fabrication enquiry

8/20/2019 Fabrication Enquiry

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JNK HEATERS CO.LTD.

DANGOTE OILREFINING

COMPANY LIMITED.

DOC NO: A545-JNK-121-XX-XX-XXXX REV : 0TITLE: FABRICATION ENQUIRY OF DUCTS AND DUCT SUPPORT

(121-FF-2001 A/B)DATE : 17-02-2016

OWNER : DANGOTE OIL REFINING COMPANY LTD.

PMC : ENGINEERS INDIA LIMITED

DEC : JNK HEATERS CO. LTD.

UNIT : 121-FF-2001 A/B

DOCUMENT SUBMISSION STATUS – JNK REVIEW STATUS - EIL

DOC. CATEGORY: (USE TICK MARK) (1) REVIEWED - NO COMMENTS

(2) REVIEWED, AS COMMENTED, BUT REVISED DRAWINGREQUIRED

(3) NOT MEETING SPECIFICATION, RESUBMIT

A

R

I

ISSUED FOR

INFORMATION APPROVAL


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INFORMATION APPROVAL

1. Introduction:This doument defines the scope of work for procurement, fabrication, modularization, materialhandling (Raw and completed modules) for PFR HEATER (121-FF-2001 A/B)

2. Reference Drawings/ Documents

PFR HEATER - Ducts and Duct Supports

Sr.No.

Drawing/ Document No Drawing Document Title RevNo ofPages

Remarks

JNK HEATERS CO. LTD.DANGOTE OIL REFINING

COMPANY LIMITED

UNIT: PFR HEATER (121-FF-2001 A/B) Rev: 00

COMPONENT: Ducts and Duct Support Modules Date: 15-02-2016

2 A545-121-05-42-0201 General Arrangement Cross section & Plan B 1

EIL Documents1 A545-121-05-42-0100 Foundation Loading Plan B 1

4 A545-121-05-42-0203 General Arrangement of Plans-I B 1

3 A545-121-05-42-0202 General Arrangement Long section & Plan B 1

6 A545-121-05-42-0205 General Arrangement Stack & Plans B 15 A545-121-05-42-0204 General Arrangement of Plans-Il B 1

8 A545-121-05-42-0207 Str Member Configuration Frame Detail B 17 A545-121-05-42-1206 Intermediate Tube Sheet & Tube Sheet Bracket B 1

10 A545-121-05-42-0121 APH System Ducting Layout Plans-2 B 19 A545-121-05-42-0120 APH System Ducting Layout Plans-1 B 1

11 A545-121-05-42-0122 APH System Ducting Elevation-1 B 112 A545 121 05 42 0123 APH S D i El i 2 B 1


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JNK HEATERS CO. LTD.DANGOTE OIL REFINING

COMPANY LIMITED

UNIT: PFR HEATER (121-FF-2001 A/B) Rev: 00

COMPONENT: Ducts and Duct Support Modules Date: 15-02-2016

4. Scope of Modularization1 Ducts to be modularised in length of 10-12m2 Details of Splices to be provided in Details drawings.3 Open structure to be modularised in portals and loose beams.4 Assembly of Opem structure into Modules shall be carried out at Port area or at Site on grade.5 Platforms to be dispatched in panels along with gratings installed.6 Gratings shall be FIM

MT With all Applicable NDT

2Open Structure - Duct Supports,

APH Supports, Platforms,Handrails, Ladders

MT

Sr.No.

Item Description Material UOM Remarks

Refractory Anchors SS316L Nos With all Applicable NDT

6 Lifting and Transportation Steel S275JR MT With all Applicable NDT5

Quantum Of Work

374

522.5

12103050

145

Retainer Plates SS310/304 MT With all Applicable NDT

4 Instrument Nozzles 2"/3" SS310 Nos With all Applicable NDT

With all Applicable NDT

1

Steel Structure - Duct casing,Stiffeners, doors, support saddles

GradeS275JR

conforming toEN10025


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PATTERN NO. A545/121/1617/201

DETAIL OF INTERMEDIATE TUBE SHEET1617/201

PATTERN NO. A545/121/1614/202

DETAIL OF INTERMEDIATE TUBE SHEET 1614/202

PATTERN NO. A545/121/1623/205DETAIL OF TUBESHEET SUPPORT BRACKET 1623/205

TUBE SHEET SUPPOR

PATTERN NO. A545/

PATTERN NO. A545/121/1624/201DETAIL OF WALL TUBE HANGER 1624/201

PATTERN NO. A545/121/1624/202DETAIL OF WALL TUBE HANGER


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STANDARD SPECIFICATIONNGINEERS

INDIA 1JMITED FOR STEEL WORK OF FIREDGovt of Ind.a Undelfakingt EATERS APH SYSTEMS

STANDARD SPECIFICATION No.

6-17-0002 Rev. 5Page 1 of 12

t h r z r d t r e T a f r <

~ 4 1 w gwvf rrw rcifg‘i

STANDARD SPECIFICATION FOR


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ENGINEERS TANDARD SPECIFICATION FORSTANDARD SPECIFICATION No.

INDIA LIMITED TEEL WORK OF FIRED -17-0002 Rev. 5I lo i z i

$'gz:rr £;Me517117R CA Govt o ftl,aunde^aking) EATERS APH SYSTEMS age 2 of 12

Abbreviations:

APH : ir PreheaterAS lloy SteelASTM : merican Society for Testing and MaterialsBIS ureau of Indian StandardsBOM : ill of MaterialsCS arbon SteelEIC ngineer-in-ChargeETS : nd Tube SheetHMTD : eat & Mass Transfer DivisionIS ndian StandardITP nspection & Test PlanSS Stainless SteelUON Unless Otherwise NotedVDR • Vendor Data Requirements


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INDIA LIMITED TEEL WORK OF FIRED -17-0002 Rev. 5A Govi of Inda Undeflak,o9) EATERS APH SYSTEMS age 3 of 12

a2es2. -~ 5 1 J W I TA

CONTENTS

1.0 SCOPE 4

2.0 GENERAL .4

3.0 CODES & STANDARDS .4

4.0 MATERIALS 5

5.0 DESIGN AND DETAILING 5

6.0 FABRICATION DRAWINGS 7

7.0 FABRICATION 8

8.0 ERECTION 10

9.0 GROUTING UNDER STEEL STRUCTURES 12

10.0 INSPECTION AND TESTING 12


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ENG1NEERS TANDARD SPECIFICATION FORSTANDARD SPECIFICATION No.

INDIA LIMITED TEEL WORK OF FIRED -17-0002 Rev. 5Govt of indo Undertakog) EATERS APH SYSTEMS age 4 of 12

1.0 COPE

1.1 his specification covers requirements towards residual design, detailing, supply,fabrication and erection of steel works for Fired Heaters and connected APH systems.

2.0 ENERAL

2.1 teel work broadly consists of columns, beams, bracings, portals, casing plates, floor,arch, header boxes, end tube sheets, breeching, off-takes, ducts, stacks, all appurtenances

and fabricated auxiliaries, retainer plates, sleeves, platforms, ladders, stair case, handrailing etc. and other connected works, including miscellaneous items of AS / SSwherever required.

2.2 teel work shall be in accordance with the applicable drawings, standard details,specifications, and relevant Codes & Standards.

2.3 pproval of Contractor design / documents / drawings and shop / site work at any stage

shall not relieve the Contractor of his responsibilities / guarantees and correctness of workin any way.

