, outlet collector, support

beams, quench nozzle etc., shall be trial assembled in shop on actual shell and checked for required fitting and gap before and after PWHT.

4.3 General, Welding, Packing and Forwarding 1) All flanges shall be of forged and shall be lined with weld deposit in two layers as per

Licensor specifications. 2) There shall be a minimum clear distance of minimum 200mm between weld seams

of shell/head and any attachments such as nozzles, internals support rings, cleats, etc., where R is radius of shell/head and T is thickness of shell/head.

4) Supplier shall note that sufficient and requisite number of production test coupons

shall be made available of different heat treatment cycle for building up the history of heat treatment. This history would help to know how much excess heat treatment the vessel can take during repairs at vendor shop or during operation. Similarly a history shall also be built up for intermediate stress relieving.

5) Intermediate stress relief (ISR) shall be conducted as per procedure approved by

Jacobs/Owner/Licensor. A low temperature dehydrogenation heat treatment (DHT) instead of ISR may be allowed on confirmation from Licensors. Vendor shall check the requirement of ISR and comply with code requirements.

6) PWHT for the equipment shall include the skirt and anchor block at skirt-base. 7) Supplier shall provide sea worthy packing and pressurized N2 filling arrangement for

the reactor with N2 cylinders and pressure gauges. 8) The tolerance on diameter shall be restricted to + 0.25% of reactor inside diameter. 9) For hydro test, supplier shall note that chloride content of hydro test water shall be

limited to 25 ppm only (Chemical analysis of the water sample shall be presented to the inspector).

10) Also hydro test gaskets shall be of same specification as that of service gaskets.

After hydro test, all gaskets used for hydro test shall be replaced with new gaskets. After final hydro test and subsequent drying of internal surfaces, the reactor shall be

boxed up to fill nitrogen at 0.5 kg/cm2

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


5.0 INSPECTION AND TESTING 5.1 Shell forgings / Plates a) All Plates / forgings shall be 100% ultrasonically examined before and after hot

forming in accordance with ASME Section VIII Div. 1 after the specified heat treatment.

In addition 100% ultrasonic examination shall be carried out within 2t of material

thickness of all weld joints prior to welding as per requirements of ASTM A578. The maximum acceptable indication shall be 50% or greater loss of back reflection within an inch diameter circle.

b) Magnetic particle examination by wet fluorescent technique shall be performed

before welding on all bevels as per code ASME Sec. VIII Div. 1 c) Liquid penetrant examination shall be conducted on all inner surfaces after hot

forming and heat treatment 5.2 Fittings All fittings shall be of forged construction. Ultrasonic examination shall be conducted on fittings after hot forming and heat treatment as

per code and Sec. V. Magnetic particle examination by wet fluorescent technique shall be done on all edges to be

welded after final machining. Liquid penetrant examination on all outer surface of elbows after forming and heat treatment

as per ASME Sec. VIII Div. 1 and Sec. V. 5.3 Bolting Magnetic particle examination shall be conducted on entire surface before machining of

threaded portion 5.4 Flange forgings Ultrasonic examination shall be carried out on entire volume after machining. PT examination shall be carried out on entire volume after final machining. 5.5 Internals All internal material shall conform to materials as specified in Process data sheet − In case of SS 321, raw materials used for internals shall be procured in solution-

annealed condition. − All formed components involving deep drawing/bending shall be solution annealed

after forming/bending and hardness shall not exceed 180 BHN. Intermediate solution annealing may be carried out, if required, to meet hardness requirements.

− All dimensional checks shall be carried out after any heat treatment, if carried out.

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


− 10% of components which are deep drawn / bent shall be liquid penetrant examined. If the rejection is more than 50%, liquid penetrant examination shall be conducted for the entire lot for each reactor.

5.6 Radiography For Radiography in relation with final PWHT, please refer respective clauses mentioned else

where in the specification. a) 100% of all Category A, B and D welded joints before weld overlay and after ISR

(category C joints with corner welds are not permitted) b) 100% of Category B joints in top inlet and bottom outlet c) 100% of all Cr – Mo butt welds of skirt, attachment weld of skirt to Y – section forged

ring (if forged Y ring is provided) and butt weld of Cr – Mo to CS joint of skirt. d) 100% of all circumferential seams of skirt in CS portion. All other butt-welds of skirt in

CS portion shall be spot radiographed and shall include T – joints. e) Weld overlay surface shall be 100% DP tested after PWHT. f) Internal attachment welds shall be 100% DP tested after PWHT.

