hindustan petroleum corporation ltd. mumbai diesel hydrotreater...

of 30

HINDUSTAN PETROLEUM CORPORATION LTD.

MUMBAI

DIESEL HYDROTREATER PROJECT - HGU

TITLE: JOB SPECIFICATION FOR REFORMER

DOCUMENT NO : 44LK-5100-00-V-02-0201-A4

Rev No.

Issue Date Pages Rev Description Prepared By

Checked By

Approved By

0 08.08.2008 32 Issued for Feed SNK CR HSC

1 19.12.2008 30 Revised as marked and issued SNK CR HSC

Jacobs

HPCL-MUMBAI Job specification of 30

44LK-5100 For Reformer Rev 1

DOC.NO. 44LK-5100-00-V-02-0201-A4 Date: 19.12.2008

44LK-5100-00-V.02-0201-A4 Job specification for Reformer

TABLE OF CONTENTS 1.0 Introduction 2.0 Bidder’s experience

3.0 Reformer capacity

4.0 Bidder’s Scope of supply 5.0 Spare parts

6.0 Information required regarding past experience

7.0 General and engineering requirements

8.0 Inspection and testing 9.0 Quality requirements 10.0 Instructions to vendor

11.0 Vendor data requirements

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DOC.NO. 44LK-5100-00-V-02-0201-A4 Date: 19.12.2008


1.0 Introduction

HINDUSTAN PETROLEUM CORPORATION LTD. (HPCL) is planning a Residue Upgradation & MS/HSD Quality Improvement project at Mumbai Refinery (located at Mumbai in the state of Maharashtra) to increase the processing capacity of High Sulphur crude in the refinery and also to meet Euro-III / Euro IV specifications for MS & HSD.

This specification outlines the minimum requirements for Thermal / Mechanical design, Detail engineering, Material procurement, manufacture / fabrication, testing, assembly, site erection, Pre-commissioning and Performance guarantee run of Hydrogen Reformer and Waste Heat Recovery system for HPCL unit at Mumbai Refinery, Mumbai.

Selection of Process Licensor and sourcing of process design package from the Licensor of complete HGU is in the Bidder’s scope. It is expected that bidder shall source the complete thermal / mechanical deign, detail engineering, procurement specifications for critical items from Licensor for further engineering and execution of Reformer package.

2.0 Bidder’s experience LEPCC BIDDER should have executed at least one Hydrogen Reformer package by the steam-

hydrocarbon reforming route having similar capacity as mentioned in tender. The Reformer package executed by the Bidder meeting the above mentioned criteria should have

been executed within the last 10 years and should have been in operation for at least one year. BIDDER shall submit the following documents as part of their technical offer:

• Past experience list in relation with the above mentioned requirement • Certification from client regarding supply and satisfactory working condition of the Reformer

package

For Licensor’s qualification criteria and other requirements refer tender documents

2.1 Sub-vendor qualification criteria

All items in the Reformer package shall be sourced from the vendors listed in the Licensor approved vendor list. For items which are not included such list, bidder shall follow the approved vendor list enclosed with this tender. In any case for all items respective supplier / vendor must have proven track record (PTR) of supply of similar items as under:

i. Auxiliaries / sub components (Dampers, APH, Steam drum, Catalyst tubes)

− At least 2 jobs in last 5 years out of which at least one shall be in successful operation for last 1 year

ii. Auxiliaries / sub components (pressure parts, skin thermocouples, fabric expansion joints, castings, refractory items, spring hangers etc.)

− At least 2 jobs in last five years

iii. Waste heat / Process Gas Boilers

− At least 2 jobs in last five years out of which at least one shall be in successful operation for last one year

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DOC.NO. 44LK-5100-00-V-02-0201-A4 Date: 19.12.2008


iv. Heat Exchangers

− At least 5 jobs in last five years out of which at least 2 shall be in successful operation for last one year

v. Sub-contractor for structural fabrication, erection & assembly

− Sub-contractor shall have experience of executing similar activity fro minimum two heaters in last 10 years

− Name of proposed sub-contractors with work experience shall be submitted

3.0 Reformer Capacity

Reformer capacity shall be as given by the selected Licensor in line with the total capacity of HGU

unit and shall be indicated by the bidder. 4.0 Bidder’s Scope of supply

The scope of supply for the REFORMER PACKAGE includes all the items, services and other points as elaborated in the following paragraphs treating the same as one single complete package:

4.1 Supply LEPCC Bidders Scope includes Supply of the items as mentioned below 1 Reformer Box 2 Catalyst Tube Assemblies + Reducers and Outlet Cone Assemblies 3 Refractory Material (Bricks, Castable for Boiler Modules along with Anchors) 4 Refractory Material (Bricks, Castable for Reformer Radiant Chamber, Cold Outlet

Collector, from Convection Section to Outlet, Boiler Module, along with Anchors) 5 Special Parts, Cast Parts, Tubes, Fittings & Hardware for Convection Coils 6 Hairpin Tubes 7 Inlet Distributor 8 Waste Heat (RG) Boiler 9 Steam Drum 10 Pre-Reformer, when required as per Licensor’s package

11 Cold Collector 12 External Insulation Material for Inlet Hot Parts and Catalyst Outlet System 13 Burner Assembly with Refractory Blocks with Portable igniters - 10 nos.