3.0 ODES STANDARDS

Compliance shall be ensured to the following Codes & Standards. Equivalent internationalcodes & standards can be used when specifically permitted in the job specifications :


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NGINEERS TANDARD SPECIFICATION FORSTANDARD SPECIFICATION No.

$'garfffieg NDIA LIMITED TEEL WORK OF FIRED -17-0002 Rev. 5IA Govt of InOw Undenaking) EATERS APH SYSTEMS Page 5 of 12

Tolerances for fabrication of steel structuresDimensions & section properties for hot rolled parallel flange steel

sections for beams, columns and bearing pilesSpecification for seamless & welded black and hot dipped pipes (usefor pipes for sleeves)Couplings plugs pipe capsAlloy and stainless steel bolting for high tem perature serviceCarbon and alloy steel nuts for bolts for high pressure, hightemperature serviceSpecification for stainless steel plates

Low and intermediate strength CS (use Grade C for ETS U ON)Specification for stainless steel bars and shapes (use for pipe spind le)

IS: 7215IS: 12778

ASTM A53

ASTM A105ASTM A193ASTM A194

ASTM A240

ASTM A283ASTM A479

4.0 ATERIALS

4.1 ll materials shall be new and conform to their respective specifications of BIS, ASTM orapplicable standards and supported with mill test certificates. The use of equivalent oralternate materials will be considered a deviation which will need prior written approval.

4 2 ll materials shall be sourced from approved Vendors as per Vendor List attachedelsewhere in the Package.

4 3 ll grating and grating clamps shall be hot dip galvanized.

4.4 tructural steel shall confirm to IS2062 Gr.A/B or ASTM A36 UON. For metaltemperatures exceeding 4 25 degC , alloy or stainless steels shall be used.


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INDIA LIMITED TEEL WORK OF FIRED -17-0002 Rev. 5iA Go, of Ind ,o UnoloOak,f,g) EATERS APH SYSTEMS age 6 of 12

2zir22 g- - o lo a a0 3~1 I

5.8 n welded construction, the ends of angle, channel, beam etc. are to be preferably notchedto suit the profile of connecting members. All welded moment resisting connections shallnecessarily have profile cutting.

5.9 rovide minimum 10 mm diameter drain holes at all water traps at suitable locations so asto ensure effective draining of water without affecting integrity of the structure.

5.10 ll flange bolts to straddle principal centerlines.

5.11 tiffeners on radiant shell (including ones at bracket / knee brace, terminal anchor

locations etc.) convection wall, ducts and at openings shall be provided based onstiffening requirement and detail engineering.

5.12 ll welding on heater casing / ducting shall be continuous on outside and intermittent 50-100 on inside. Welds on horizontal channel stiffeners to be continuous on topside anddiscontinuous on bottom side. Vertical stiffeners shall be provided with continuouswelding on both sides. Minimum fillet size shall be 5 mm, unless otherwise noted.

5.13 ase plates shall be shop welded to columns.

5.14 inimurl thickness of gussets shall be 6 mm.

5.15 plice Connection

5.15.1 ll splice connections shall be submitted for approval indicating locations as well asdetails. Splice joints shall be full strength butt welded, single `V' for thickness


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ENGINEEFZS TANDARD SPECIFICATION FORSTANDARD SPECIFICATION No.

INDIA LIMITED TEEL WORK OF FIRED -17-0002 Rev. 5IA Govt of lnehaundertaking) EATERS APH SYSTEMS age 7 of 12

Ct _ r1O g-ar 02- g1~1 l,9 1,151~1)

working point shall be the centerline of the column web and the top or bottom flange ofthe beam.

5.17.2 or the connection of bracing to beam 300 mm or smaller at the mid-span, the workingpoint shall be the inter-section of the horizontal centerline of the beam and the centerlineof the bay.

5.17.3 or connection of underlying bracing to beams 350 mm and larger at the mid-span, theworking point shall be taken as 125 mm above the bottom flange of the beam. Similarly,the working point of overlying bracing for such beams shall be 125 mm below the top

flange of the beam.

5.17.4 ertical bracing connections shall be as described for horizontal bracing.

5.17.5 t wind moment connections, allowance shall be made for mill overrun in beam depth byallowing for shims to facilitate erection.

5.18 russes

5.18.1 n welded trusses, splices to ship the largest possible shop assembled units shall bedetailed. Splices for welded or bolted joints shall also be detailed. All splice details to besubmitted.

5.19 latforms and Ladders

5.19.1 nless shown in prefabricated sections on drawings, top rail, middle bar and toe platesshall be supplied in random length for field welding to handrail posts. Bent section and


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ENGINEERS TANDARD SPECIFICATION FORSTANDARD S PECIFICATIO N No.

$1g a[22 - g NDIA LIMITED TEEL WORK OF FIRED -17-0002 Rev. 5IA GovI al Intlta underiak.g) EATERS APH SYSTEMS age 8 of 12

6.6 f any modification is made in the design drawings during the execution of the job, reviseddesign drawings will be issued to the Contractor. Contractor shall revise his fabricationdrawings and seek re-approvals as required.

6.7 abrication in the form of modules / pre-fabricated assemblies at shop is preferred. Detailssuch as individual module drawings, assembled module drawings, module markings, sitejoints / joint lines, splices, lifting arrangement of modules, procedures and sequence oferection etc. shall all be shown in the detailed drawings. Job requirements, facilitiesavailable at shop / site, transportation and handling etc. shall all be considered. Thecomplete details shall be got approved from EIL.

6.8 fter the completion of all works, as-built details shall be marked in EIL drawings,incorporated in Contractor fabrication drawings and submitted to the EIC for certification& approval of all revisions made before submission of requisite number of copies as perVDR.

6.9 or detail requirement of fabrication drawing submission refer VDR given in tenderdocument.

7.0 ABRICATION

7.1 abrication shall be in accordance with IS: 800 and standard fabrication practices asapproved by the EIC.

7.2 abrication shall be done as per design drawings in conjunction with details / drawingsapproved by EIL-HMTD / EIC.


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1 ENGINEERS TANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.2 1 5 1-egWr N D I A L J M I T E D TEEL WORK OF FIRED -17-0002 Rev. 5

HEATERS APH SYSTEMS age 9 of 12

above double `V' butt weld shall be used. Longitudinal welds shall not be in the sameline. Welds shall not be in line with any opening in stack. No welding shall be carried out

during poor weather condition. For stack shell plate more than 38 mm thick, preheat &stress-relieving requirement shall be applicable as per ASME code.

7.10 11 steel surfaces shall be cleaned of all rust, dirt and loose mill scale by wire brushing orother approved method. Use of box sections for main columns and beams shall beavoided. While using box or tubular section, the ends shall be properly sealed using endcaps against ingress of moisture. Also before sealing, the inside surface shall be ensuredas dry and shall be primer painted.

7.11 11 fabrication shall be of rigid construction and care shall be taken against weldingdeformation.

7.12 11 bolt holes shall be sheared only and not gas cut. For matching parts, bolt holes shall bematch marked and holes drilled.

7.13 11 erection bolts shall be left in position.

7.14 abricated structures shall be given primer coat compatible with the final painting as perpainting specification, immediat,Aly after completion at site or before dispatch from shop.

7.15 hannels that require rolling / bending may be fabricated out of plates or angles asapproved by EIC.