5.7 100% ultrasonic examination shall be carried out on the following: a) Category A, B and D joints in shell and head (after final PWHT) b) Category B joints in top inlet and bottom outlet (after final PWHT). c) Attachment weld of skirt to ‘Y’ section forged ring (if Y ring is provided) and all joints in

skirt (after final PWHT). d) Weld build-up of all internal support rings (if weld built up is proposed) after final

machining (after ISR) e) First layer of SS overlay (after ISR) f) Final layer of SS overlay (after final PWHT) h) All attachment welds. 5.8 Magnetic particle examination shall be done on the following: a) All inside surfaces of category A, B and D joints prior to weld overlay (after ISR) b) Back Chipped surfaces of category A, B and D joints (before ISR) c) After finish machining or grinding of weld build-up before overlay (after ISR) d) Temporary attachment welds and the area where temporary attachments and arc

strikes have been removed. e) All outside surfaces of category A, B and D joints by wet fluorescent technique after

final PWHT and after hydro test.

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


f) Inside and outside surface of attachment weld of skirt to Y – section forged ring after final PWHT.

g) Circumferential and longitudinal weld seams in support skirt (on both sides) after

hydro test. 5.9 100% liquid penetrant examination shall be done on the following as specified below: a) Full area of first layer of weld overlay cladding (after ISR). b) Full area of final layer of weld overlay cladding (after final PWHT) c) Gasket seating surface of nozzles (after hydro test) d) Outside surface of circumferential joints of top and bottom spools (after final PWHT) e) Weld overlay cladding where internals are to be welded. 5.10 Hardness Survey One hardness reading shall be taken on each shell section, head, nozzle, circumferential

weld girths, nozzle weld and weld heat affected zone after final PWHT. The Brinell hardness reading shall be as per Jacobs / Licensor specifications

6.0 Chemical analysis 6.1 Chemical analysis of Low alloy steel weld metal shall be done after welding: two per each

circumferential seam between head and shell, shell and shell and one per each nozzle attachment of weld of head and shell.

6.2 Weld overlay procedure qualification tests shall provide chemical analysis at different depths

to confirm that minimum 3 mm of uniform undiluted composition of SS347 is provided at the surface exposed to the environment.

7.0 TEST SPECIMENS (TO BE SUPPLIED WITH EACH REACTOR) Additional production test plates/forged piece that have gone through same cycles of

fabrication and heat treatment shall be supplied in sufficient quantities. These are required for mechanical tests such as hot and cold tensile tests, impacts tests (with and without step cooling), chemical analysis, etc. for future.

Such production test plates must represent each shell ring, each head, main weld girth,

nozzles and other important components. These plates / forging pieces must be clearly identified, marked and packed and shall be supplied along with each reactor vessel.

8.0 PAINTING In general 1

st coat of paint shall be applied using Heat resistant silicone aluminium paint (40-

50 Microns DFT) suitable upto 500 oC after surface preparation. Surface preparation shall

be done by shot blasting only with surface finish of SSPC-SP-10. Please refer project painting specification for more details

9.0 GAURANTEES All guarantees shall be as per tender requirements

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


Minimum stage-wise inspection requirements with Hold points by AE / TPI for bought out components:

S. NO. ITEMS/PROCEDURE WITNESS (HOLD POINT)

REVIEW APPROVAL

1 RAW MATERIAL AT MILL

Plates, nozzle forgings, raw materials for all internals

�

2. AT SHOP

A Material Certificates �

B PMI-all materials �

C QAP �

D WPS, PQR & Welder’s qualification / approval � �

E Welding consumable qualification � �

F

Manufacturing procedure including weld overlay procedure / sequences, heat treatment procedure (ISR, PWHT etc.), NDT procedure, NDT personnel qualification, hydro test procedure etc.

� �

G H2 disbonding test � �

H UT examination �

I RT � J MP examination � �

K Liquid penetrant examination �

L Chemical analysis and ferrite check of production alloy weld overlay.