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14 Air pre-heaters as required 15 VFD Panels for Fans (with one VFD as hot stand by) 16 Constant Load Hangers for Catalyst Tubes with Tie-Rods, Turn Buckles 17 Welding Electrodes and Filler Wires for Welding of Hot Parts and Catalyst Tube

Outlet System 18 Welding Electrodes and Filler \wires for Welding of Catalyst Tube Outlet Reducers

and the Outlet Cold Collector 19 Spring Hangers with Tie-Rods, Turn Buckles 20 WHR modules 21 Combustion Air Ducting & associated components

22 External Burner Piping, Riser and Down-comers, Inter connecting Piping within Reformer Package

23 Thermo-indicative Paint 24 Miscellaneous (Studs and Bolts, Special and other miscellaneous items) 25 Commissioning Spares 26 Refractory Materials i.e. Lining Materials (Ceramic Fibre Materials, Castable for

lower end of Reformer & convection section and stack along with anchors) 27 Convection Coils 28 Combustion Air Blower including motor 29 Flue Gas Fan including motor 30 Boiler Blow-down Drum 31 Boiler Blow-down Cooler 32 Dampers 33 Expansion Bellows (Metallic, Fabric) 34 Actuators for Dampers, Air Flow Venturi 35 Combustion Air Ducting & Casing 36 Structural Steel & plates 37 Reformer Stack 38 Silencer for Steam Drum Vent

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39 Gratings as required for platforms and staircase 40 Ladders as shown in the drawings 41 First Fill of Oil Lubricants 42 Miscellaneous Items like rope gaskets etc. 43 Commissioning Spares for indigenous Items 44 Electric Motors for Fan (type shall be suitable for Zone & Area) 45 Aviation lamp and Lightening arrestor including cabling as required from top position

to bottom panel 46 Pipe racks as required for piping inside reformer package 47 All structural supports for pipe lines inside reformer package 48 Pipe supports as required inside reformer package 49 Valves as required for piping 50 Materials for various Nozzle assemblies required for instruments 51 Accessories required for loading of catalyst 52 All anchor bolts, templates for anchor bolts, connection bolts for structural steel Note: 1 Any item identified and added as a result of detailed engineering shall be in the

scope of supply of LEPCC Bidder. 2 Inspection and testing for all shop-fabricated items shall be carried out by Third

Party Inspection agency (TPI). LEPCC Bidder shall include the same including charges in their scope

3 Inspection and testing for all bought out components shall be carried out by Third

Party Inspection agency (TPI). LEPCC Bidder shall include the same including charges in their scope

4 LEPCC Bidder shall provide necessary certification for suitability of motors for VFD

application. Hot standby is required for VFD and by-pass arrangement shall be integral part of the system. No separate switch gear / feeder will be provided by Client / Jacobs

5 Stack height shall be decided by vendor based on the stipulations given by Ministry

of Environment and Forests gazette notifications 18th March 2008.

Minimum height of stack shall be 60 m and vendor shall substantiate the provided

height by way of calculations 6 For fans, LEPCC Bidder shall provide vibration monitoring system

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4.2 Scope of work of Reformer package LEPCC Bidder scope shall include complete detailed engineering of the Reformer package

including selection of Licensor and Reformer execution agency, all the items mentioned above and other associated items required for completeness of the package

LEPCC Bidder’s scope shall include, but not limited to following engineering activities: 1 Complete thermal / Hydraulic design including preparation of Datasheets for

Reformer package (including all the equipment involved in the package) 2 Thermal rating of Convection coils and Air pre-heater coils 3 Detailed integration of the Waste heat boiler comprising the Process Gas boiler,

Steam drum and the inter connecting risers and down comers 4 Noise level assessment 5 Design of Fuel / Combustion air distribution (including carrying out Combustion air

duct flow modelling or CFD) to the Reformer 6 Preparation of data sheets for ID/FD/Penthouse fans 7 Complete flexibility analysis of Reformer and its inlet / outlet system, Waste heat

recovery system, process / fuel / steam / blow down piping 8 Verification of civil works during execution and on completion 9 Structural design of the Reformer, convection box, associated ducting, platforms,

ladders, staircase etc for all the external and internal loadings as per design code (refer Licensor package for details)

10 Arrangement and detail drawings for Reformer, convection box, associated ducting,

platforms, ladders, staircase etc 11 Design of structural connections for Reformer, Convection bank, all ducts and

accessories like staircase, platforms etc 12 Engineering, stress analysis, Arrangement drawings, Isometrics of all pipe lines

covered in the Reformer package 13 Design calculations for catalyst tubes as per API 530 14 Foundation loads for the complete package 15 Design, Strength calculations and Arrangement and fabrications drawings for Stack 16 Design, Strength calculations and Arrangement and fabrications drawings for Pre-