7.16 or base plate sizes above 300 x 300 mm, grouting holes may be provided at suitablelocations. Such holes shall be indicated in the base plate drawing submitted for EIL

1.1R7r 2 .1~70 , ~1 A Govt of India Undertaking)


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E N G I N E E R S TANDARD SPECIFICATION FORSTANDARD SPECIFICATION No.

INDIA LIMITED TEEL WORK OF FIRED -17-0002 Rev. 5Page 10 of 12

'f g-u 12 - gIA Govt ot Inct. Unclertak.g) EATERS APH SYSTEMS

1 . traightness of columns (with cap/base plate) Length/1000Outer & inner intermediate columns about XX axis ± 6Outer & inner intermediate columns about YY axis ± 3.0Outer & inner end columns about XX axis 3 .0Outer & inner end columns about YY axis 3 .0

m. Twisting (with respects to any two sections at a Length/1000distance of L) measured on point farthest from c.g. 5 (maximum)

n. Twisting of cross section measured in its own plane 2.5

o. Flatness of base plates from mean surfaceSize upto 250 mm 1.0Size above 250 mm 1.5

P. verall length on fabricated membersbeams with shear connections 2.0beams with moment end connections 1.0

columns with splices (including cap and plates) 3.0columns without splices (including cap and plates) 2.0trusses, between supports/rockers 3.0

q. uality (stack, radiant shells) 1°/o± 5.0 (maximum)

r. verall height of heater segments (non-cumulative)upto 5 m height 3


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ENGINEERS STANDARD SPECIFICATION FORSTANDARD SPECIFICATION No.

STEEL WORK OF FIRED 6-17-0002 Rev. 5e.j1 054-3 INDIA LIMITED1~ 29~=~1 1 A GuN Wlndia Undertak.91 HEATERS APH SYSTEMS Page 11 of 12

8.6 routing below base plates shall be done as per clause 9.0 of this specification.

8.7 he positioning and leveling of the structure, alignment and plumbing of the stanchionsand fixing every member of the structure shall all be in accordance with the drawings.

8.8 are shall be taken at all slotted holes connections while tightening of bolts to allowfreedom for expansion. Check nuts with suitable washers shall be used in all such cases.

8.9 eater shall be of air tight construction and welded throughout, except wherever called forotherwise. All casing splicing shall be seal welded after erection. In order to minimize air

infiltration into heater, extreme care must be taken to ensure closing of all openings andcrevices after assembly of heater is complete.

8.10 he following erection marking systems shall be followed:

8.10.1 ll structural steel and sub-assemblies shall be clearly identifiable and suitably marked toprovide an easy means of erection in the field.

8.10.2 n vertical cylindrical heaters, all columns, and sections shall be marked clockwise fromthe 'N' direction.

8.10.3 herever there is possibility of erecting the member inverted, the members to be marked`Top'.

8.10.4 here a member is shipped in two or more pieces, each piece shall have the same marksuffixed by a, b, c etc.


40/180

E N G I N E E R S TANDARD SPECIFICATION FORSTANDARD SPECIFICATION No.

INDIA LIMITED TEEL WORK OF FIRED -17-0002 Rev. 5HEATERS APH SYSTEMS age 12 of 12

5gar 92e5è1. -2,1 cwer,r, IA Govt ot Inolta Unclettatungt

f. lear spansat beam connectionat Radiant section and columnsRadiant section intermediate columns

Convection section, all columns

± 1.0± Span/1000 but max.6± Span/1000 but ±6

(max.) from CL

± Span/1000

g. evels of U/S base plate (on C.L.) 1.0

9.0 ROUTING UNDER STEEL STRUCTURE

9.1 he grouting material shall solidly fill the spaces to be grouted and permanently retain itsoriginal volume so that the base plate will be held firmly in the set position. The amountof water used in mixing shall be kept to a minimum such that the grout shall not flow.

9.2 fter final alignment and plumbing of the structure, the forms shall be constructed all-round and joints made tight to prevent leakage. Grouting (under the base plates/shoe

plates including grouting of sleeves & pockets) shall be done with non-shrink grouthaving compressive strength (28 days) not lens than 40N/sq. mm Non shrink grout shall beof free flow premix type and of approvel quality and make.

9.3 he grout shall cover all shims that are to be retained.

9.4 reparation for grouting shall be undertaken as follows:

ll anchor boltholes shall be completely filled with grout.


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5


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TANDARD SPECIFICATION TANDARD SPECIFICATION No


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Oz e NGINEERSTANDARD SPECIFICATION TANDARD SPECIFICATION No

r ai ge.n 9 9 : 5 s MACHINERYNDIA LIMITED FOR ERECTION O F EQUIPMENT 6-76-0001 Rev. 3Page 1 of 22

6 k-cm vd zit r TW IT

tq Hot Far4t2T

STANDARD SPECIFICATIONFOR

ERECTION OF EQUIPMENTMACHINERY

TANDARD SPECIFICATION FOR STANDARD SPECIFICATION No


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ENGINEERSTANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.

INDIA LIMITED RECTION OF EQUIPMENT -76-0001 Rev. 3IA Gobi of India Undetakingi ACHINERY age 2 of 22

ierSiglIT °f a

Abbreviations:

ASME merican Society of Mechanical Engineers

EC rection Contractor

EIC ngineer-in-charge

ELCB arth Leakage Circuit Breaker

GAD eneral Arrangement Drawing

IS ndian Standard

NDT on Destructive Testing

SS tainless Steel

TANDARD SPECIFICATION FOR STANDAR D SPECIFICATION No


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azieT to ENGINEERSTANDARD SPECIFICATION FOR STANDAR D SPECIFICATION No.

Ogelf laliteS NDIA LIMITED RECTION OF EQUIPMENT -76-0001 Rev. 3MACHINERY age 3 of 22

CONTENTS

1.0 SPECIFICATION FOR ERECTION OF EQUIPMENT AND MACHINERY 4

2.0 ERECTION OF COLUMNS, TANKS, VESSELS AND DRUMS ETC 5

3.0 ERECTION OF MECHANICAL EQUIPMENT 8

4.0 HEAT AND MASS TRANSFER EQUIPMENT 10

5.0 ERECTION OF ROTATING EQUIPMENT 16

6.0 EQUIPMENT GROUTING 19

7.0 REFERENCE EIL STANDARDS/ SPECIFICATIONS 22

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INDIA LIMITED RECTION OF EQUIPMENT -76-0001 Rev. 3

Page 4 of 22O,l of India underlakPrigi ACHINERY

1.0 SPECIFICATION FOR ERECTION OF EQUIPMENT AND MACHINERY

1.1 cope

This specification covers technical requirements for erection of all static and rotatingequipment by erection contractor at site. This specification is applicable for all the erectiontenders operated by EIL.

1.2 eneral

1.2.1 ll necessary handling equipments, tools, tackles and precision instruments for carrying outthe works as specified shall be provided by the Erection Contractor (EC) at his cost. EC mustprovide all tools and gauges for erection and alignment. Special tools, if any, received as partof machinery, will be given to EC for erection purposes, which shall be returned in goodcondition after use. Suitable deductions will be made by the Engineer-in-Charge (EIC) incase of loss or damage of the special tools. The value of such loss or damage will be decidedby the EIC and EC shall be bound by such a decision.