�

M Chemical analysis of production welding of base metal

� �

N ISR & PWHT � �

O Hardness survey �

P Dimensional inspection �

Q Hydro test �

R Assembly of internals �

S Nitrogen filling at 0.5 kg/cm2 �

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


Notes: 1. Supplier shall prepare a comprehensive fabrication, inspection and test plan (QAP) indicating

clearly the hold points correlating the contract specifications and code requirement by third party as well as authorised ASME inspectors.

2. Supplier shall submit one copy of third party approved documents to Owner / Jacobs for final

approval by Jacobs/Owner 3. In case of conflict between AE / third party requirements and Owner / Jacobs requirements the

matter shall be referred to Jacobs /Owner in writing for resolution/decision.

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


10.0 INSTRUCTIONS TO VENDOR FOR QUALITY REQUIREMENTS

10.1 INTRODUCTION As a part of services rendered to the client, Jacobs purchases Product/Services for Projects

on behalf of Client (including in-house projects) from various vendors. 10.2 PURPOSE The purpose of this standard is to describe the Vendor Quality Data Requirements which

shall form a part of every material Requisition (MR)/Purchase Requisition (PR) released by Jacobs, so as to ensure that all purchased products/services consistently conform to planned quality and projects’s stated and implied needs are met to Client’s total satisfaction.

10.3 SCOPE The requirements of this standard are applicable to all Vendors for supply of Packages,

Equipments and Material which are purchased on behalf of Clients for Projects handled by Jacobs

10.4 DEFINITION “Vendor “means the person(s), firm, company, organisation from whom Jacobs procures

products/services on behalf of client, as a part of services rendered to the Client 10.4.1 “Contractor”, “Sub-contractor”, Sub-vendor”, Supplier”, Seller”, gents” are considered

synonymous to “Vendor”. 10.4.2 MR means Material Requisition and Purchase Requisition. 10.5 INSTRUCTIONS 10.5.1 Quality Assurance Plan Vendor during bidding stage, shall confirm compliance to his QUALITY ASSUARABCE (QA)

Pans (consisting of relevant Procedures covering various activities like design and engineering, material procurement, manufacturing, inspection and testing, documentation, despatch to site, erection and commissioning where applicable and maintenance of Quality records) which have already been approved at the time of vendor enlistment. In the post order stage, the vendor shall confirm the validity of their QA plans and submit only revisions/deviations if any to these plans, to the concerned Jacobs Inspector office/Third Party Inspection Agency for approval within 2 weeks from the date of receipt of PR.

10.5.2 Inspection and Test Plan Vendor shall submit Inspection and Test Plan for approval within 2 weeks of PR and before

commencement of manufacture to concerned Jacobs Inspection Office/Third Party Inspection Agency. The Inspection and Test Plan shall also cover “bought out” items from sub-vendors.

10.5.3 Drawing Schedule Vendor shall submit a total index of drawings and documents required for review/records

based on the Vendor Data requirement given in the PR along with the scheduled date of submission of each drawing/document within 2 weeks from Telefax/Letter of Intent. The Drawing schedule shall be specific with regard to drawing/document No., the exact title and the size of the drawings/documents.

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


10.5.4 Progress Report and schedule Vendor shall submit Monthly Progress Report and updated procurement, engineering and

Manufacturing Schedule every month, beginning within 2 weeks from Telefax/Letter of Intent.

10.5.5 Waiver and Deviation Vendor shall strictly comply with PR stipulation and no deviations shall be permitted.

However, if the need for deviation arises under exceptional circumstances, on the post-order stage, such deviation shall be subjected to the approval of Jacobs/OWNER and shall be submitted through Jacobs Regional Inspection Office in the prescribed “Concession Request / NCN” format as enclosed in the Attachments shall be followed.

10.5.6 Procurement of Bought out Materials All critical materials such as casting, forging, fittings, pressure holding parts, electrical and

instrument accessories etc. shall be purchased by the vendor from Jacobs approved supplier meeting Qualification Criteria stipulated if any. Vendor shall submit a list of bought out material and sub-vendors for these bought out materials for Jacobs approval within 2 weeks from Telefax/Letter of Intent.

