inspection and test plan for heat...

INSPECTION AND TEST PLAN FOR HEAT EXCHANGERS STANDARD SPECIFICATION NO.

6-81-0009 Rev.0 Pae 1 of 7

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INSPECTION AND TEST PLAN

FOR

HEAT EXCHANGERS

Applicable code & specifications: As per PR SCOPE OF INSPECTION SL. NO.

INSPECTION ACTIVITY & COMPONENT

CHARACTERISTICS QUANTUM OF CHECK

REFERENCE DOCUMENT

ACCEPTANCE STD.

FORMAT OF REPORT

SUB VENDOR

VENDOR GAIL/TPI

1.0 PROCEDURES 1.1 Heat treatment ,NDT

and other procedures including tube to tube sheet expansion/ welding, mockup test and testing

Documented Procedures

100% ASME Sec II A/IIB /VIII Div 1. / TEMA –R /Spec/Drawings

ASME Sec II A/IIB /VIII Div I. / TEMA –R /Spec/Drawings

Document - W R

2.0 MATERIALS INSPECTION

2.1 Materials At Mills Plates, Pipes, Tubes, Tube sheets, Forging, Fittings Fasteners etc. (TO BE PROCURED FROM REPUTED MANUFACTURERS)

Chemical analysis Mechanical properties, Addl. Tensile on hub, Bend test, (including impact test of plates/forging, Hardness check, simulation Heat treatment, Non Destructive Tests(ECT). Along with supplementary properties (if reqd.).Visual & dimensional inspection

100% ASME Sec II A/IIB /VIII Div I. / TEMA –R /Spec/Drawings


Mill Test Certificates

W W R

2.2 Materials After Receipt (for Pressure Parts) Plates (Shell (Tube Sheet). Pipes (shell/Nozzle ), Forgings ( nozzle/ tube test ), tubes ,fittings ,fasteners, Gaskets etc.

Review of test certificates markings Visual & Dimensional inspection Identification, Correlation & transfer of identity.

100% ASME Sec II A/IIB /VIII DivI. / TEMA –R /Spec/Drawings


Material Clearance Record

- W R

2.3 Non Pressure Parts (including internals, supports ,baffles, sliding plate etc.

Review of test certificates

100% ASME Sec II A/IIB /VIII DivI. / TEMA –R /Spec/Drawings


Insp. Report - R R

GAIL (India) Ltd.

Pata.

INSPECTION AND TEST PLAN FOR HEAT EXCHANGSERS

STANDARD SPECIFICATION NO.

Rev.

6-81-0009 Rev. 0 0 of 7

Applicable code & specifications: As per PR. SCOPE OF INSPECTION SL. NO.



REFERENCE DOCUMENT

ACCEPTANCE STD.

FORMAT OF REPORT

SUB VENDOR

VENDOR GAIL/TPI

3.0 Inspection of Formed Components

3.1

(Dished end, cone, bellows, expansion joints, floating cover etc.)

Visual & dimensional Inspection

100% Drawings/Spec 6-12-0001

Drawing /Spec/ ASME Sec.VIII-1

Insp. Report

W R R

RT of long seam if any. 100% ASME Sec V / Spec/ Drawings

ASME Sec/ Spec/ Drawings

Insp. W R R

DP/MPI

On knuckle portion and welds after forming .

ASME Sec V / Spec/ Drawings

ASME VIII-Div1 & Sec V, Spec/Drawings

Report W R R

IHT/HT chart review, if applicable

100% ASME Sec VIII -1/Spec/Drawings

ASME Sec VIII-1/Spec/Drawings

HT Chart - R R

Test Coupon

100% ASME Sec II A/Spec/Drawings

ASME Sec II A/VIII-I/ Spec/Drawings

Insp. Report

- W H

4.0 WPS and PQR (Including Weld Overlay)

4.1 PQR Welding parameters 100% ASME sec IX/ Spec.

ASME sec IX/ Spec

WPS/PQR - W R

4.2 WPQ Qualification Requirement

100% ASME sec IX/ Spec./Drawings

ASME sec IX/ Spec/ Drawings

WPQ - W R

GAIL (India) Ltd.

Pata.



6-81-0009 Rev. 0 of 7




REFERENCE DOCUMENT

ACCEPTANCE STD.

FORMAT OF REPORT

SUB VENDOR

VENDOR GAIL/TPI

4.3 Tube to Tube Sheet Welding

Chemical & mechanical properties

100% Spec/Drawings. Spec. DRG. WPS/PQR - W W

4.4 Welding consumable Chemical & mechanical properties

Per Batch & routine

ASME Sec II C Spec. Drawings

ASME Sec II C Spec. Drawings

Batch test certificates

W R

5.0 INSPECTION DURING FABRICATION

5.1

Weld Edge preparation & set up of pressure parts

Visual & Dimensional inspection, weld edge, Root gap. Offset, cleanliness etc.

100% Spec/Drawings ASME Sec VIII-1

Spec/Drawings ASME Sec VIII-1

Insp. Check List

- W R

MT/PT of weld edges as applicable

100% Spec/Drawings ASME Sec V

Insp. Check List

- W R

5.2 Intermediate Insp. of welds

Visual/interpass temp/ ISR/PT insp. after chipback etc.

100% Spec/Drawings Spec/Drawings Insp. Check List

- W R

5.3 Inspection of Completed welds

Visual inspection for reinforcement, Undercuts, surface defects etc.

100% Drawing / Spec/ASME SecVIII-1.

Drawing / Spec/ASME SecVIII-1

Insp. Check List

- W R

GAIL (India) Ltd.

Pata.



6-81-0009 Rev. 0 of 7




REFERENCE DOCUMENT

ACCEPTANCE STD.