1.2.2 Equipment Manufacturer's recommendations regarding preservation during storage at site anddetailed specifications for the installation alongwith layout drawings, generalarrangement/equipment outline drawings and sub-assembly drawings of the various equipmentand machinery will be provided to EC during the performance of work. The requirementsstipulated in these shall be fulfilled by EC in addition to what is stated in this specification.Erection shall be carried out as per the instructions and supervision of Machinerymanufacturer's representative, wherever such supervisory services are applicable.

1.2.3 All the items of work covered in the tender shall be carried out as per this Specification and

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INDIA LIMITED RECTION OF EQUIPMENT -76-0001 Rev. 35 g a r f a k r e s IA Govl 01 haw undeptakingl ACHINERY age 5 of 22

1.3.3 During the performance of the work, EC shall keep structures, materials or equipmentsadequately braced by guys, struts or otherwise approved means which shall be supplied and

installed by EC as required till the installation work is satisfactorily completed. Such guys,shoring , bracing, strutting, planking supports etc. shall not interfere with the work of otheragencies and shall not damage or cause distortion to other works executed by him or otheragencies.

2.0 ERECTION OF COLUMNS, TANKS, VESSELS AND DRUMS ETC.

2.1 cope of work of Erection Contractor

(a) Preparation of erection scheme and rigging procedure and obtaining its approval fromEIC wherever necessary.

(b) Withdrawal of equipments from Owner's storage point, checking and reporting itsconditions, transporting the same to EC's stores of work site including unloading etc.

(c) Erection on foundations furnished by Owner including aligning, levelling and grouting.

(d) Assembly and fixing of demisters, grids, internal distributors and other internal fittings inColumns, Vessels etc.

(e) Filling of Columns, Reactors, Vessels/Drums etc. with Raschig rings, supportingelements, sand, concrete etc. as required.

(0 Welding of washers for equipments, erection of pipe davit & minor welding of their partsas per specifications and instruction of EIC.

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I N I F E z i e ?SIgtIT keg

2.2.2 Rigging procedures and erection schemes for all the heavy lifts weighing 10 MT & aboveshall be prepared by EC and got approved by EIC. Approval by EIC shall not relieve EC of

his responsibilities. The details to be submitted will include the location of equipment fromwhere it will be lifted, location of crane(s), details of crane(s) (like configuration, boomlength, operating radius, boom point elevation, clearance underside the boom and theequipment, lifting capacity, counter weights to be deployed, holds on any neighbouringfoundations, structures, equipments etc.), the load chart of the crane(s), design of the liftingtackles like spreader beam, D-shackles, wire rope slings etc. Unless the erection scheme andrigging procedures are approved by EIC, erection of such equipments shall not be undertakenin any case by EC.

2.2.3 Before starting the erection of Columns, Vessels etc., top surface of the foundations is to becleared/chipped, roughened to obtain proper bond, while grouting. Also the sleeves are to becleaned before erecting the equipments. Line (orientation) and levels are to be marked on allthe foundations to facilitate checking of alignment.

EC shall also check the correct elevation and orientation of civil, structural foundations, beforeproceeding with the erection work. Discrepancy, if any, shall be brought to the notice of EIC.However, minor rectifications and chipping of foundations upto a thickness of 15 mm infoundation height shall be carried out at no extra cost, by the EC. EC shall be responsible forsupply of levelling plates, (if required) and shall carry out levelling of equipment under thedirections of EIC.

2.2.4 While handling, transporting or erecting the equipments, care shall be taken not to damage thenozzles, instrument connections, structural clips etc. EC shall also take care of the orientationof the nozzles and other connections of the equipments while erecting the same and ensurecompliance with the drawings and specifications supplied. Discrepancy, if any, in the

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MACHINERY age 7 of 22

laratleila g,

2.2.8 EC shall carry out minor welding for attachment of prefabricated pipe davit parts such as raincovers, handles etc. with pipe davit, during or after erection of the same as per the

manufacturer's specifications, at no extra cost to the Owner.

2.2.9 EC shall execute erection of wooden pillow for saddle support for cold horizontal vesselswherever necessary as indicated on the drawings/ EIL STD 7-12-0003 and as per theinstructions of EIC.

2.2.10 EC shall execute assembly & erection of agitator/mixer along with drive unit including allaccessories as per supplier's instructions, specification drawings & instructions of EIC.

2.3 lushing & Cleaning of Columns, Vessels, Drums etc.

2.3.1 After the erection, alignment and grouting of these equipments are complete, flushing andcleaning shall be carried out by EC as per specifications and instructions of EIC.

2.3.2 After flushing, cleaning and draining, equipments shall be dried by compressed air at thepressure and for duration decided by the EIC. The Vessel interior shall be thoroughlyinspected to the complete satisfaction of EIC before it is finally boxed up. Boxing up ofmanholes and handholes shall be leak proof. All joints which need remaking, shall be remade.Compressed air for drying shall be arranged by EC.

2.4 nspection and Acceptance Limits for Level and Alignment

2.4.1 Co-ordinates of foundations/supporting structures/mounting holes etc. shall be checked withrespect to the plot plans by EC.

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STANDARD SPECIFICATION FOR

ERECTION OF EQUIPMENT -76-0001 Rev. 3MACHINERY age 8 of 22

a arm a NGINEERSslig2li EVIegU NDIA LIMITED

IA Gori al India undenakrnyi

2.5.3 EC shall do the necessary excavation, backfilling and removal of surplus earth at the site asper the directions of the EIC. EC's rate shall include the excavation, blast cleaning, painting,

wrapping by kraft paper, placing and fixing of Vessels, backfilling and removal of excessearth.

3.0 ERECTION OF MECHANICAL EQUIPMENT

3.1 cope of Work of Erection Contractor

The scope of EC shall consist of withdrawal and transportation of equipments and accessoriesfrom Owner's stores to site, assembly of loose supplied components/parts erection ofequipment on foundations, levelling, aligning and grouting, preparation of equipments for trialruns and hand over in fit condition for the start up of the plant as per instructions of EIC.

3.2 etails of Owner Supplied Equipments

Equipments to be erected shall be supplied by the owner. Equipments may be supplied in anyof the following conditions.

Single equipment such as filter, static mixer, silencer etc.Skid mounted equipment, fully assembled.

Skid mounted equipment with some items supplied loose or as subassemblies involvinginterconnections also.

System comprising of many equipments, skids with interconnected piping & hook up.

3.3 echnical Requirements

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GoN at India Undenakg,91 ACHINERY age 9 of 22

3.3.9 After installation and levelling the equipment shall be grouted with the specified groutingapplied to the baseplate and support.

3.3.10 EC shall remove all the packing and protective devices used during transport and handlingfrom the equipment such as shock absorbent materials from machined faces, blocking of shaftsor rolling bearings & restraining devices from instruments, safety devices and protectiveequipments.

3.3.11 After the grouting is set & cured, the foundation bolts shall be checked to make sure that theyare in straight and vertical position and properly tightened. Shims, if used, shall be on eitherside of the foundation bolts.

3.3.12 Desiccant, catalyst where supplied loose shall be loaded on to the respective vessels inspecified quantities as per the suppliers instructions.

3.3.13 Internals, where supplied loose shall be assembled as per the drawings and manufacturer'sinstructions.

3.3.14 Unless otherwise specified, all the instruments such as pressure gauges, sight glasses

temperature recorders etc. including instrument panels, if any, supplied along with theequipment with necessary connections, shall be installed by EC as part of Equipment erection.