10.5.7 Calibration Records Vendor shall use only calibrated measuring and test instruments and maintain calibration

records. Vendor shall furnish records of Calibration of measuring and test instruments including recalibration records to concerned Jacobs Inspection Office/Third Party Inspection Agency.

10.5.8 Inspection Test Status Inspection and Test status of product shall be identified by markings, authorised stamps,

tags, route cards, inspection records etc. during the course of manufacture to clearly indicate acceptance/rejection of tests/stages of inspection performed during its manufacturing cycle. The identification of inspection and test status shall be maintained and records thereof shall be submitted as and when demanded by Jacobs Inspection Engineer or Third Party Inspection Agency.

10.5.9 Quality Records Vendor shall maintain quality records as per his procedures. Inspection Reports and Test

Records shall be furnished to Jacobs Inspection Engineer or Third Party Inspection Agency. 10.5.10 Identification and Traceability Vendor shall establish and maintain a standard written procedure for identifying the products

from applicable drawings, specification or other documents during all stages of production, delivery and installation. A copy of this Standard procedure shall be made available at concerned Jacobs Inspection office. On job-to-job basis, vendor shall confirm its validity and only revisions/deviations, if any, shall be submitted for approval. Vendor shall ensure that each product, which is going in the process of fabrication / manufacturing / construction / erection, has proper identification throughout the process of including the final output.

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


10.5.11 Vendor Documents for Jacobs Review/records General i. All documents shall be in ENGLISH language and in M.K.S. system of units. ii. Review of the vendor Drawings by JACOBS would be only to review the

compatibility with basic design and concepts and in no way absolve the vendor of his responsibility to comply with PR requirements, applicable codes, specifications and statutory rules/regulations.

iii. Unless otherwise agreed, submission of Documents fore Review/Records shall

commence within 4 weeks from the date of Telefax/Letter of Intent. iv. Unless otherwise agreed, vendor shall submit all drawings and documents in

number of copies as stipulated in the Vendor Data Requirement Form, along with Document Index. The Documents shall be supplied in soft copies where specified.

10.5.11.1 A blank space duly marked measuring 75 mm (W) x 38 mm (H) shall be provided on the

body of all Vendor Drawings for marking of review Codes by Jacobs 10.5.11.2 Documents for Review and Documents for Records shall be submitted in separate folders

with separate covering letter to facilitate expeditious processing at Jacobs 10.5.11.3 Before forwarding the drawings and documents, vendor shall ensure that the following

information are properly entered in each drawings: PURCHASE REQUISITION: : NAME OF EQUIPMENT : EQUIPMENT TAG NO. : NAME OF PROJECT : CLIENT : DRAWING/DOCUMENT TITLE : DRAWING/DOCUMENT NO. : REVISION AND DATE : JACOBS VENDOR DOC NO. : 10.5.11.4 The Drawings/Documents shall be checked, approved and duly signed/stamped by vendor

before submission. Revision Number shall be changed during submission of the revised Vendor Documents and revisions shall be highlighted by clouds. Before submitting any sub-vendor drawings for review by Jacobs, the vendor shall ensure that these sub-vendor drawings have been reviewed, commented and stamped by the vendor. Direct submission of sub-vendor’s drawings without vendor’s review shall not be entertained.

10.5.11.5 While resubmitting the Drawings/Documents, the vendor shall, in a covering letter,

specifically confirm whether all the comments have been incorporated, if not, shall furnish reasons with justification.

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


10.5.11.7 Vendor shall forward all Drawings/Documents (transparencies and printed matter) to Jacobs Engineering India Pvt. Ltd., H&G House, Sector 11, CBD Belapur, Navi Mumbai 400614.

10.5.11.8 Documents Under Review Category Following review codes shall be used for review of Vendor Drawings/Documents: Review Code A - Comments as indicated, revise and resubmit; work may proceed

subject to incorporation of changes as indicated Review Code B - Comments as indicated, revise and resubmit; work may not proceed

Review Code C - Review not required; work may proceed

Review Code F - Final certified; work may proceed 10.5.11.9 Documents under Record Category Documents under this category are meant for Jacobs Records. These documents would not

be returned to vendor. However, comments, if any, will be communicated to vendor. 10.5.12 Final Documentations 10.5.12.1 Final Drawings/documents consisting of Technical Data Manual/Mechanical Catalogue is a

compilation of “as built” certified, drawings and data, manufacturing and test records, installation, operating and maintenance instructions. For drawings where Purchaser’s approval was required, the final certified drawings shall be included. Final Documents shall be legible photocopies in A4, A3 or A2 size only. The Purchase Requisition shall also form a part of final documentation.