FORMAT OF REPORT

SUB VENDOR

VENDOR GAIL/TPI

Nondestructive Test as applicable

100% Drawings/ Spec/ASME Sec VIII-1

Drawings/ Spec/ASME Sec VIII-1

NDT Report - W R

PWHT 100% Drawings/ Spec/ASME Sec VIII-1

Drawings/ Spec/ASME Sec VIII-1

HT Chart - W R

Hardness test Each weld seam & as per spec/Drawings

Drawings/ Spec.

Drawings/ Spec Insp. Report - W W/R

Production test coupon Testing

As per spec/Drawings

ASME Spec VIII-1/ Spec/ Drawings

ASME Spec VIII-1/ Spec/ Drawings

Insp. Report - W H

6.0 MACHINING DRILLING

Tube Sheet Hole dia, drift, tube hole surface finish, groove depth, spacing, ligament check and positional accuracy etc

100% Spec/ Drawings TEMA-R

Spec/ Drawings TEMA-R

Insp. Report - W W

Baffles Hole dia & finish, ligament check and positional accuracy etc.

100% Spec/ Drawings TEMA-R

Spec/ Drawings TEMA-R

Insp. Report - W R

6.1 Assembly Tube bundle 100%

Skeletion of tube bundle before tube inspection

Completeness of assembly

100% Drawings STANDARD Insp. Report - W W

GAIL (India) Ltd.

Pata.



6-81-0009 - Rev. 0 of 7




REFERENCE DOCUMENT

ACCEPTANCE STD.

FORMAT OF REPORT

SUB VENDOR

VENDOR GAIL/TPI

Final assembly after tubes insertion

Alignment, completeness of assembly

100% Spec/ Drawings

Spec/ Drawings Insp. Report W W/R

Shell Final before release for PWHT

Completeness, passing of box template

100% Spec/ Drawings

Spec/ Drawings Insp. Report - W W

Channel /Bonnet /Foating Head

Dimensions ,completeness of assembly

100% Spec/ Drawings


Tube to Tube Sheet Expansion /welding

% Thinning, Length of Expansion, finish & hardness/Visual, distortion & DP of welds

Random Spec/ Drawings


PWHT PWHT chart Review 100% Spec/ Drawings

Spec/ Drawings Insp. Report - W R

Hardness test Each weld seam & as per Spec/ Drawings

Spec/ Drawings


Production test coupon Testing

As per Spec/ Drawings

Spec/ Drawings

Spec/ Drawings Insp. Report - W W/H

7.0 FINAL INSPECTION 7.1 Visual and Dimensional

Insp. (Internals & externals)

Dimensions, completeness of assembly

100% Drawings Drawings Insp. Report - W H

7.2 Air test of pads & Tube to Tube Sheet joints

Leak Check 100% Drawings/ Spec. TEMA-R

Drawings/ Spec. TEMA-R

Insp. Report - W R

GAIL (India) Ltd.

Pata.



6-81-0009 Rev. 0 of 7




REFERENCE DOCUMENT

ACCEPTANCE STD.

FORMAT OF REPORT

SUB VENDOR

VENDOR GAIL/TPI

7.3 Hydrostatic Test Shell side Tube side

Leak Check 100% Drawing/Spec/ ASME Sec VIII-

1

Test Report Insp. Report - W R

7.4 Surface preparation /cleaning

Visual insp. for workmanship

100% Drawing/Spec Drawing/Spec Insp. Report - W R

7.5 Painting Visual insp. for workmanship

100% Drawing/Spec Drawing/Spec Insp. Report - W R

7.6 Final Stamping of equipment and marking etc.

Verifying stamping details

Name plate & Rub off stamping

Drawing/Spec Drawing/Spec Name plate/ Rub off

- W H

7.7 Drying of equipment Cleanliness Full vessel Drawing/Spec Drawing/Spec Insp. Report - W R 7.8 Nitrogen Filling N2 pressure & non

return valve. Full vessel Drawing/Spec Drawing/Spec Insp. Report - W R

8.0 DOCUMENTATION Verification & Compilation of inspection & test records and other documents for submission to customer, certificate of completeness with index.

100% Spec (VDR) Spec Q.C. Dossier - W H

Legends: H-Hold (Offer for Witness obtain clearance) ,W-Witness ,R-Review ,A-Approval ,I- Information ,X-submit, PO – Purchase Order ,PR – Purchase Requisition ,.VDR- Vendor Data Requirements. All the NDT /Leak testing /Heat treatment /Special manufacturing procedures have to be specially approved or only previously approved procedures have to be used. In case of conflict between purchase specification, contract documents and ITP more stringent conditions shall be applicable. This document describes generally the requirements pertaining to all types of Heat Exchangers, Requirements specific to the item are only applicable.

GAIL (India) Ltd.

Pata.



6-81-0009 Rev. 0 of 7

•

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TUBE TYPE MA,Tf .ll•AL

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GENERAL NOTES

(1) iu5E StDE flANGE SURFACE FrNI:;;H 12!) AAf1>1

(2) TUBE,'TU8ESHEET WELDS SHALL BE SUBJECTED TO AN AIR;SOAPY WATER LEAK TEST

PRIOR TO f,~AL. EliPANOING

t3} PRESSURE DROP AT FULl VAPOR ROW THROUGri TUBES (LOSS OF COOLANl) • 0.04

(4) SLUGS OF LIQUID MAY ENTER PROCESS SIDE WITH VAPOR

(5) OAILL A HIGH POINT VENT THROUGH THE TOP TuBE SHEET FROM WATER SlOE

(ldiJ DEG FROM CW INLE: I) 3'4 '

(6) UNIT TO BE DESIGNED FOR COCURAENT F1..0W

(7) TWO IDENTICAL ~iEAT EXCHANGERS ARE REQUIRED AND -.AE INSTALLED IN PARALLEL

(9) ONE METEP lo 8 t ADDED TO TH~ OVERALL TUBE LENGTH TO ~OMPENSATE

FOR POl.'fMER FOULING

- :r.