3.3.15 Equipments shall be checked for final cleanliness before boxing up.

3.3.16 Any interconnected piping & ducting shall be properly installed and supported. EC shallconnect the gas, steam, air, utility piping, instruments, oil piping etc. as per manufacturer'sdrawings, specifications and instructions of the EIC.

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.Rn el7mTV aezmil A Govt of India uncienakiv ACHINERY age 10 of 22

3.4 rial Runs

3.4.1 Wherever specified, Machinery & Equipment erected & installed by EC under the supervisionof Machinery/Equipment supplier shall be subjected to trial runs in accordance with clause 5.4of this specification. Job specific trial run procedure, if specified, supersedes the trial runprocedure as described in clause 5.4.

3.5 ystem Start-up

During this phase of work, EC shall provide as part of his work necessary skilled personnel asper requirement of EIC. Any defects noticed in the Equipment shall be made good by EC athis cost if such defects are attributable to him.

4.0 HEAT AND MASS TRANSFER EQUIPMENT

This section covers the minimum requirements for erection of the following equipment by theEC.

Deaerator

Trays/tower Internals And Tower PackingsSeparators And InternalsShell And Tube Heat ExchangersDouble Pipe ExchangersElectric HeatersPlate ExchangersPlate Fin ExchangersSulphur Recovery Unit Equipment like Combustion Chambers, Waste Heat Boilers,


lociMewl


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lociMewl5gTzIT fel f5lt°

4.1.7 Assembly and fixing of trays, tower internals (distributor, bed limiter, support plate, chimneytrays, vapour distributor etc.), demisters, grids, internal distributors and other internal fittings

in columns, vessels etc.

4.1.8 Installation of transformers on desalters and their electrical connection to electrode grid etc.

4.1.9 Welding of chimney trays, lattice girders, beams etc. wherever required.

4.1.10 Carrying out minor adjustments, modifications, seal welding of seal plates etc. wherevernecessary during installation.

4.1.11 Checking of installed trays & tower internals and filling of installation formats as referred in6-14-0016.

4.1.12 Filling of columns, vessels/drums etc. with Raschig rings/Pall rings/ Structured packing, asrequired.

4.1.13 Welding of washers for equipment, erection of pipe davit & minor welding of their parts asper specifications and instruction of EIC.

4.1.14 Hydrotesting of shell and tube heat exchangers if the time gap between last hydrotest is morethan six months or in case it is found to be necessary by EIC. Procedure is given in para 4.3 &4.4 below. EC to note that any equipment which are refractory lined at shop shall not behydrotested.

4.1.15 Flushing, cleaning and drying of equipment using compressed air and blinding to preventingress of rain, dust etc.

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lardaeg (L tit ENGINEERSSIgof latiregW INDIA LIMITED RECTION OF EQUIPMENT -76-0001 Rev. 3

.2/7 erenw7 nnn A G cnn ol India Undenavingi ACHINERY age 12 of 22

qualification of welders as per ASME Section IX. EIL/Owner's Inspector may acceptpreviously qualified WPS/PQR at his sole discretion.

4.2.4 Lattice girders wherever provided for supporting tray & tower internals have been designed insuch a way that various components pass through column manway. Components/parts oflattice girders are to be welded inside the column as per respective drawings. EC shall alsoensure that all parts of lattice girder are properly welded & levelness of the lattice girder shallbe checked before & after the welding. The limits of levelness as mentioned in GA drawingsshall be adhered to.

4.2.5 The rigging procedure shall include the following as a minimum:

Location of equipment from where it will be lifted, location of crane(s), details of crane(s)(like configuration, boom length, operating radius, boom point elevation, clearance undersidethe boom and the equipment, lifting capacity, counter weights to be deployed, holds on anyneighbouring foundations, structures, equipment etc.), the load chart of the crane(s), design ofthe lifting tackles like spreader beam, D-shackles, wire rope slings etc. Unless the erectionscheme and rigging procedures are approved by the EIC, erection of equipment shall not beundertaken in any case by the EC.

4.2.6 While handling, transporting or erecting the equipment, care shall be taken not to damage thenozzles, instrument connections, structural clips, refractory lining etc. EC shall also take careof the orientation of the nozzles and other connections of the equipment while erecting thesame and ensure compliance with the drawings and specifications supplied. Discrepancy, ifany, in the number/orientation of the nozzles, cleats etc. should be brought to the notice of theEIC before actual erection is started.

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latfaeleg ft NGINEERSsitZ r laigleg NIP INDIA LIMITED RECTION OF EQUIPMENT & -76-0001 Rev. 3

IA Gent 01 Inda Undenaing) ACHINERY age 13 of 22

4.2.12 Levelling and plumbness shall be approved by EIC and shall be checked using theodolitebefore grouting and final finishing of the foundations. The record of the same shall be

maintained.

4.2.13 EC to ensure that shell and tube exchangers shall be firmly bolted down to foundations at thefixed end. Further EC to ensure that foundation bolts at the sliding saddle end are at the centreof slotted holes & nuts at sliding end are only hand tightened. Projected bolt threads shall beproperly protected by application of grease etc. to avoid rusting and for facilitating freemovement of nuts.

4.2.14 EC shall ensure that no equipment is subjected to any corrosion during any stage during hisperiod of work till handling over to EIC/Client.

4.2.15 Instruments, as required, shall be mounted by EC. On instructions of EIC, EC shall alsoremove and hand over the instruments to EIC for calibrations. During this period, EC shallcover all openings to protect the equipment.

4.2.16 Before transportation to site, EC shall check and report to EIC on the condition of equipment,specifically highlighting the nitrogen pressure indicated in the nitrogen gauges and the absence

of blinds on any of the nozzles.

4.2.17 In case the shell and tube exchangers are to be stacked, but have been stored as single shells atthe store, then EC shall erect the bottom most shell, then erect other shell(s) sequentially usingthe nozzle gaskets/bolting and saddle bolting supplied by owner. Additional shims, ifnecessary, shall be supplied by EC. If the exchangers do not have interconnecting nozzles,then nozzle elevations shall be maintained as per piping GAD.

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4.3 ydrotesting of Shell and Tube Exchangers including Condensers

4.3.1 hese shall hydrotested at site using potable water. Hydrotesting of both shell and tube sidesshall be carried out as per procedure given below or as per instructions of EIC. Forexchangers fitted with SS bellow or SS part, potable water with max. 25 ppm chlorides shallbe used for hydrotesting.

4.3.2 Suitable pump set, piping, test pressure gauges and other instruments, water-hoses, temporarygaskets, metallic blinds, bolts, nuts, consumable and other temporary arrangements andequipment for testing shall be provided by the EC at his cost. Test pressure gauges shall becalibrated by the EC and got approved from EIC.

4.3.3 Stacked exchangers shall be hydrotested in stacked conditions.

4.3.4 Test pressure shall be as indicated in the name plates mounted on each exchangers. Durationof hydrotest shall be at least one hour. Test pressures and duration of hydrotest may bereduced by EIC. Minimum test water temperature shall be 20°C.

4.3.5 Any defects noticed during hydrotesting shall be repaired by EC as per the procedure

approved by EIC. Cost for rectifying defects, not attributable to the EC shall be paidseparately.

4.3.6 No equipment shall in general form part of the piping loop during hydrotesting and shall beblinded off, except when instructed otherwise by EIC.

4.3.7 EC to take adequate care during pressurising & depressurising the equipment. EC shall alsotake care of any instruction given regarding hydrotest in the exchanger drawing.