10.5.12.2 Final Documentation shall be bound in Hard board folder(s) of size 265 mm x 315 mm (10

and a half inch x 12 and a half inch) and shall not be more than 90 mm thickness, it may be several volumes and each volumes shall have a volume number, index of volumes and index of contents of that particular volume.

10.5.12.3 Each volume shall contain a Title Block indicating Equipment Tag No., Equipment Name,

P.O./Purchase Requisition No., Name of project and name of Client. 10.6.0 ATTACHMENT Refer Attachments

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


11.0 INSTRUCTIONS TO VENDOR

11.1.0 Bidding instructions 11.1.1 Bidders to note that no correspondence whatsoever shall be entered into or entertained after

the bid submission 11.1.2 Bidders to note that they shall obtain all technical / commercial clarifications before submission

of price-bid 11.1.3 Bidder shall furnish quotations only for those items, which he can supply strictly as per MR

specifications including fulfilment of bidder’s qualification criteria. 11.1.4 11.1.5 The submission of prices by the bidder shall be constructed to mean that he has confirmed

compliance with all technical specifications of the corresponding item(s). 11.1.6 It is understood that a) The quoted price includes for the details and dimensions under “HOLD” in accordance

with details indicated on respective equipment Engineering Drawing. b) The weights indicated on Jacobs Mechanical Data Sheet do not form the basis for

offer, since these are approximations only. c) Spares are as required are considered for in the quoted price 11.2.0 Technical instructions 11.2.1 The shape of dished ends and overall height shall be as per engineering drawing. Minimum

thickness of shell and dished end shall be achieved taking into account thinning and scaling etc.

11.2.2 Dished ends and hot-formed pressure parts shall have 10% or 2mm (whichever is higher)

allowance for scaling and thinning, in order to achieve minimum thickness specified on the drawing.

11.2.3 a. Wherever hot forming and subsequent heat treatment is involved, adopted procedure

shall not impair the mechanical properties of the material beyond the limits specified in respective material specification.

b. For low temperature equipment and hot formed parts, number of production coupons and the tests thereon shall be as per material requisition.

11.2.4 Post weld heat treatment and all non-destructive testing like radiography, ultrasonic testing,

magnetic particle/dye penetrant examination etc. shall be conducted as per material requisition. 11.2.5 Transportation of equipment shall be in a single piece. 11.2.6 Workmanship and materials, in vendor’s scope of supply, shall be guaranteed. 11.2.7 The main equipment shall not be subcontracted, however the bought out items/components

can be sub-ordered or sub-contracted to Jacobs approved vendors/sub-contractors only. Bidder shall furnish documentary proof of their experience in the design and

procurement of internals of similar reactors.

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


In case sufficient experience is not available with the bidder for design and fabrication of

internals of similar reactors, bidder shall furnish the name and track record of back-up consultant along with the bid.

11.2.8 Client’s / Jacobs authorized expeditor / inspector may visit vendor’s shop for assessing the

progress of the job. Vendor shall provide all the required information and allow the authorised person to review the physical status of the job inside the shop.

When required / invited, vendor’s authorised person shall visit Jacobs / Client’s office for review

of the job progress. Vendor shall submit monthly progress report indicating engineering, procurement and

fabrication status (planned and actual) till the end of the job 11.3.0 General instructions 11.3.1 Raw material procurement may proceed prior to approval of vender drawings on the basis of

Purchase Requisition. 11.3.2 Material for shell, dished ends and skirt shall be considered as major raw material wherever

identification of major raw material in one of the payment milestone. 11.3.3 Final nozzle sizes (without any holds) shall be issued along with purchase requisition or latest

with in one month of Fax on intent. 11.3.4 Nozzle orientation of the equipment shall be issued latest by mid of contractual delivery

period reckoned from date of issue of Fax of intent. (Not Applicable in case of LEPCC) Pipe support cleat details, if any, shall be issued latest by 3 months before contractual

delivery date. (Not Applicable in case of LEPCC) 11.3.5 If any discrepancy is found during design and fabrication stages, the fabricator shall inform

Jacobs immediately and shall obtain necessary clarification/approval before proceeding with that portion of the job any further.