Reformer 17 Design, Strength calculations and Arrangement and fabrications drawings for Steam

Drum (including all risers and down comers)

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18 Design, Strength calculations and Arrangement and fabrications drawings for Waste Heat (RG) Boiler

19 Design, Strength calculations and Arrangement and fabrications drawings for Boiler

Blow-down Cooler 20 Design, Strength calculations and Arrangement and fabrications drawings for Boiler

Blow-down Drum

21 Design and engineering of support structures for Steam drum, Waste Heat Boiler,

Boiler Blow-down cooler and Boiler Bow-down drum

22 Design, Strength calculations and Arrangement and fabrications drawings for all ducting

23 Design, Strength calculations and Arrangement and fabrications drawings for all

pressure bearing components including catalyst tubes, convection bank coils, feed pipe etc

24 Flow induced Vibration analysis for convection bank coils, if required 25 Calculations and drawings for expansion bellows (metallic / cloth) 26 Design / selection and all related drawings of rotating equipment 27 Sizing and pressure drop calculations for ducts 28 Design calculations and Arrangement and detail drawings for respective refractory

materials 29 Anchor bolt sizing calculations for all the supports 30 Design, engineering, Arrangement and detail drawings for all inter connections of

various items of Reformer Package 31 All other calculations, though specifically not mentioned above but required for

completeness of the Reformer package 32 PDS model for the complete Reformer package 33 Inspection requirements including stage wise third party inspection 34 Fireproofing of structures as per the requirements of OISD STD 164 35 First load of catalyst in the Reformer Catalyst tubes as per the directives if Client /

Jacobs 36 Testing and verification of complete Reformer and ducting system for fabrication

and gasketing to prevent air leakage 37 Primer and final painting of Reformer package 38 Performance testing of bought-out equipment like Air Pre-heater, Burners etc at the

supplier’s work and its witnessing if required by Licensor

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39 Flushing / chemical cleaning (pickling / passivation / neutralization) as required 40 Pre-commissioning and refractory dry out 41 Start up and commissioning 42 Demonstration of Performance guarantee 43 Obtaining approval from any statutory required as per statutory rules and regulations

of Central / State government including the necessary co-ordination and liaison work Note: Engineering and design shall meet all the requirements of Licensor specifications

and API 560. Services − LEPCC Bidder shall provide services for customs clearance and port handling for

IMPORTED ITEMS. − LEPCC Bidder shall provide inland transportation of the IMPORTED ITEMS from port

to site of the UNIT − LEPCC Bidder shall provide inland transportation of INDIGENOUS ITEMS from vendor

workshop(s) to site of the UNIT − All required Insurance services shall be included in the scope of LEPCC Bidder Erection work Erection of all supply material by LEPCC Bidder of Reformer Package shall be as broadly

detailed here below: 1 Erection of all steelwork including installation of roofing 2 Piping together with valves and fittings 3 Installation of refractory lining 4 Installation of pressure parts including reformer tubes, inlet manifold, inlet hairpins,

inlet hairpins & tube suspension system with field jointing as required 5 Installation of waste heat recovery system comprising pre-fabricated convection

coils, steam drum and process gas boiler, risers and down-corners and boiler blow-down equipment with field joints as required

6 Installation of Combustion-air Pre-heaters and Combustion-air ducting 7 Installation of Combustion air blower and Flue gas fans with VSD drives (including

hot stand-by), their dampers and air intake stack with strainer & venture, and flue gas stack

8 Erection of burners & burner blocks

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9 Hydraulic testing of piping and equipment after installation 10 Installation of special thermal insulation of inlet manifold, inlet hairpins and outlet

system 11 Application of painting of equipment, piping and structural 12 Installation of pre-reformer 13 Installation of miscellaneous items 14 Statutory clearance from IBR authorities and any other for erection of Reformer

package 15 Dry-out of the furnace during pre-commissioning 16 Loading of catalyst during pre-commissioning 17 Providing non-shrink grout (25 thru 50 mm thk) below column base plates / shoe

plates including sleeves and pockets as per drawings / manufacture's specification Notes: 1. LEPCC Bidder shall refer Licensor package documents for specific details. In case

of conflict between this document / Jacobs documents and Licensor’s documents, stringent one shall become applicable

2. Reformer box steel wall panels, floor & ceiling panels are to be engineered and

constructed as pre-fabricated modules (semi-finished materials) 3. Convection box shall be in modular construction 4.5 GUARANTEES for Supply portion 4.5.1 Performance guarantee LEPCC Bidder shall guarantee the performance parameters for Reformer in line with Licensors

process package requirements. Same shall include the following as a minimum: 1 Reformer capacity in terms of heat absorbed in line with Licensor’s design 2 Overall efficiency of the Reformer, expressed as total heat absorbed in the radiant

and convection section (excluding Air pre-heaters) as a percentage of total heat input, shall be equal to or more than 90% based on LHV of fuel used during the performance test run

3 Steam export quantity from Reformer Package as defined in HGU process package

4 Maximum pent-house temperature shall be less than or equal to the maximum

ambient temperature +20°C 5 NOX emission from the Reformer stack shall be less than or equal to 100 ppmv.