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afae eget ENG INEERSOgal laMeg W NDIA LIMITED RECTION OF EQUIPMENT -76-0001 Rev. 3

+nen eixanvmoan) . Gort ol Intha Undertaing) ACHINERY age 15 of 22

4.4.5 When hydrotested as per above procedure after floating head gasket replacement, if it isobserved that test pressure is still dropping, this could mean leakage from tube to tubesheetjoint. For such cases matter shall be reported to EIC for further investigations/instructions.

4.5 lushing Cleaning

4.5.1 After the erection, alignment and grouting of these equipment are complete, and afterhydrotest if any, flushing and cleaning shall be carried out by EC as per specifications andinstructions of the EIC.

4.5.2 After flushing, cleaning and draining, equipment shall be dried by compressed air at thepressure and for duration decided by EIC. The equipment interior shall be thoroughlyinspected to the complete satisfaction of EIC before it is finally boxed up. Boxing up ofmanholes and handholes shall be leak proof. All joints which need remaking, shall be remade.Compressed air for drying shall be arranged by EC at his cost.

4.6 nspection and Acceptance Limits for Level Alignment

4.6.1 Co-ordinates of foundations/supporting structures/mounting holes etc. shall be checked with

respect to the plot plans by EC.

4.6.2 Before equipment are placed on foundations, orientations shall be checked with respect topiping drawings.

4.6.3 When equipment are firmly bolted down but prior to grouting, verticality of all equipmentshall be checked by using theodolite. Tolerances for equipment after erection shall be as perEIL Standard 7-12-0001. The allowable deviation from plumb line shall be 1 mm per metre

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shall be complied with. Inspection aids for carrying out the inspection of internals shall also beprovided.

5.0 ERECTION OF ROTATING EQUIPMENT

5.1 cope of Work of Erection Contractor

The scope of work shall consist of transportation of Rotating Equipments and accessories fromOwner's stores to site, assembly of sub-assemblies/parts, erection of Rotating Equipments onfoundations, levelling, aligning and grouting, preparation of Rotating Equipments for trialruns, carrying out no load/trial runs, return of any unused material to the owners stores andhand over in fit condition for the start- up of the Plant, as per instructions of EIC.

Defects due to EC's fault noticed during trial runs shall be rectified by him. Schedule ofQuantities, indicate estimated numbers, dimensions and weights of the Rotating Equipments.The actual data on dimensions and weights will be in the vendor data manuals.

The term 'Rotating Equipment' includes all pumps, compressors, steam & gas turbines, fansand blowers, diesel engine/steam turbine/gas turbine generator sets along with drivers

accessories & auxiliary systems.

5.2 eneral Conditions of Erection

5.2.1 All Rotating Equipment erection shall be done by experienced fitters. For this purpose ECshall employ experienced and suitably qualified erection supervisor and crew who have donesimilar jobs.



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5.2.6 The local mounted instruments such as pressure gauges, sight glasses, temperature gauges etc.and Local instrument panels, if any, with necessary connections, shall be installed by EC aspart of rotating equipment erection.

5.2.7 After initial alignment, the Rotating Equipments shall be properly grouted. Grouting shall becarried out as per this specification. Wherever grout holes are provides in the base plates,grout shall be filled through them also.

Epoxy grout where recommended by the rotating equipment manufacturer, shall be providedby EC and shall be as specified in this standard.

5.2.8 Alignment between the Driver and driven equipment shall be done without connecting theequipment nozzles to respective piping. After completion of alignment, the equipment shallbe connected to Piping. After the piping has been connected, the alignment shall be re-checked by EC, to ensure that piping connections do not induce any undue stresses on theRotating Equipments. After making necessary corrections on the piping, if any, re-alignmentshall be done by EC and he will ensure that no undue stresses are induced on the RotatingEquipment.

5.3 pecial Instructions

EC in addition to general instructions for erection as out lined in para 5.2 above, shall alsofollow the following special instructions.

5.3.1 Pumps

Depending upon the size of equipment, Pump train will be supplied for erection in any of the


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ENGINEERSINDIA LIMITED RECTION OF EQUIPMENT -76-0001 Rev. 3

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aT fd g IA GUN Q1 India UndelaKingi ACHINERY age 18 of 22

5.3.2.3 The compressor, driver and other accessories shall be erected on their respective foundationsand the compressor, couplings, gear box and driver shall be aligned and grouted as per themanufacturer's instructions and instructions of EIC and the manufacturers supervisor (whenpresent). There-after all process and utility, drain & vent connections shall be completed asper the relevant drawings/instructions of equipment manufacturer and advice of EIC.

5.3.2.4 Final alignment shall be done after all the piping connections such as water, steam, drains andconnection to coolers etc. are made. olerances for alignment shall be maintained asspecified in the Manufacturer's Instruction Manual. To ensure that piping connections do notinduce any undue stresses on the Rotating Equipment, the alignment shall be checked onceagain by EC after the piping has been connected. Any correction necessary for proper

alignment shall be done by EC.

5.3.2.5 EC shall carefully study the vendor drawings, manuals and other data before start of the job toensure correct erection, alignment and commissioning.

5.3.3 Centrifugal Compressors Expanders

5.3.3.1 Centrifugal Compressors are supplied for erection in multiple packages such as,

Compressor casings

Drivers (Electrical motors, Steam/Gas turbines -.)

{. : Steam/Gas turbines would be further supplied in multiple packages}

Base plates (or skids)

Lube oil/control oil systems

Sealing systems



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5.4.2 Unless otherwise specified, all the rotating equipment will be subjected to trial runs for acontinuous operation of 72 hours. In case of motor driven rotating equipments, motors shallbe decoupled and turned over to other agencies doing electrical work for testing and no loadrunning of motors. After the no load runs of motors are satisfactorily completed, EC shallrecouple the motors to the rotating equipment and recheck the alignment. The trial run of therotating equipment shall be started only after the above is completed. EC shall provide, as partof his work, necessary skilled personnel (excluding the operating personnel) for conductingthe trial runs round the clock during the trial runs period. The duration of trial run may beextended if it is considered necessary in the opinion of EIC and EC shall provide personnel forsuch extended period also. Final inspection of bearing etc. shall be carried out by EC after theMachinery had gone through the trial run and defects, if any, shall be made good for renderingthe rotating equipment ready for start up.

5.4.3 During the trial runs, readings of bearing temperature, cooling water inlet and outlettemperatures, lube oil inlet/outlet temperature and pressure, rotating equipment dischargepressure and temperature, starting in current, no load/full load current etc. shall be recorded,wherever necessary, by EC. Trial reports shall be prepared in the approved proforma by ECcontaining all the above details and submitted to the EIC as part of completion documents.

5.4.4 EC shall also provide necessary improvised fencing and watch & ward personnel as safety

measures during trial runs.

5.5 ystem Start up

During start-up, EC shall provide necessary skilled personnel as per requirement of EIC, torectify defects noticed in the rotating equipment, if such defects are attributed to him.

6.0 EQUIPME NT GROUTING

laraae? ENGINEERS TANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.

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INDIA LIMITED RECTION OF EQUIPMENT -76-0001 Rev. 3Grm of India uncienalong) ACHINERY age 20 of 22

6.1 rout (Material)

All material used for grout shall be in EC's scope. Only approved grout material shall beused. EC shall submit details of grout materials for prior approval of EIC.