Jacobs review of fabricator’s drawings and documents must not be considered as a check and

shall not relieve the fabricator of his responsibilities to supply equipment as per requisition. Fabricator shall remain responsible for conflicts between his drawings/documents and JACOS drawings/documents.

11.3.6 English language and metric units shall be used in all documents. Drawings shall be prepared

in prescribed size as standardized by bureau of Indian standard (BIS) and shall be preferably in the sizes such as 210 x 297, 297 x 420, 420x 597, 597 x 841, 841 x 1189 mm.

11.3.7 All fabricator’s drawings submitted to Jacobs shall bear reference number and revision of

corresponding Jacobs drawings. In addition, it shall indicate item number, client’s name, project name, fabricator’s name, purchase order number, drawing number, revision number etc. all in the lower right hand corner. All revisions shall be clearly marked by encircling with

revision marks. 11.3.8 Submission of required drawings/documents shall be the responsibility of fabricator. In the

event of fabricator’s failure to meet this requirement, the supply of equipment shall be considered as incomplete.

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


11.3.9 Drawing index shall be prepared for each item giving serial number, description of drawing, drawing number and revision number. Updated index shall be forwarded along with each submission.

11.3.10 All drawings shall be thoroughly checked and duly signed by fabricator. Unchecked drawings

and drawings without revisions clearly marked shall be returned without review. Successive review of the same fabricator’s drawing shall apply only to Jacobs latest data sheet/comments on the previous revision. Drawings and documents returned to fabricator for revision shall be resubmitted preferably within ten days of receipt.

11.3.11 Dimensions of all flanges shall be as per ASME B 16.5 for nozzle sizes 600NB and below and

as per ASME B 16.47 series B for sizes greater than 600NB, unless otherwise stated. 11.3.12 Fabrication drawings shall be submitted in following stages: • General arrangement drawing indicating design data, fabricated equipment’s weight,

general notes, nozzle schedule, derail of shell, heads, skirt/supporting arrangement, main weld seam, nozzle orientation plan etc.

• Complete Design Calculation of main reactor including nozzle reinforcement,

calculations, FE analysis as defined in specification • Details of all nozzles, manholes, accessories etc • Bill of material for each item showing part size, quantity, material specification, scope of

supply and weight etc • Details of internals such as inlet distributor, outlet collector, liquid distributor trays,

distributor trays, quench mixing trays, catalyst support grid etc • Design calculations of all internals

• Bill of material for each item showing part size, quantity, material specification, scope of

supply and weight etc 11.3.13 After receipt of order, fabricator shall submit to Jacobs, the planning of fabrication which shall

indicate the details and scheduled date of:

• Sub orders • Purchase of materials such as shell forgings, plates, pipes, forged flanges, bolting,

gaskets, etc

• Start of fabrication of dished ends and shell, welding of shell and heads

• Welding of nozzles and external attachments like skin thermocouple mounting

• Phased programme of shop fabrication of equipment section, shop assembly, testing

and dispatch to site This planning shall be established to extend from purchasing of equipment components to the

end of fabrication and delivery of equipment.

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


11.3.14 Vendor shall submit a list of those drawings, which are to be submitted for review to Jacobs

along with the submission dates for each drawing within 15 days of placement of FOI. Vendor shall strictly adhere to this drawing submission schedule.

11.3.15 All drawings shall be drawn in AUTOCAD latest version. No hand drawn drawings shall be

accepted. All residual calculations shall be computerised. 11.3.16 Documents and letters shall be furnished in electronic format. The software used shall be MS

OFFICE latest, ADOBE ACROBAT latest and AutoCAD. 11.4.0 ADDITIONAL TECHNICAL REQUIREMENTS 11.4.1 Minimum thickness of shell and dished ends shall take into account stress analysis, nozzle

loading, thinning and scaling. 11.4.2 Bidder to note that all materials (pressure and non pressure parts) shall conform to ASME code

Sec. VIII 11.4.3 Bidder to indicate reactor weight with fixed internals in the offer. 11.4.4 Bidder to note that all internals shall be installed at shop and reactors shall be shipped with all

internals fitted at shop. All temporary attachments, wedges if any, provided for transportation shall be removed at site by Owner/Owner’s agency under the supervision of the reactor supplier.