-.. -·· .... _ .. -..

.,.,., ·I I Pr t !Ufld '" (.-{ " A:J iliC t £1~

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1917

Shell dia. 1830

N6, N7

N8

S3

S2

S1

N7 (0.5”)

N6 (0.5”)

N3 (16”)

N4 (18”)

N2(16”)

N8 (0.5”)

N5 (1.5”)

66

00

ALL DIMENSIONS ARE IN MM

N1, N2, N3 HAVE 1.5” LINE OF DRAIN.

N2 AND N3 HAS SAME DIMENSIONS.

13

0

14

0 37

0

46

0

41

0

24

50

37

0

38

0

64

3

21

0 1

43

29

0

13

0

11

3

10

0

N1 (12”)

LIFTING HOOK

(2 NOS AT 180)

SUPPORT PAD

(4 NOS. AT 90)

N2, N3, N4

N1, N5

400

EQUIPMENT NAME – EA-201A

LOCATION: LLDPE-1, 200 AREA

DESCRIPTION: SHELL AND TUBE TYPE CONDENSER.

30

0

50

295

350

40

360

60

20

0

MISCELLANEOUS DETAILS FOR EA-201A

1. OPERATING PARAMETERS:

SHELL SIDE : COOLING WATER INLET PRESSURE : 4.5 kg/cm2 INLET TEMPERATURE : 33®C

OUTLET TEMPERATURE: 45C

TUBE SIDE : HYDROCARBON INLET PRESSURE : 0.45 kg/cm2

INLET TEMPERATURE : 227®C


2. TUBE DETAILS: NO OF TUBES : 2262 TUBE ID : 19 mm TUBE OD : 25 mm LENGTH : 7000 mm TUBE MATERIAL: SA 179. TUBE ORIENTATION AS PER THE ATTACHMENT (FIG-2).

3. STUD DETAILS: S1: 93 NOS OF STUD (3/4” * 19”) S2: 36 NOS OF STUD (3/4” *10”) S3: 71 NOS OF STUD (1” * 15”) 4.BAFFLES AND SUPPORT: AS PER TEMA STANDARD.

5. PROCESS PARAMETER AS PER ATTACHMENT.

EQUIPMENT NAME – EA-201A

LOCATION: LLDPE-1 200 AREA

DESCRIPTION: SHELL AND TUBE TYPE CONDENSER. ALL DIMENSIONS ARE IN MM

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[2. OS AT 1.00,

K5 [O . .S.j

S'U PPORT PA D

[4 OS. AT 9D,

MISCELLANEOUS DETAILS FOR EA-201A

1. OPERATING PARAMETERS:

SHELL SIDE : COOLING WATER INLET PRESSURE : 4.5 kg/cm2 INLET TEMPERATURE : 33®C


TUBE SIDE : HYDROCARBON INLET PRESSURE : 0.45 kg/cm2

INLET TEMPERATURE : 227®C


2. TUBE DETAILS: NO OF TUBES : 2262 TUBE ID : 19 mm TUBE OD : 25 mm LENGTH : 7000 mm TUBE ORIENTATION AS PER THE ATTACHMENT (FIG-2).

3. STUD DETAILS: S1: 93 NOS OF STUD (3/4” * 19”) S2: 36 NOS OF STUD (3/4” *10”) S3: 71 NOS OF STUD (1” * 15”) 4. PROCESS PARAMETER AS PER ATTACHMENT.

T u B E s N 0 s. I , 2, 3

ROWS NOS. I, 2, 3 ...

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ooo• o••••••••••oe o e oo • ~oe ooaoeoooo•~•••o• ••~•oo c ooooo•ooo•••ooooo •oooococoJoooooooooo•o~• )••• oco ooo••••o•••••o~o•~•coo • 0o••••o•••o•ooeoooo •c~o0•o ooo•eooooo•••ooooo••••o • c • ooe ooo•••• o• o• o • oo

20-1-f---- ooooo• oo••••••oooo e ooooJooo • oooooo••••c • o• o o • <' 20-53 oooo• oeeoo•••ooo• ooo e ooC'e ooooooooeeoo•••••o •• ~ •• ~a oooo••o•••••••ooe oooo•••oooooooooo••oooe oe •••••••oc oooe oooee oeeeo • ooo e oo• oooe ooooooooo• o • ooo••••oooooooo ooo • ooocoo e o•••ooo• ooooooe ooooe ooooooo,•• oooooeeoooo

25-1+---- ooooeeoooe•o • o e ooooe ooooooo • ooooooooooce ooooooooooooo---1-- 25-53 ooooooooooo ooooooooooooo oooooe ooo•••• oooe ooo• oooo ooooooooooooooooo~ooooooooooooooeoooooo•ooooooooooooo ooooooooooooooooooooooooooooooooe oooe oooooooooooooooo oooooooo• uooooo• oooooooooooooooooo• cooooooooooooooooo

30-1-+--- oooooooooooooe ooa ooo e ooooo ooooooooe o 00 • ooo• oc• ooooo- - 1--30-53 oooooooe oe o e oo•••••ooooc• oooooooooooe oooooooooooooooo oooa oo••••oo••••ooooooooo• o • o • oooooe o e ooooooooooooooo

oooooooe o e oooe oooooooooooooooo8ooooooaeo e oooooooooo ooooooooooooooooooooooooooooooooooooe oooeeo e ooooooo