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DOC.NO. 44LK-5100-00-V-02-0201-A4 Date: 19.12.2008


6 Casing temperature shall be less than or equal to that calculated as per API-560 method.

Exempted from this guarantee are peep door, access doors, casing over burner

blocks, inspection doors, all locations of tube-sheet ears, weld stiffeners, on support on the inside walls, area around catalyst tube entry, instrument connections, floors and walls in vicinity of hot header etc.

4.5.2 Price discount and liability If not otherwise mentioned elsewhere in the tender documents, following shall be the applicable

price discount and liability of LEPCC bidder:

Reformer Package

For proper accountability of performance of Reformer package, LEPCC bidder shall indicate the value of the Reformer package and based on this value, following shall be arrived at:

4.5.2.1 Penthouse

allowable temperature

Refer process related chapter

4.5.2.3 Steam export Refer process related chapter

4.5.2.4 Thermal efficiency Refer process related chapter

4.5.2.5 Reformer capacity Refer process related chapter

4.5.2.6 NOX emission Refer process related chapter

4.5.2.7 Casing temperature

Refer process related chapter

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DOC.NO. 44LK-5100-00-V-02-0201-A4 Date: 19.12.2008


4.6 Mechanical warranty for materials LEPCC Bidder shall stand warranty to HPCL for a period of 12 (twelve) months from date of

commissioning or 18 (eighteen) months form the date of mechanical completion of the package whichever is earlier. All items of the Reformer package delivered to HPCL shall be free from defects in design, material and/or workmanship

Remedy under warranty If the Reformer package fails to conform to the specifications or proves defective in material or

workmanship or if any defect occurs in Reformer package or in any part or component thereof within the period of warranty LEPCC Bidder shall, investigate the failure or defect and at their option, and at their expense, promptly either repair or replace the Reformer package or the applicable parts or components thereof.

Bidder shall bear the responsibility for the costs of repair or replacement excluding those for

removal and reinstallation of any defective material or component, but including any related freight costs and duties.

If the Erection work proves defective in workmanship within the period of warranty Bidder shall,

investigate the defect and at its option, promptly rectify the defect. Bidder shall bear the responsibility for the costs of rectification and/or replacement.

4.8 Safety Regulations, Accident and Damage LEPCC Bidder shall be responsible at his own cost in and relative to performance of the work

and Agreement to observe and to ensure observance by his sub-contractors, agents and servants of the provisions of the Safety Code as hereinafter appearing and all fire, safety and security regulations as may be prescribed by HPCL from time to time and such other precautions and measures as shall be necessary and shall employ/deploy all equipment necessary to protect all works, materials, properties, structures, equipment’s, installations, communications, and facilities whatsoever from damage, loss or other hazard whatsoever (including but not limited to fire and explosion) and shall during construction and other operations to minimize the disturbance and inconvenience to HPCL, other contractors, the public and the adjoining land and property owners and occupiers, and crops, trees and vegetation and shall indemnify and keep indemnified HPCL from and against all losses and damages and costs, charges and expenses and penalties, actions, claims, demands, and proceedings whatsoever suffered or incurred by or against HPCL as the case may be, by virtue of any loss, alteration, displacement, disturbance or destruction or accident to any works, materials, properties, structures, equipment, installations, communications and facilities and land and property, owners and occupiers and crops, trees and vegetation as aforesaid, with the intent that Bidder shall be exclusively responsible for any accident, loss, damage, alteration, displacement, disturbance or destruction as aforesaid resultant directly or indirectly from any breach by Bidder of his obligations aforesaid or upon any operation, act or omission of Bidder or his sub-contractors(s) or agent(s) or servant(s).

5.0 Spare parts 1 For mandatory, Erection & Commissioning spares refer spares list attached elsewhere in the

tender / amendment document. Spares for fans and electrical components shall be as mentioned in respective documents

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6.0 Information required regarding past experience

LEPCC Bidder shall supply the following information along with their bid regarding their past

experience: 1 Name of the unit / company 2 Whether the company is captive / non-captive 3 Name of the contact person, Address, Telephone & Fax nos 4 Details of Licensor & EPCC Bidder 5 Name of the supplier of Reformer Package 6 Month & Year of start-up of the unit 7 Capacity − Design: Guaranteed & Actual

8 Fuel − Fuel fired and Type of firing (Top, side or bottom)

9 Operating problems experienced, if any

Note 1) EOR condition may please be provided if catalysts have been replaced. 2) BIDDER to furnish documentary proof regarding Reference Unit meeting the

guarantees 7.0 General and engineering requirements For static equipment under pressure, all designed flanges shall be checked as per ASME

Section VIII Div. 1 Appendix 2 and blind flanges as per UG-34 of ASME Sec. VIII Div. 1 using allowable stress as per Div. 1.