6.1.1 Non-Shrink Grout

Non-shrink grout shall be premix type of cementitious (cement pregraded fibre and additive)non-shrink, ready to use grout in dry powder form. It shall have free flow property whenmixed with required quantity of water. It shall have initial setting time of 30 minutes.

It shall have the following features:

- Non corrosive to anchor bolts, base plate/saddle/frame, sliding plate.Not harmful to concrete and reinforcing steel.Non toxicFrost, oil and fire resistantRequire normal curingSuitable to use under restraints and grout thickness requiredExpansive to counteract initial shrinkage

Ensure high early strength without surface crack.Suitable for temperature of above 0 deg.0 to 200 deg.C.Maximum flow distance is compatible to the dimensions of base plate/ saddle/frame.It should be resisted to the chemicals, gases etc. being handled in equipment/machines.

It should have the following physical properties:

Min. Compressive strength at 3 days 25 N/mm 22


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7.0 REFERENCE EIL STANDARDS/ SPECIFICATIONS

6-14-0003 nstallation Procedure for Trays & Tower Internals

6-14-0011 pecification for Packing the Column

6-14-0016 tandard Specification for Review of Site Installation of ColumnInternals.

6-79-0011 tandard Specification for Corrosion Protection Tape Coating forUnderground Steel Piping.

6-79-0020 tandard Specification for Surface Preparation and Protective Coating

(New Construction)

7-12-0001 essel Tolerances.

7-12-0002 upport for Horizontal Vessel

7-12-0003 ooden Pillow for Saddle Support

7-12-0004 kirt Base Details

7-12-0024 ifting Lug Top Head Type

7-14-0001 onstruction Tolerance for Welded Supports for Tray / TowerInternals

SPECIFICATION FOR DOCUMENT No.


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QUALITY CHECKS FORFABRICATION ERECTION AND

EXECUTION OF FIREDHEATERS

A545-999-05-42-SP-12 Rev. 0

Page 1 of 45

DOCUMENT No.


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SPECIFICATION FOR QUALITYCHECKS FOR FABRICATION

ERECTION AND EXECUION OFFIRED HEATERS

A545-999-05-42-SP-12 Rev. 0

Page 2 of 45

CONTENTS

S.NO. DESCRIPTION

1.0 PURPOSE …………………………………………………………………4

2.0 REFERENCES …………………………………………………………… 4

3.0 DEFINITIONS …………………………………………... .........................4

4.0 SCOPE …………………………………………………………………… 5

5.0 ATTACHMENTS / FORMATS ………………………………………... 10

DOCUMENT No.


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A545-999-05-42-SP-12 Rev. 0

Page 3 of 45

1.0 PURPOSE

This document covers the minimum inspection requirements and quality checks forFired Heater Systems during the construction & prior to commissioning of heatersystems.

In order to ensure overall quality during execution, it is Package Vendor ’s

responsibility to meet the specified technical requirements and execute the job asper applicable documents issued by PMC as well as PMC approved documentsprepared by the Package Vendor. Records of all quality checks shall be maintainedby the Package Vendor duly counter checked by Engineer-in-Charge.

2.0 REFERENCES

Following shall be considered as reference documents for carrying out the work:

i) All Technical documents issued along with Tender & Agreed Variations (ifany).

ii) All referred Standards Codes and Drawings (issued for construction /engineering).

iii) Q lit A Pl / ITP (d l d b P k V d ) d

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4.1.1 Execution of work defined in Scope para of job specification and specification 6-17-0001 issued with tender document. The detail concerning different portions of workare covered in separate technical specifications e.g. Steel Work, Coil, Refractory etc.Inspection & Test requirements for different portions of work are covered in theseseparate Technical Specifications and the compliance of the same is PackageVendor ’s responsibility.

4.1.2 Prior to usage, Package Vendor shall ensure that all the material / sub-assembliesbeing used for Job execution are in good condition & meeting the specificationrequirements.

4.1.3 Tolerances on fabrication and assembly of various works are also specified intechnical specifications for Steel work, Coil work & Refractory work. These shall bestrictly complied during execution of work. Deviation from these is not permittedunless authorized by a Deviation Note.

4.1.4 Maintaining the Records of all Tests & Inspections in line with requirements ofTechnical Specifications shall be Package Vendor ’s responsibility. Whereverrequired the same shall be got witnessed / counter checked from Engineer-in-Charge. Tests / Inspection Records shall include but not limited to following:

i) Steel work fabrication tolerances as per para 7.17 of Spec. 6-17-0002.

ii) St l k ti t l 8 11 f S 6 17 0002 UON

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ii) Prior to start of refractory lining of Convection Box (to avoid hot work afterlining).

iii) Prior to Erection of Coil within Radiant Box (to inspect refractory lining).

iv) Prior to start of refractory in the convection section but after erection ofIntermediate tube sheets (to inspect Tube sheet clearances with the Steel

works and Specialist check stage C(i)).

v) Prior to start of tubing of Convection Section (to inspection refractory andspecialist check stage C(ii).

vi) Prior to lifting of tubed & lined convection box wherever the same is envisaged(to ensure readiness of convection box, completion of convection supportingsteel work & adequacy of lifting arrangement).

vii) Prior to connecting jump overs / cross-overs in Radiant & Convection Coilpasses (for witnessing of cold pull requirements).

viii) Prior to Stack Erection (to ensure completion of stack support steel work andadequacy of lifting arrangement).

ix) Prior to removal of internal scaffoldings from the heater (to facilitatei ti t B & C(iii)

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4.2.3 Ensuring that all hot work is performed on steel work surfaces before the same isreleased for refractory lining.

4.2.4 Counter checking of various dimensions / tolerances / tests as recorded by PackageVendor as per para 4.1. These records shall be maintained at site and shown toSpecialist for his review.

4.2.5 In case of any deficiency found by Engineer-in-Charge during stage-wise / finalinspection, the directions shall be provided to Package Vendor for necessaryrectification / modification or examine the Package Vendor ’s proposal forrectification.

4.2.6 Review & approval of Package Vendor ’s Quality Assurance Plan for stage wise /final inspection & the same shall be sent to Heater Specialist for information.

4.2.7 Review of sequence of various activities & the erection scheme proposed byPackage Vendor vis-à-vis crane capacity, crane availability and schedules. Activitiessequence to be reviewed by Engineer-in-Charge and forwarded to specialist forconcurrence.

4.2.8 Organizing specialist’s Stage wise / final checks and providing all facilities e.g.approach, lighting, safety gadgets for conducting site checks.

4 2 9 Att di t P h Li t id d b i li t t th d f hi i d i

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viii) Witnessing the hydrotest of coil assembly / sub-assemblies according torequirements.

ix) Ensuring that all structurals, specially the load bearing structurals are inaccordance with approved drawings.

x) Checking the quality of external insulation material and weather proofing (i.e.aluminum cladding etc.).

xi) Ensuring that all painting jobs are done after adequate surface preparationand the paints meet the specifications.

xii) Ensuring that explosion doors are seating properly and are operable withouthindrance.

xiii) Witnessing of cold condition placement of all terminals before and afterconnection to piping to ensure cold pull as per requirements.

xiv) All checks as per formats enclosed (Annexure-II).

4.2.12 For all refractory related work, following are some of important checks which shall bei d t b E i i Ch d d h ll b k t f f

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xi) Verify the overlap of top most blanket layer with respect to flow direction sothat it does not permit flue gas ingress within the lining.

xii) Verify that the Ceramic fiber module orientations are as per approvedrefractory drawings.

xii) Ensure that Refractory Dry Out is done as per PMC approved procedure.During dry out check heater casing and stack shell temperatures and recordfor verification by Specialist.