35-1--+----- ooooooooe oeeoooe ooo•• oocooo oooooooooc oooooooo oooooc --1-- 35-47 oooooooo••••ooooe oooe ooa ooooe ooo• oo e ooooce o e oooooo' oooooooo••••oooooooooooJoooooooooooooooooe o e ooooc ooooooooooooooooo• oooocoooooooo• ooooe ooeeooooooc

oooooe oooooooooe oooooooooooooe ooooe ooeeoooooo ----\,----oooo•••••••••••eooo oooooo ooooooooo~.., oC'e ooooo oo 40-47

ooo•••••• ••••••ooooo ooooooooooo ooooooo oooo•••••••••••••ooooooooooooooooooooooc• ooo•••••••••••••ooooooooooooooooooo• oooe ooo••••••••••••oooooooooooooooooooooo0

--".,---- ooo••••••••••ooooooooooo• oooooooooo o 45-39 oo••••••••••ooooooooo• ooooooooooo oo•oo•••••••oooooooooooooooooo~ oooo•••••••••ooooooo• ooooooooQ ocooo•o••••ooooooooooooo~r(

__,......_,.__ 0000000000000000000 00 ~ 0 ---::;7"~-

• S~ E.tT f C'f 7 GENERAL DATA-· EA-201 CASE I

POINT DUTY*- DUTY% TEMPC WT%VAP VAPORMWT 1 0 0.0 206.75 100 83.17 2 -0.6506 11 .1 172.42 100 83.17 3 -1.3013 22.2 135.14 100 83.17 4 -1.952 33.3 93.83 100 83.17 5 -1 .9886 34.0 91 .35 100 83.17 6 -2.6028 44.4 90.99 80.43 82.96 7 -3.2533 55.6 90.39 59.84 82.61 8 -3.9038 66.7 89.41 39.49 81 .99 9 -4.5546 77.8 87.39 19.77 80.66 10 -5.2053 88.9 81 .42 2.48 76.82 11 -5.3223 90.9 79.31 0 12 -5.856 100.0 49.99 0

MIX LIQUID DATA POINT DENSITY TH COND VISC. Cp SURF TENS ENTHALPY

KG/M3 KCAL/HR.M .C. Cp KCAL/KG.C DYNES/CM KCAL/KG 6 708.62 0.0886 0.3481 0.5105 16.81 42.01 • 7 709.01 0.08872 0.3504 0.5099 16.86 41 .71 8 709.57 0.08893 0.3539 0.509 16.94 41 .23 9 710.64 0.08933 0.361 0.507 17.11 40.24

10 713.48 0.09051 0.3825 0.5016 17.57 37.35 11 714.44 0.09092 0.3902 0.4997 17.72 36.33 12 744.4 0.09757 0.5855 0.4677 21.06 22.18

VAPOR DATA POINT DENSITY THCOND VIS C. Cp COMPRESS ENTHALPY

KG/M3 KCAL/HR.M .C. Cp KCAL/KG.C Z(DRY) KCAL!KG 1 3.0833 0.02686 0.01137 0.5216 0.981 177.4 2 3.3242 0.02316 0.01057 0.4842 0.977 160.2 3 3.6396 0.0194 0.009705 0.4421 0.97 142.9 4 4.0797 0.01557 0.008738 0.3941 0.959 125.7 5 4.1027 0.01536 0.008679 0.3912 0.958 124.7 6 4.088 0.01535 0.008678 0.391 0.958 124.6 7 4.061 0.01534 0.008674 0.3907 0.959 124.4 8 4.024 0.01532 0.008671 0.3902 0.959 124.1 9 3.962 0.0153 0.008667 0.3894 0.96 123.4

10 3.813 0.01523 0.00865 0.3873 0.962 121 .3 • 6< C. 0- \ / 'r '(') ('A \ 0 - b J )j(. 'D VT'-1" S' \~ -:;uJ 1) f.... ': I ' /

• • EA-201 CASE I ·

FIRST STAGE CONDENSER

220 l 2oo 'f . - ! ____ I__ I I I I 1 1

180]

~ 160 - -- ~--._. . ------ ---

-

a: ~ 140 ----<( I· +·--·-· •

ffi 1 20 ·-· ·- - - - - - --

~ ""' w 1 00 ---- . h -f- I -- 1 •• ~-;-. i p I [=1-- I -. ~ -

t--.40I.!U [ ~ E ·--

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10 20 30 40 50 60 %DUTY

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90 100

"' ":t:. ~ "\

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• GENERAL DATA-- EA-201 CASE VI