Nozzle flanges conforming to ASME B 16.5/ASME B 16.47 series B shall be used for process

nozzles. Specially designed nozzle flanges, violating standard flange parameters for reducing their

weights shall not be permitted. All flanges shall also be checked for actual piping loads of connected piping systems are

available. Wind and seismic requirements − Wind load design shall be as per IS 875 (including latest amendment) considering the

following parameters: − Seismic design shall be as per the IS 1893

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DOC.NO. 44LK-5100-00-V-02-0201-A4 Date: 19.12.2008


Piping loads Refer General specification for Pressure vessels for piping loads The test results including details of heat treatment shall be reported and documented. All weld metal tensile tests at room temperature as well as high temperature tests shall meet

the minimum requirement of the base metal. Hardness Hardness of forgings and plates shall meet requirements of Process Licensor’s project

specification. Hardness measurement shall be conducted by portable hardness tester type EQUOTIP or equivalent.

Painting Primer and final Painting shall be carried out as per Jacobs specification for painting For all the materials in bidder’s scope of supply, fabrication, erection, commissioning spares

shall also be included in their quoted price For making purchase specifications, bidder shall supplement procurement specifications

prepared by Reformer contractor / Licensor with the requirements of bid package, standard specifications and code requirements

7.1 Structure 7.1.1 Structural steel shall be to IS 2062 Gr A or equivalent 7.1.2 Radiant and Convection casing plate shall be 6 mm (min) thick. Arch and floor plate shall be

min 8 mm thick 7.1.3 All field joints between modules shall be seal welded after erection to minimise the leakage in

operation. 7.1.4 All gratings shall be fabricated, hot dip galvanized. Each grating shall be fixed with minimum 4

clamps at a maximum spacing of 850 mm. Clamps also shall be hot dip galvanized. Bidder shall consider Jacobs civil engineering standards and specifications for all civil / structural related issues.

7.1.5 Gratings shall be of 500 kg/cm

2 capacity

7.1.6 For all anchor bolts bidder shall refer Jacobs civil standard 7.1.7 For all main connections minimum M20 bolts shall be used and for all secondary connections

minimum M16 bolts shall be used 7.1.8 For stack, duct joining the stack shall be provided with flexible expansion joint near stack

connection so that ducting loads are transferred to stack 7.1.9 For stack minimum 5% of welded joints and all T joints shall be radiogarphed 7.1.10 Stack and cold flue gas duct erection shall be done after completing refractory lining and heat

dry-out at ground

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DOC.NO. 44LK-5100-00-V-02-0201-A4 Date: 19.12.2008


7.1.11 No of splice joints on stack shall be minimum and such joints shall be strength welded after

erection 7.1.12 Sliding supports for ducting shall be provided Teflon, Graphite and other low friction sheets as

per temperature limitations along with roller supports 7.1.13 Lap joints of casing plates with structural members shall have continuous fillet weld on outside

and 50 mm long fillet welds on 200mm centres on inside 7.1.14 Structural steel shall be designed to permit lateral and vertical expansion of all parts and ducts

as applicable 7.1.15 All ducts shall be stiffened suitably to prevent deflection and warping. 7.1.16 Unsupported duct length shall generally be limited to 4 times the smaller cross-sectional

dimension of the duct. 7.1.17 Deflection of refractory lined ducts shall be limited to 1/360

th of the span and for other ducts to

1/240th of the span

7.1.18 For structural design following requirements shall be considered − Design margin shall be +10% (minimum) for all types of estimated loads − Minimum gravity loads case shall be either erection condition or maintenance condition

whichever results in lower gravity load. For minimum gravity -10% design margin shall be considered

− Corrosion allowance for Reformer radiant, convection casing plate and ducting shall be

1.5 mm and stack shell shall be 3 mm. − Wind and earthquake load shall not be considered acting simultaneously − All superimposed loads from connected piping shall be taken care during structural design − Following live loads shall be considered in design • 300 kg/cm

2 for stack platforms

• 250 kg/cm2 for other platforms

• 100 kg/cm2 for Radiant floor

• Dead load for all platforms shall be 150 kg/cm2

− Design metal temperature of structures, ducts and appurtenances shall be as indicated in

the drawings and minimum 150 oC in general

− Maximum deflection of beam member shall not exceed 1/325 of the span − Seismic zone shall be as per IS 1893. For earthquake design importance factor of 2 shall

be considered for heater, stack & duct support structure with damping factor of 2% − Stack shall be self supporting and shall be analysed fro wind induced vibration and

strakes shall be provided

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− All nozzle openings in the stack shall be suitably reinforced either with steel members or fabricated steel members or reinforcing pad plates as required by the design calculations.