Liquid penetrant test shall be done at all local removal points. All loose internals (if any) which

have been shipped looses with reactors shall be erected by Owner/Owner’s agency under the supervision of the reactor supplier. Bidder shall furnish list of loose internals, if any along with the bid.

Any rectification/replacement of internals after inspection by owner shall be carried out by the

reactor supplier at his own cost 11.4.5 Bidder to note that installation of reactor bed thermocouples shall be done by owner /

owner’s agency under the supervision of the reactor supplier. Vendor shall include cost of supervision in their offer and confirm in their technical offer.

11.4.6 Surface preparation shall be done by shot blasting only (sand blasting is not acceptable) with

surface finish of SSPC-SP-10. One coat of paint shall be applied using heat resistant silicone aluminium paint (40-50 Microns DFT) suitable up to 500

0C after surface preparation.

Refer Jacobs project painting specification for more details 11.4.7 Fresh PQR for shell to shell, head to shell, head plate to head plate, shell to nozzle and head to

nozzle are required and this shall be witnessed by AE. For other weldings, existing PQR certified by Third Party Inspection Agency can be used and the same shall be furnished.

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


12.0 UNIT RATES FOR ADDITION/DELETION OF NOZZLES (Not Applicable in case of LEPCC)

S. NO. Description Price List

(To be filled in by bidder)

1. Change in skirt height per kg basis

2. Schedule of rates for addition / deletion of Nozzles as per ASME B 16.5 / ASME B 16.47 (including weld overlay as applicable and complete in all aspects including assembly)

#900 WNRF #1500 WNRF

WITH BL WITHOUT BL

WITH BL WITHOUT BL

2”

3”

4”

6”

8”

10”

12”

16”

20”

24”

2” LWNRF

Note:

1. Vendor shall furnish the price part in price offer and un-priced offer in technical offer

2. Above details shall be furnished even if same are not specified in SOP form

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


13.0 VENDOR DATA REQUIREMENTS

13.1.0 DOCUMENTS TO BE SUBMITTED ALONG WITH THE OFFER a) Bidder shall indicate in his offer whether he shall be adopting single layer or double layer

weld overlay. Details of overlay (single layer or two layer) to be adopted shall be furnished. In case bidder is considering single layer overlay, bidder shall furnish record of jobs executed by him in single layer overlay. In case two layer overlay is to being considered, vendor shall furnish thickness of overlay being proposed.

b) Experience of internals design and fabrication 13.2.0 DOCUMENTS TO BE SUBMITTED AFTER AWARD OF ORDER a) Vendor shall furnish detailed list of drawings and the schedule of submission of

drawings. b) For all fabrication drawings that are needed to be approved by Process Licensor, 2 sets

of drawings shall be submitted for licensor approval. c) List of documents to be submitted as follows: 1 For approval General arrangement drawings indicating design data, fabricated equipment weights, general

notes, nozzle schedule, details of shell, heads, skirt supporting arrangement, nozzle orientation plan.

Details of nozzle manholes accessories, Details of internals such as perforated trays beams etc. All calculations including computer outputs with description of computer program and FE

analysis report Calculations and details of anchor bolts WPS, PQR, QAS Material procurement specifications Number of hard copies and soft copies shall be as defined elsewhere in the tender / amendment

documents. 1 Note: Manufacturer’s report shall be sent within 4 weeks after shipment of equipment This report shall consist of the following: • Requirements of manufacture, heat treatment, inspection and testing of materials

conforming to ASME Code with addition and/or modification as specified • Mechanical and chemical properties • Certified material test reports • Manufacturer’s data report and manufacturer’s data report as per ASME