POINT DUTY* DUTY% TEMPC WT%VAP VAPORMWT

1 0 0.0 227.81 100 90.77

2 -0.857 11.1 193 100 90.77

3 -1 .714 22.2 155.62 100 90.77

4 ·2.5709 33.3 114.84 100 90.77

5 -2.6895 34.9 108.86 100 90.77

6 -3.428 44.4 106.33 80.71 89.57

7 -4.285 55.6 103.69 58.54 88.43

8 -5.682 73.7 101.55 36.43 87.57

9 ·5.9989 77.8 99.87 14.29 86.95

10 ·6.5507 84.9 99.02 0

11 -6.856 88.9 86.45 0 12 -7.713 100.0 50.01 0

MIX LIQUID DATA POINT DENSITY TH COND VIS C. Cp SURF TENS ENTHALPY

KG/M3 KCAL/HR.M . Cp KCAL/KG.C DYNES/CM KCAL/KG

6 664.55 0.08681 0.2577 0.5463 14.51 52.77

• 7 671.07 0.08717 0.2698 0.5419 14.88 50.94

8 676.7 0.08746 0.2807 0.5379 15.19 49.45

9 681.29 0.08767 0.2898 0.5345 15.44 48.28

10 683.73 0.08778 0.2947 0.5326 15.57 47.68

11 696.58 0.09074 0.3414 0.523 16.9 41 .05

12 731.77 0.09913 0.5424 0.4968 20.87 22.45

VAPOR DATA POINT DENSITY TH COND VIS C. Cp COMPRESS ENTHALPY

KG/M3 KCAL/HR.M. Cp KCAL!KG.C Z(DRY) KCAL/KG

1 3.2262 0.02837 0.01126 0.5524 0.981 189.9

2 3.4714 0.02468 0.0105 0.5176 0.976 171.3

3 3.7871 0.02093 0.009676 0.4788 0.969 152.7

4 4.2164 0.01711 0.008772 0.4347 0.958 134.1

5 4.2827 0.01657 0.00864 0.4282 0.956 131 .5

6 4.244 0.01639 0.008654 0.4224 0.956 130.5

7 4.201 0.01619 0.008662 0.4164 0.957 129.4

8 4.1 66 0.01603 0.008666 0.4117 0.957 128.5

9 4.138 0.0159 0.008666 0.4081 0.958 127.9

• * J)v\~ S\-\oi)JrJ As C \~ ~ 1 I h '() (:. l o _,)

•

240

220, 1'"" '""' 200 -l ...

tJ ' 0 180_1 ---w

160 a: :::> .,__ <! 140 a: w 120-a.. ~

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• EA-201 CASE VI·

FIRST STAGE CONDENSER

-

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GENERAL SPECIFICATION

FOR

HEAT EXCHANGERS

. 0

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Rl'VISED .6 ADSSum AS ITO SPECIFICATION

REVISED & OfiSSUEO MJ SPECIFIC:A rtOH RKA ---·· 1-SSU(O A$ sPECif'ICA 1lON RKA BSG .... AI REVISION BY CHeCK£0 """'DOOR CH.t. IR MAN ($, 8 I

! ~~ti:<INcEilS IN:liA LIMITEO! GENERAL SPECIFICATION SPECIFICATION REV

FOR 1 tio' --.:_~ -~"" !I OH.HI ! P.~AT ~YCHAN:;ERS ~-15-0001

2 I ,_

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I ki '1'1- '·'~,~~ r1.: MNII!ltV.u: S~"tu::u:tomroo" 1 · . ' • ..., • • m .. · , · ·'- . ~:g111 .ru:;• ,! r'1 ,,. ··d••tTllihJt t~ ,·nnflf)EH":"!_:., ,~;.,• ,tJ l-'f• ' ' ;_rr • -~M:· ; .: 1i!F'PM~ y.,~._; ~ _ • "' _ · II ~~~~ 1~.! tJy ~~r ... USi=.llm'LI'l\1 ur W!Stf!t:u!i•JI • .;, :ut ;J._.rrJ.n•i ol .:111'/ v; J!! of~~-~ ••. .:·tll .. 'llW.I.t tl!1:. .n6:-'d"'..: ... -sr-~ JC1 L 'Y PI~OJI! flll ED. Tltc 4'tfl~tl~ e'(!•r~sl'.rd "'t~ 1 l:t~~ ~t .l!t! 'ICtMCI an.-j dt:l net .:eV:~.-s..;nt)· iefl::rt I ~~~)' ... •.!f u'~1{h'~•!' F~~J\YfO\(j( th ... btP.lt..ired! '•.:l!)!'_' ... l, pl.;;.~ I~I)!H}•:f til$> .... l)lf~r tlv '-'UMII ~rt<! ._1 .. !•-•P .,;(!

i'{9P~S you-r cccpe·rotu:.r. 1nlhts tegard l<.< .. ,ppt~ated f ~ ~ S.O NON DE~'1'RUCiJVE TESTS : ;z ·-j),; 6.0 .~

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HEAT TREA T'MENT

INSPECfiON AND TESTING

STAMPING, NAME PLATES AND WAR.NING PLATES

PROTECf!ON AN'D DESPATCH

VENDOR'S GUARANTEES

GENERAL SPECIFICATION , fOR

Hf.A T EXCHANGERS

SPECIFIC.A TION a ENGIN'EERS INDIA liMITED w NEWOELHI

L-~~.~-~~---------------------<-.---·--~--~---------------~--------~~.~~·?0

REV

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tlus Sf"'CU•catton eo~cn !hi! •(l"!l~rU rec;um~mt:"l': fer resid!W ~~n d-:1 1illQS. t ""'-ttu.b tabroatioo, wO<tDWISbop, impcalon and teruns of ohell alld !Ube h03! oxclnr>~~ers :tnd is uXe&.-.lc:d tu suppler:tl«:fft the: minin1u,1 teqlllrement'J of the 2pplic:lblc codes EJL simcWds wherever lndicol.o4 in 1bG roqu;.izion wU be followed unleA tndi<oted ccllenrl5C.

This 'fCCinco.tion sh•ll not be eoosickred limilioa and it sluU be Vend«' a "'!"'ftlibiliry «> """'1)1y with :oil rcquirtmCiliS of MJI.enol or Putcllase Rllqulsiuon or Bid documcnu 10 wblch this apeciflc:uion is annexed.

I .2 R.efaulit!tA

12.1 CODES AND R£G\JLATIOHS

The followi,g coda in l!lttr edition ~lmor:ed In t!rawlnp or data shec!s or cloaign basis shall form the buis for desl8n. materials, fnbricalion, lni!POC!Ion, lesling and acc<plaOOO of !be equipmefll :

(a) ASMB Boiler and Pressure Vm<l Code Section VUI Division I (Code), ASI-IE Section U Port A, 8 , C and 0, A$1-1£ Section V. ASME Soction IX .