− Minimum number of anchor bolts for stack shall be 32 − For stack allowable stresses shall be as per IS 6533. Combined membrane and bending

stress in stack steel and stiffening ring shall not exceed 90% of minimum yield strength as design temperature

− No increase in permissible stresses shall be considered for stack design. For other

structures increase in permissible stresses as per code can be considered where design loads are dictated by earthquake and not by wind

7.2 Centrifugally cast tubes and cast fittings − Centrifugally cast tubes shall be made in accordance with the requirements of ASTM A

608 − Statistically cast fittings shall be made in accordance with the requirements of ASTM A

351 − Heat analysis of tubs and fittings shall be carried out as per ASTM A 608 S4 and A 703

respectively − Stress rupture test shall be performed on 5% of the heats used for centrifugally cast tubes

(minimum one each) in accordance with ASTM A 608 S3 − Entire inner surface of catalyst tubes, after machining, of 55 of total no. of sections,

selected at random with a minimum of two per purchase order shall be Boroscopically examined with acceptance criteria as per clause 9.1 of ASTM A 608

− Roughness examination for entire outer surface and one reading for inner surface shall be

carried out from each size of tube / fitting fro 5% of total no. of tube sections / fittings, selected at random with a minimum of two per purchase order

− Holding time for hydro test shall be maximum 30 minutes − Each tube assembly shall comprise of minimum nos. of tube sections of which none is

shorter than 1000 mm − Bow in any complete tube shall not exceed 1 mm per meter to a maximum of 6 mm − Tempering temperature shall not exceed lower critical temperature and PWHT shall not

exceed tempering temperature − Hardness testing of weld metal and heat effected zone on the job shall be carried out as

per clause 331.1.7 and hardness shall not exceed the values specified in table 331.1.1 of ANSI B 31.3. Weld procedure including PWHT shall be qualified for the required hardness values

− All branch connections in coil pressure parts shall be with weldolets

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− Pigtail bend surface shall be free from cracks and buckles. Bend surface and 150 mm surface adjacent to bends shall be checked by dye penetration examination and no indications are permitted

− In addition to radiographic examination, all nozzle welds in CS and Cr/Mo steels shall be

examined by MP and all austenitic steels by DP − Steam and boiler feed water service coils shall be hydro tested in accordance with the

requirements of IBR − Piping for and around burner shall be routed in such a manner that it does not obstruct

removal and installation of burners, access to any instrument connections and walkway & head room of 2m minimum for operator’s movement

− All pressure part welding shall be 100% radiographed − All inlet, outlet terminal and manifolds shall have vent or drain. Any high external points

and low points on coil shall be provided with vent and drain − Coil stress / flexibility analysis shall be carried out combined with external piping.

Complete coils including external crossovers shall be analysed and supported properly. Flange rating adequacy shall be checked for external loads due to piping

− Coil shall be hydro tested at shop for prefabricated assemblies and again at site fro

completed coil 7.3 Tube support castings − Each pilot casting of tube support castings shall be 100% radiographed in accordance

with ASTM E-446 and for all production tube support castings following minimum radiography examination shall be carried out:

− Tube support castings : 100% on 5% of production castings with a min of two

nos. per pattern − Tube sheet castings : Radiography at critical sections on all tube sheets (Min

of 5 locations per tube sheet) − For 25Cr-12Ni castings, materials shall conform to ASTM A 447 type –II. To limit number

of tests to two, MP & Stress Rupture tests shall be carried out − Maximum delta ferrite content in 19 Cr – 9 Ni castings shall be 6% 7.4 Combustion Air Pre-Heater − Air Pre-heater shall be recuperative type – either plate type or cast iron tube type − For APH, leakage rate between combustion air and gas shall be maximum 0.04% of

normal flow APH − Design temp. of carbon steel plates for hot air ducting is allowed upto 427

oC

− Under all operating conditions, including turndown, skin temperature of air pre-heater coil

shall not fall below sulphur dioxide dew point plus 15 oC

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− APH shall be leak tested at supplier’s works before dispatch 7.5 Dampers − Damper frame shall be strong enough to take external loads coming on the same. It shall

meet all structural requirements of API 560 as well as IS 800 − Damper shaft shall be corrosion resistant material capable of transmitting full operating

torque without exceeding 33% of shear yield stress − Damper bearings shall be self-aligning, high temperature, non-seizing, self lubricating,

sealed for life − Damper actuators shall be capable of delivering 150% of the maximum required operating

force used with the minimum available air pressure. Damper shaft and bearings shall be suitable for the force of 150%.

− Damper shall be tested in shop along with their actuator prior to dispatch − All dampers shall have provision for winch and cable arrangement fro manual operation. − All dampers shall use SS 316 wire rope and turn buckles shall be located at the platforms 7.6 Process Gas Boiler and Steam drum − Equipment shall be post weld heat treated if required as per data sheets and/or code − Equipment shall be 100% radiographed and radiography shall be done after PWHT when

PWHT was carried out − Necessary access platforms and steel supporting structure shall be provided as required − Nozzles shall be checked for local nozzle loading − These equipment fall under IBR and shall be provided with all necessary certification from

CIB. Process Gas Boiler − Steam generation system is to be designed for minimum circulation ratio as specified by

Process Licensor for entire range of operation including turndown operation. − Process gas boiler shall be high Heat flux boiler with minimum residence time − Tube to tube sheet joints shall be strength welded 8.0 Inspection and testing

8.1 For Plates and pipes (pressure bearing)

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DOC.NO. 44LK-5100-00-V-02-0201-A4 Date: 19.12.2008


a) All Plates greater than 20mm thick shall be 100% ultrasonically examined for laminations as per requirements of SA 435

b) Full penetration joints of all static equipment under internal pressure, pipelines with

feed gas & fuel, Convection bank coils, Cold collector shall be 100% radiogarphed c) Magnetic particle examination by wet fluorescent technique shall be performed

before welding on all bevels d) Liquid penetrant examination shall be conducted on all inner surfaces after hot

forming, if applicable, and heat treatment e) Stringent of the NDT, PWHT, inspection & testing requirements specified in

Licensor Process package, this Job specification and respective design code shall be governing

8.2 Fittings Ultrasonic examination shall be conducted on entire volume after hot forming and heat

treatment as per ASME Sec. VIII and Sec. V. 100% UT thickness gauging of elbow shall be at extrados section.