4.2.13 Engineer-in- Charge shall also ensure that all checks are made as per ‘CHECK LIST’ Annexure-III, by Package Vendor and witnessed by Engineer-in-Charge as routinechecks and same are kept as RECORD. Heater specialist shall review the same andcarry out some random checks.

4.2.14 A critical review by Engineer-in-Charge is required at following stages of work:

(A) When Package Vendor informs the readiness to begin Radiant Section lining.

(B) After Radiant Coil erection work including jump-overs between Radiant Tubesis completed but the approach scaffoldings inside radiant shell are notremoved

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i) For convection section modules after erection of Tube support casting insidethe modules before refractory lining.

ii) When modules with coils are nearing completion at shop / fabrication yard.iii) Completely modularized Fired Heater where major fabrication activities are to

be performed at shop.

PMC- Heater specialist checking shall be done after confirmation that all checksas per requirements of specifications have already been carried out by thePackage Vendor as per the various defined stages. In case the actual dimensions/ tolerances are not meeting the tender requirements the same shall be rectifiedby Package Vendor before offering the Heater for PMC- Heater specialistchecking.

4.2.17 For the fabrication work carried out at shop outside the refinery premises, all the

quality formats shall be duly signed by Package Vendor and the inspection agency. And the same shall be made available along with the Inspection Release Note at thetime of bringing the modules / panels inside the refinery premises.

4.2.18 Incase of modular construction it shall be the responsibility of the Package Vendor toprepare and transport the foundation templates to the Package Vendor ’s shop so asto ensure correct interfacing / seating of the modules at foundations.

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ANNEXURE – I

REFERENCE DOCUMENTS CHECK LIST

FOR

HEATER JOB EXECUTION

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S. No. DOCUMENT DOCUMENT NO. REMARKS

1. Tender Document including :

(a) Job Specification

(b) Other Technical Specification

(c) Referred Standard Drawings

(d) Referred Standard Specification

(e) Quality Documents – 6-78-0001,6-78-0002

(f) Referred latest rev PMC Job Drawings“Issued for Engineering / Construction”

2. Addendum to Tender Specification

3. Latest rev PMC Job Drawings “Issued forEngineering / Construction”

3 1 Index of Drawings

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ANNEXURE - II

HEATER QUALITY CHECKS

REPORTING FORMATS

DOCUMENT No.A 4 999 0 42 S 12 0


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JOB NO. . . . . . . . . . . . . . . . . PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .

HEATER NO. . . . . . . . . . . . .

PACKAGE VENDOR . . . . . . . . . . PACKAGE VENDOR DRG.NO(S) . . . . . . . . . . .. . . . . . . . . . . . .

STRAIGHTNESS OF STRUCTURAL COLUMNS( For Panels , modules and assembledHeater Structure ) FORMAT NO: “A”

INSPECTION STAGE : STRUCT. MEMBER’S FABRICATION

REFERENCE SPEC./PARA : 6-17-0002/7.17(l) , UON.

COLUMN GRID NO. OUT OF STRAIGHTNESS OVER FULL LENGTH REMARKS

ABOUT X-X AXIS ABOUT Y-Y AXIS

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1. This format shall be filled up by Heater Package Vendor & Counter Checked byEngineer in Charge.

2. Separate forms shall be filled up for various stages of fabrication (panels, modulesand at site ).

JOB NO. . . . . . . . . . . . . . . . . PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

HEATER NO. . . . . . . . . . . . .


STRAIGHTNESS OF STRUCTURAL BE AMS, FORMAT NO: “B”

INSPECTION STAGE : STRUCT. MEMBER’S FABRICATION

REFERENCE SPEC./PARA : 6-17-0002/7.17(j&k)

BEAM GRID PLANE ELEVATION OUT OF STRAIGHTNESS REMARKS

LONGITUDINAL LATERAL

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EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .. .Notes:


2. Separate forms shall be filled up for various stages of fabrication (panels, modules

and at site ).

JOB NO. . . . . . . . . . . . . . . . . PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .

HEATER NO. . . . . . . . . . . . .


VERTICALITY OF ASSEMBLY / CENTRELINE OF COLUMNS, FORMAT NO: “C”

INSPECTION STAGE : ERECTION

REFERENCE SPEC./PARA : 6-17-0002/8.11(b)

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(SIGNATURE) (SIGNATURE)

NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .. .

EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .. .

Notes:



JOB NO. . . . . . . . . . . . . . . . . PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .

HEATER NO. . . . . . . . . . . . .


LEVEL OF HEARTH FLOOR FORMAT NO “D”

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PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . . Engineer in Charge . . . . . . . . . . .. . . . . . . . .


NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .. .

EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .. .Notes:



JOB NO. . . . . . . . . . . . . . . . . PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .

HEATER NO. . . . . . . . . . . . .

PACKAGE VENDOR PACKAGE VENDOR DRG NO(S)



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NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .. .

EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .. .Notes:


2. Separate forms shall be filled up for various stages of fabrication (modules and atsite).

JOB NO PMC DRG NO(S)



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210 o

240 o

270 o

300 o

330 o


(SIGNATURE) (SIGNATURE)NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .. .

EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .. .Notes:

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2

NOTE: 1. Pitch Nos. shall be counted starting from 0 and moving in clock wise direction for

VC heater.For Box heaters pitch no. shall be counted starting from bottom most pitch.

2. Pitch must be measured at least 4 locations along tube length.



NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .. .

EMP NO

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1 2 3 4

0o

45 o

90 o

135 o

180 o

225 o

270 o

315 o

NOTE: 1. TCD shall be measured at least at four locations along the height of RadiantSection.

2. This Format is applicable for Vertical as well as Helical Tube Radiant Section.

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REFERENCE SPEC./PARA : 6-17-0003/2.3

ORIENTATIONREQUIREDDIMENSION

(mm)

MEASURED POINT LOCATION(mm) REMARKS

1 2 3 4

NOTE: 1 Tube No in case of VC heater shall be counted clockwise starting from 0 o For Box



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JOB NO. . . . . . . . . . . . . . . . . PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .

HEATER NO. . . . . . . . . . . . .


OUT OF PLUMB FOR VERTICAL TUB ES, FORMAT NO: “J”

INSPECTION STAGE : COIL ERECTION


TUBE NO. OUT OF PLUMB (mm) REMARKS



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2. Separate forms shall be filled up in case of modular construction and at site aftererection.



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JOB NO. . . . . . . . . . . . . . . . . PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .

HEATER NO. . . . . . . . . . . . .


STRAIGHTNESS OF TUBES, FORMAT NO: “K”

INSPECTION STAGE : PRIOR TO FABRICATION / DURING FABRICATION


TUBE NO. STRAIGHTNESS DEVIATION ON

OVERALL LENGTH (mm)

REMARKS



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2. Separate forms shall be filled up for various stages of modular construction and atsite.

HEATER NO. . . . . . . . . . . . .


COIL SUPPORT CASTINGS LOCATION, FORMAT NO: “L”

INSPECTION STAGE : AFTER CASTING ERECTION/COIL ERECTION


SUPPORT CASTINGS.NO.

ALIGNMENT OFCASTING

TUBE RESTINGCHECK

REMARKS



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EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .. .Notes:

1. This format shall be f