(b) TEMA (Cbss U lij)eCi(l<d on !be dnw\oa> or dau sbcus or desill' basis).

(c) Indian Boiler RcguiJitlon (IBR). If applicable (latest edition witb amendn>cl¥s UIXO date).

(d) Natlooai and loco! laws or regulooons, as oppiiCAbk.

1.2.2 POR HEA'f EXCHANOE'RS UNDER THE PURVIEW OF IBR.

(a) VePdor •11311 cany "'" d.,isn calcuhuioos as per IBR and only in cue <>f any doubt, refer the ..,... 10 Pun:l>asu and ElL for clarilicauons.

(b) In case lbc equipmcN is nwruftctuttd in India. the design calall&ll<lCIS and fabrication dnwmgs al\er preliminary review of Purcllascr and lliL lhllll be go1 •pprovcd by Vendor from Chief lllspector or Boilers (CIB) of the scate wbcre VendQr's shop Is loaued, bet- sun of fabrlearion. Vendor sboll .also provide necessary as&iitance to Puroh.aser for obtaining approval from CJa. of S£a(c of ins:t:aJJ.ation such. as providina addicionaJ copies of calcul•dons tnd dnwinp as R>qllired by CIB, otc.

(t) In case tbc equi~ is ~ OUISidc India, the design ealell!slion• and robricatlon drawings after prellmln•ry review by Purchaser and ElL Jball be p approved by Vendor fr<>m the agency JUtllorbed by tBR in tbc coonuy oflabncauon and CJB of che J.tare where th:e equrpment is r.o be i~lalled, berore the start of rabric:ulon.

(dl It shall be !lie rcopon~lbility of me Vendor to incorporolc rnodlfoc•dOI\$ "' oddilions if required by CJB Of i!S au&horisod ...,.:Y in (b) and (c) above and oboaOI the fino! approval .

(c) l'll.rcba.erlnd ElL 5ball be kep< infonncd of all ehanget or mQdificatioM desired by CIS. All cosiS toward$ approval from CIB wll be borne by Vendor.

(() AJI materials, ftbri~don, wcldins, testin& etc. shall mte1rhe requlremervs of rnR.

A EHGINElRS INOlA LIMITED GENERAL SPECIRCATION

FOR SPECIFICATION REV

,. NEWO£Lt-tf HEAT EXCHANGEJIS 2 '---------'---------··--

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'li lh~ 't.;ntlc.>r bXic:..J. un ,J'i:uhbl<! f.il!llj'Jt$ Such t.i.("'f!~U,n'IS muM~ C~'lrht P~.Wr-'1:' ... ,,: ;..--.

dlt" funl\:llt "SCHEDULE OF DEViA l iONS " tn the Vt&vJv~'•s 'f.hiUllon, 5Y :a'"J to 1v,)~ .UYy

CX)QIIJSiufl 'I'" ambti'Ul}' m:! f.t) l3ClJIIJ.IC atnf)S.U of~ m ~~~ ~i~e tJ11! ([ shaiJ be: r~k.tu for !fMled thlf except foe the dcv~.o~t.vns p.A;IUd out ul"ttkr IJ IC .. SCHf.rt.iLE OF OEVIA'IlONS" in me Vc.udot'!i off~r. all Other teehntcal Tt'qUh'!IT\CI"W'i llhall hr. ll.IJ(feQ

10 by !he Vendor

Ot-nc:ralJy nn de..,.i.aclons sh.;ill be cntcrta;iru.-d after the order tl:l:s beto :\iXel)ted by 1he ~or un.J,cs$11 lt to c.o~Jy wjth st:llutocy or code requueOlCru. Aii w".ivers and dwi:l:iOD after Ot<ler slull be "'""" clu"ou&b llw: R<g;ioml Procur<mffll Of l"'l!eC'oon Office Loduts•m <he prescn"bcd ful11lllt. Delay in supply or llw: cqulpm<nt h<cauoe or IIJCb ck•~arioos beOS not emertaiotd or approved by PurcllJscr or Bit or any delay in r1roe«sln' the sane by Putctw<r or Ell s!WI be ro Veodor's lllXOUn< Any additiooal design wolk in supfKl of such a dcviarioo sholl be pcrfonnallly llw: Vendor and submlll<d along wrlll the 4e.,.;on

c..otradlctory nqull'ftllftlll

In case or ~&ny comndiction between the requimnenu of the requJsatioo, drawings ani oth¢r documenu rormlna pan of the requisition. the mancr shall be resolved by Vc!Por in consu!Wioo wirh Purd"..ser 0< ElL. Decision of Purcil»er or Ell. shall be bindJ>i and without sny implic:ttion of cos' and time, il not resolved ac biddtng suge

2 0 1\tftTERIAL SPECIFICATION

2. I Gener:ll

2. Ll All mmnals and accessories required ror llw: f'abricatoon, inspecuon, leSlil\l CIC. ofihe heat e.ct.an;er shall 1>< supplied by !he Vend<>r unloss olhtllllis< IIUIIJ!. Wh<ntVer SOOlt ll'leriaJ Is to be supplied by the Puttha!;f!-r. thlt sl\all bt so indic;u~ as Free Issue Ma.tenalllnd the supplcmenlary spcoirlcarl""' in lllis rcgard shall be oortlpl1ed wirh.