Magnetic particle examination by wet fluorescent technique (WFMPT) shall be done on all

edges to be welded after final machining. At site, based on the availability MP can be carried out by WFMPT or dry powder MP / DPT by visible dye solvent removable method can be adopted. In case of austenitic steels DPT shall be carried out by visible dye solvent method.

Liquid penetrant examination on all inner and outer surface of elbows after forming and heat

treatment as per ASME Sec. VIII and Sec. V. For inaccessible inner surfaces, DPT shall be carried our on outer surfaces.

8.3 Bolting Magnetic particle examination shall be conducted on entire surface before machining of

threaded portion 8.4 Flanges/Forgings Ultrasonic examination shall be carried out on entire volume after machining. Liquid penetrant examination shall be carried out on entire volume after final machining. 8.5 Radiography For all pressure bearing components radiography shall be as per design requirements Radiography shall be conducted before and after final PWHT, where PWHT is required as per

code. For structural joints, 5% of total butt joints shall be radiographed 8.6 Magnetic particle examination shall be done on the following: a) All inside surfaces of accessible category A, B and D joints.

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b) Back Chipped surfaces of accessible category A, B and D joints 8.7 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.

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Minimum stage-wise inspection requirements with Hold points by third party at shop and

Jacobs at site:

S. NO.

ITEMS/PROCEDURE WITNESS (HOLD POINT)

REVIEW APPROVAL

1 RAW MATERIAL

Plates, nozzle forgings, raw materials � 2. AT SHOP / Site

A Material Certificates �

B PMI - all pressure bearing materials �

C QAP �

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

E Welding consumable qualification � �

F Manufacturing procedure including weld procedure /

sequences, heat treatment procedure (PWHT etc.), NDT procedure, NDT personnel qualification, hydro / pneumatic test procedure etc

� �

G UT examination �

H RT �

I MP examination � � J Liquid penetrant examination �

K Chemical analysis �

L Chemical analysis of production welding of base

metal � �

M PWHT � �

N Hardness survey �

O Dimensional inspection and hydro test �

P Nitrogen filling at 0.5 kg/cm2 as required �

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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 Jacobs 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 third party requirement and Owner / Jacobs requirements the matter shall be referred to Jacobs /Owner in writing for resolution/decision.

4. Tolerances and requirements mentioned in Jacobs Standard specifications shall be complied with

by vendor. In case there is a conflict of requirements with respective code requirements, they shall be addressed to Jacobs site inspection / Engineer-In-Charge and shall be resolved on case to case basis.

Jacobs



DOC.NO. 44LK-5100-00-V-02-0201-A4 Date: 19.12.2008


9.0 Quality requirements 9.1 Introduction As a part of services rendered to the client, Jacobs purchase Product / Services for various

projects on behalf of Client from various vendors. 9.2 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 project’s stated and implied needs to Client’s total satisfaction.

9.3 Scope The requirements of this standard are applicable to all Vendors for supply of Packages,

Equipment and Material 9.4 Definition ‘LEPCC Vendor’ means the person(s), firm, company, organisation on whom Order is placed by

client for HGU plant 9.5 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.

9.6 Inspection and Test Plan Vendor shall submit Inspection and Test Plan for approval within 4 weeks of PR and before

commencement of manufacture to concerned Third Party Inspection Agency. Inspection and Test Plan shall also cover “bought out” items from sub-vendors. TPI Approved copy shall be submitted to Jacobs for review / comments

9.7 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 4 weeks from Telefax / Letter of Acceptance. The Drawing schedule shall be specific with regard to drawing/document No., the exact title and the size of the drawings/documents.

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

Manufacturing Schedule every month.

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9.9 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.

9.10 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 Licensor approved vendor list and for items not covered in that list 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 4 weeks from Telefax/ Letter of Acceptance. 9.11 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.

9.12 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.

9.13 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. 9.14 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 jab to job basis, vendor shall confirm its validity and only revisions/deviations if any, shall be submitted for approval. The 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.

9.15 Vendor Documents for Jacobs Review/records General i. All documents shall be in ENGLISH language and in M.K.S. system of units.

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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 for 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.

v. Vendor shall submit list of documents and drawings that require approval from Jacobs.