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


• List of heat number of pressure bearing parts • Material test results of all pressure bearing parts indicating the following: a) Mechanical test and chemical analysis b) Dimensional inspection c) NDT • Record of production weld tests • Records of ND examination of welds a) RT b) UT c) PT d) MT • Record of temper embrittlement testing • Record of dimensional inspection • Others a) Hardness (including that of internals) b) Ferrite Check c) Chemical Analysis of overlay cladding, UT d) Result of disbanding test • Record of Chart of hydrotest • Facsimile of name plate • Record of ISR & PWHT • Mill test certificate for electrodes, wires, consumable inserts, fluxes • Mill test certificate for skirt, bolts, nuts and gaskets and all other non-pressure bearing parts

including internals Notes: a) All documents shall be hard bound with facility to remove and attach papers. All papers

should have end protectors. b) All documents are to be properly indexed. c) All documents shall be in English Language. d) All drawings shall be drawn in AutoCAD latest version. All calculation shall be

computerised.

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 14.08.2008


14.0 SPECIFICATION FOR WELDING CONSUMABLES FOR REACTOR

14.1.0 General Requirements given in this specification are supplementary to code requirements in case

conflict, the stringent requirement shall govern. 14.2.0 Tests on welding consumables All the welding consumables shall be subjected to qualification tests for each batch of

electrodes and each combination of heat of wire and batch of welding flux. The consumable qualification tests shall be done as per ASME Section II C with additional requirements as specified. The test shall be repeated for each heat treatment condition i.e. for each post weld heat treatment temperature, post weld heat treatment time, minimum and maximum at the temperature. The test shall be carried out under Third Party Inspection by.

The welding consumables shall be consistent in the test results and shall produce results well

above the minimum specified limits. Consumables having the scatter band going down below the minimum expected value shall be rejected. Re-test shall be permitted only in cases attributable to localized defects. Re-test when done shall include double the number of test specimen originally envisaged for the test i.e. if one specimen out of five fails to meet the expected results ten specimens (double the number of five specimens) shall be carried out. No further testing shall be permitted.

The thickness of the test plate shall be 50 mm minimum. Weld parameters shall be the same

as proposed to be used in the actual production weld. 14.2.1 Details of tests 14.2.1.1 CHEMICAL ANALYSIS: Welding consumables shall meet the nominal chemical composition

of the base metal with respect to the alloying elements. Mn and Si shall be as low as possible. P, Sn, Sb & As shall be controlled accordingly.

14.2.1.2 HARDNESS: Hardness shall be as per stringent of Jacobs / Licensor specifications / code

after post weld heat treatment. 14.2.1.3 All weld tensile tests: a) All Weld Tensile Test (RT) : The test specimen at room temperature shall meet the

minimum requirements specified for the base metal. b) High Temperature Test: The weld sample shall be exposed to maximum heat

treatment time at the temperature of PWHT + two additional heat treatment cycles and shall be subjected to high temperature test as provided in above-mentioned specifications. The all weld tensile and yield strength shall meet the requirements specified.

14.2.1.4 Impact tests Charpy V notch impact tests shall be made on all weld metal which have been given min.

predicted heat treatment and which have been given max. attainable treatments. A min. of 5 nos. of impact tests shall be performed at –30

0C. The test value shall be as per code.

Jacobs



Spec. No.: 44LK-5100-00-V.02-0114-A4 Date: 19.12.2008


14.2.1.5 Temper embrittlement screening tests: Temper embrittlement screening test shall be done by performing impact tests at six different

temperatures and generating a transition curve for the following conditions: i) a) Minimum predicted heat treatment b) Minimum predicted heat treatment plus step cooling ii) a) Maximum attainable heat treatment b) Maximum attainable heat treatment plus step cooling Acceptable criteria shall be as per project specifications. 14.2.1.6 Stress rupture test Stress rupture tests shall be carried out on each heat of filler wire and flux combination / each

batch of welding consumables. Tests shall be done at 30 ksi at 1000 0F. The time of failure

shall exceed 900 hrs. 14.3.0 Tests on production welds: One production test coupon shall be tested for each new weld seams represented by all the

variables, heat of plate, batch of welding consumables electrodes, wire & flux, welding process, heat treatment. Production test coupons shall be subjected to min. and max. times at the post weld heat treatments. All weld tensile and impact tests shall be carried out at –30

0C

14.4.0 Non-destructive examination: All production welding shall be examined using X-ray Radiography (Linear Accelerator), Wet

Fluorescent MPI and Ultrasonic Examination using recordable TOFD technique.