l. I .2 In addition 10 the rcquire-mtnll of materials as per materbl.5pecifieation:5, ITUit criaJs sl':&lltl$0 meet the rcquiremcms me,.W>ned in thl! specification and otl\er spcciftcntlons encloted with Lhc rcqui.iiuon. All mm.rWJ s.tull be certified for compliance with IBR req:Wremenl5 for tbt licm(s) so specified. Wh1lc p<OCllrlng m>rmab, VcndoT stwl $1ipul>t< ~ttiO!lal requirements such as limi1s on hardness, uhimatc tc:n$ile SCT¢fli1h (UTS). yield atrengttt , chemic.a.l COI'l'lpO$nion. beal treauntnt and any other specific req\memtnts 10 cnswc: tlw final requirement as per spctificanon a:r\d Code are nw:t with

2. l .3 All miucr~als for prusure pans andl part& welded 10 pressure pans Including ro&teriJIS in tl:te ~of oubYmlon, sball be "''"''''P•nied willl mill ,... ceniliwcs duly cenlfiod by a r<putcd rhud party l!'l>pcclion ogcncy. In rhe abccncc of mill test etttifiulellle lll$l(rill aball be gor lcslod from a rcpured third parry inspecrion agency like Ell, Lloyd$, BV, DNV «c. and tesa: results WII be submlt&ed in lieu of mill Cdl cenifieate. All cou 1owarcb such leaing and i)lSpe<Uon shall be borne by the Vendor. All nurerialuhall be Inspected 11 Vendor'• and :Rib-vendor's shop for verification prior to use on the job. The deciston of AUlhariso:l l~pectoc 10 aocq>t or reject mas.eriah on the basis of such testin., ~haU be final.

'2. 1.4 When:v¢r Simulated heal ue::Ume[lt or te3t specimens IS rtquired u per Code or speclftatiorl, the simulatiOII cycle $hall include one e.ltlra cycle of strcll$ relieving Jor mny eventu:.lily of repau JJ site by Putthase:r dUnJ18 the lire of !be equipment.

2. t .S The exchnnger minimum design rneu1l 1emperature (MOMT) shall be taken as 0 'Cor !.'he desigp Ll:n~rarure $pcc:ifiet1 in drawing or dacasheet whicbe\'ct l' lower. unle~ .spetifled Otherwise rn dC$i&n basi$ or dllasflc<ts «drawings.

r£NG~l£EIIS UIIOIA liMITED NIWOEU-6

GENERAL SPECIACATION FOR

H'"Ec-:1\T~EXCHANG'E~

SPECIFICATION REV

• ! I I

--- -------- @_ Col.~::... .• '"'' ~f..-4alt ~ 4nt1 ~{'" r.lt'r'tiiS ~...,..... 1 _ _ _, UJ ~ ;..tluw •h •ll ~;- ·::-~ :::::.: !' ...... ..,__ ·~..ui ... ~ ~ ~ cf MOMT, .;:-f .. ....:- 1"-:.• ~~ ,.tt: J:S spectf.ed te ~!.~k ~~WJ1 ~:Lf'kJ!J06 or ;t; ;:iv~n w ,,m 1~1n. ;r .. 'ft i·"'!

·~-t.:.:-.-... 4 ... ~"· Vuio:.~tt.eoncaetWt.'\1" ~'t'!i.aes ..,.=l be -.- n:-' ,er ci t:w: •ll""' .. prt 00 ... or awbcoble -....-...~ -.r- In >4dil""' 10 ""' ..... done ll dle ..U . .,.,. '""*' tet ( ttute opecimens) I"' beat shall be rcpe3led ofier receiPt of lll"t<rl31 .t the vendor"> shop with tho<""' """"'OIIUtt S>m< as Civcn obo"" U tho..., I'<SUlls clt-oes ""' m«t d-.c """""' """'IY rcquo ,..,...,.. SJ""" ....... the =<cml siWI be: rqcctllll

2 I 6 PLATES

2 I 6 1 Prmure 1"-<t: h:lvin& :1\idmw 16 01111 w 50 nun (bout meluslve) shall be ultr3S011io:ally .......S (UST) .. per SA-435

2. 1.6.2 """"""pans ha•in& tlucblcss areatcr tlll1! 50 mm sboU be UST &I per SA-578 Level 8

2.1.7 TUBES

1. 1. 7. I AU tho Gibes sball be seamleoa and ccMd drawn.

2 1.7.2 Product analysis of rubes sball be canicd ... and r<poncd.

2. L 7.3 1\Jbes sblll be in tully h<>t ll<21cd oonditioa as recei•ed fTom lh< Olill CS tl!bcs sl-.oll be in annealed condition and copper olloy - s!laU be in ~ed .....,.. coodrtion. LAS - sblll be supplied in normalised IOd tempered condition.

All unoulliliscd sulllless ....,J(SS) tubes shall be ..Wiod in tho,.,.,._ ll!!lnlcd condilJOII ..... lilsubiliscd p>des or ...Wesuuds OU<h .. ss 321 and ss 347 slllli be supplied in SUbtJtzas.eon hta1 treated cood•rion, in Diirioo ro JOtuboo Jt1De1.lina.

2 1.7.~ All Wbcs Wll be bydr~ed. llydrotcst pressure or tubes •hall be hiaJler of •cru•J .. .....,.,. 01be sick 1CS1 pr_,., "' u r<qUired by ASME s..:don Ll.

2.1.7.$ u is preknblo w~Ue ordefina rubes dle ma.<imwn Yield srrenglb and lwdne.uof rubes are Jii<CIIicd II.ICb os 10 be low« tbao .-of tubcsh<d. in O«<er 10 ~·• • 50Wld expanded lUbe to tube shea joint. C01t1J1Yina wrlh Code r<qwr-

2 1.7 6 I'<><'*"'.....,.... or u Olbes refer ElL speerfic11ion 6-15--0006.