In general these shall cover the following: − Layout of Reformer package − General Arrangement of elevations and sections − Catalyst tube details − Inlet distributor arrangement − Stack GA − Steam drum GA − WHB GA − Cold Collector GA − Prereformer GA − Arrangement of Convection Section − Design calculations for pressure retaining parts − Thermal calculations for Refractory − Fan GA, performance curves etc − Motor data sheets − Sub-vendor list − QAP vi. All other documents including piping, steel fabrication drawings shall be for information

only 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 Documents for Review and Documents for Records shall be submitted in separate folders with

separate covering letter to facilitate expeditious processing at Jacobs. 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 :

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DOC.NO. 44LK-5100-00-V-02-0201-A4 Date: 19.12.2008


DRAWING/DOCUMENT TITLE : DRAWING/DOCUMENT NO. : REVISION AND DATE : JACOBS VENDOR PRINT NO. : 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.

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.

Vendor shall forward all Drawings/Documents (transparencies and printed matter), to Jacobs

Engineering India Pvt. Ltd., Attention: Vendor Print Control, and the copy of forwarding letter/transmittal to Jacobs Inspection Department as well as to the Client.

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 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. Final Documentation 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.

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DOC.NO. 44LK-5100-00-V-02-0201-A4 Date: 19.12.2008


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.

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. 10.0 Instructions to vendor 10.1.0 Bidding instructions If the offer contains any technical deviations other than those agreed as per MOU with Jacobs

and or if the bid does not include complete scope and technical/performance data required to be submitted with the bid, the offer shall be summarily rejected.

The submission of prices by the LEPCC Bidder shall be construed to mean that he has

confirmed compliance with all technical specifications of the corresponding item(s). 10.2.0 General instructions 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 Jacobs drawings/documents.

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.

All fabricator’s drawings submitted to Jacobs shall be based on purchase requisition and shall

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

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.

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.

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.

Jacobs



DOC.NO. 44LK-5100-00-V-02-0201-A4 Date: 19.12.2008


After receipt of order, fabricator shall submit to Jacobs, the planning of fabrication which shall indicate the details and scheduled dates

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

end of fabrication and delivery 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 FOA / LOA. Vendor shall strictly adhere to this drawing submission schedule.

All drawings shall be drawn in AUTOCAD. No hand drawn drawings shall be accepted. All

residual calculations shall be computerised. Vendor shall identify the items that are pre-fabricated at shop under third party inspection and

confirm the same in their bid. Equipment which shall be completely fabricated at shop shall be completed accordingly

including final painting and shall be transported to site and erected. Respective activities shall become part of Reformer package and LEPCC Bidder shall include the work in respective categories of supply and erection.

Documents and letters shall be furnished in electronic format. The software used shall be as

follows. a) MS OFFICE latest b) ADOBE ACROBAT latest 11.0 Vendor data requirements 11.1 Documents to be submitted along with the offer a) Past Experience list b) Client’s certificate regarding satisfactory working of Reformer package c) Indicative bar chart d) Statement of compliance to Requisition requirements e) Licensor’s basic process package for Reformer f) All relevant P&IDs g) Layout of Reformer package h) Licensor’s specifications for Reformer package including vendor list i) All other documents as mentioned at respective clauses of the tender 11.2 Documents to be submitted after award of order a) Vendor shall furnish detailed list of drawings and the schedule of submission of drawings

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b) List of documents to be submitted as follows: 1 For approval Plot plan for Reformer package General arrangement drawings indicating plans, elevations, Cross sections, design data,

general notes, nozzle schedule For information

Steel General Arrangement drawings Foundation load drawings and equipment weights Piping arrangement drawings and required isometrics Refractory General Arrangement drawings Details of nozzles Piping loads near battery limits 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 Notes: 1) Above list is indicative only. 2) LEPCC Bidder shall indicate the list of deliverables and same shall be mutually

agreed by Jacobs / Owner 11.2.1 Bidder’s final documentation shall consist of the following as a minimum: a) All drawings related to all items which become part of the Reformer package including

all General Arrangement drawings, Detail drawings, Erection drawings, Isometrics, part lists, load lists, electrical drawings, sub-vendor documents, manuals including all strength calculations and Piping stress calculations

b) Requirements of manufacture, heat treatment, inspection and testing of materials c) Mechanical and chemical properties including hardness check d) Certified material test reports e) List of heat number of pressure bearing parts and Material test results of all pressure

bearing parts

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f) Mechanical test and chemical analysis g) Dimensional inspection and Record of dimensional inspection h) NDT i) Record of production weld tests j) Records of ND examination of welds k) RT reports, UT reports, PT reports, MT reports l) Facsimile of name plate m) Record of PWHT n) Mill test certificate for electrodes, wires, consumable inserts, fluxes j) Mill test certificate for all plate materials, bolts, nuts and gaskets and all other non-

pressure bearing parts including internals. k) All documents related to electrical and rotating equipment Notes: 1) All documents shall be hard bound with facility to remove and attach papers. All

papers should have end protectors and all documents are to be properly indexed. 2) All documents shall be in English Language. 3) All drawings shall be drawn in AutoCAD. All calculation shall be computerised. 4) All Final and As Built documentation shall be submitted in CD (Compact Disc) also.