2. 1.8 FORGINGS

l'<><gOAgS 10 SA·I~ and SA·266 above 75 OlD lhictness (lhictness II dtfosed 11 pon AM 200.2 of ASME Sec. VIU DIVIsion 2). all rube shea fOFSI"'!$ and all fora~ of od>cr ......WS CJU:qJ~ standard DO<Zie· flanges upto s· Nil and amall fofaings (of <Ouplm,$, plugs and eye bollS) WII ~ 1001 ultruonialty lcsted .. per SA-388. Am:po~"'• sll!ldan! shall be u per par& AM 203.2 or ASME Section V1U O.>isionl.

2. 1 9 PtPES

Pipes lhall be .....mess and •= ob<>vc I W NB Wll be hot finis~. Dimensions and tol<niiCOS slull be 1ft xcordancc "ith ANSI36 10 or ANSI 36.19opplicablc u pu nwcrial speeifiCOIIOfl.

2.l Spocillc: -.ia1 requirfmeDIS (l'rtss~ portS and parts weld<d to .,.......,. p:uu)

2.2.1 CS AND LTCS MATERIALS

(a) Catboo ..,... ... shall ""' ·~ml 0 1JI.

~ENGINEERS INDIA LIMITED w NEWOfl.Ht

GENERAL SPECIACATIOH FOR

SPECIACATION REV

HEAT EXCHANGERS 6 -16-0001 ,._,.. ,.,,- 2

I

I

•

2.2-2

• ~~. ""oo ... ·~·--·--·-'--- · -1.-11-1• 0,,, , ............... ~ ..... , ........ --A oj\,~ "''" ~·_., I •-- _ ..... • _ .. u ._., ____ -· -·-~• • ,,,. ....... -···-·-• ,_...,.._..,,_,,,, - •-

(i) Voouum treohn.,ot "' !>'' lho: >to('lllcm«•arv tcqulrefi~rnt Sl J[ ""'""' dc~:s.smg is noc rq><>ftt;d m the lcllot ~;.Cttltic::atts, then duougl\ lhid.:~s 1es.ca 1119 per SA 770 sb.aH be eoodocred ruxJ rnhdmum reduction in area or 3'% !Jhil.ll be en)ured.

(li) 0\arpy V-notch test as per supplemervary requirement SS. Test cempera.ture wll be Miro5 29•c for MDMT s=oer th:rn 0< equal 10 o•c. For MOMT IdS lhan o· c rdcr dau.u 2. 1.5 *\IC. ln~aa energy values shall be as per pua U0-34 of Code. or u per opphcablc: material spoc:ifteation, whiche><r is IUab<r OnettDUoo of lest bu sb.all be tronsverse 10 rollinJ drr«tlon

(ili) Bend ,.., os p<r S!JWI"""nruy "'JUircment SJ4 of SA-20.

(<) Unl«s sp«ified o1herwioe in requlsilion or bid doeunlent, all CS ma1uials speelrtc:d aJ HJC ICStc:ll1lull meet the following requlrancnts.

i) Carbon C{(Hivatent $ha.ll he restricrod to 0.40% maximum~ Nickel ttlmcnt st~.all be 0.2 $ maximum.

Ill Sulphur conteru shall be O.OIY.!!; tiWI for pla<eolltld 0.01 \II for tubes. pipes and rorgings.

ttl) Hanlras of pl.a<O> and pipes $1\:lil 1101 w:eed 200 BHN. an:llh3t of fors1J11S $b.all no< ex«<d 187 BHN.

IV) P1.ues shall he IO SA SJ6 Or 60 only (Hisl>et gr:ldeslik SA Sl6 Gt.6S and 10 are 110( "tepta.blc). The plata a.haU contain calcium or other rare cllnh clcrncms to create spherical inclu3iont instead of :strin.gen. 'The pliUtl sholH be tC$1ed in l)CCOtdance with NACB TM..Q2-84 U.'iiog the:: tc~U SOIUiion or NACE TM.-OJ-77. The a«:ep<ance criteria ahall be Gtock length ntio 10 ')\ maximum.

(i) All LTCS l.nd CS c:barpy plate: matcditl shall bt co fill.: grain pract:JCCI and the :tustcnlllc anin site shall be measured and reported lt'l the mill test ee-rllf.clte.

(g) CS pipes shill be SA-106 Gr. B. LTCS pipeo shall be SA 333 Gr. 1 or6.

(b) Non-- forcings (SA 266, s. ... 3SO ecc.) $b.all be in IIOnllillised and l~ml conchtion.

LAS MATERIALS

(a) All t..AS pl.,cs. pipes, forging• and fittings shall be in norm.1lised and 1c01pered CQndilionll. lise or C-1h Mo materiaJs arc prohlbitc:d

{b) For t W Cr-M. Mo materials the max.imurn room u::mptrature te.nsile SUC:r\8th of :all pressure cO,.Ilinlng components, rruucrial¥ and welds shall be 100000 psi.

(c) For LAS tubes (SA·I99. 209 and 213) hard""'',.., shill be perf()nned on ouulde of lhe tubes u pc:r SA-4SO.

a ENGINEERS INDIA LIMITED w NEW O!LHI

GENERAl SPECIFICATION FOR

SPECIFICATION REV

HEAT ~XCHANGERS 6-15-0001 + 2 . ..___ __ ~·~-·-

Pa.o• 6 ol 20 , ---~------------~----~~~~~

• ··--·------ ·-·--------- -------.

2.2.3

2.2.4

. -.. .... .. L

; .. .:,.. W ·l·~u -! ~J :ret

1\ V•·uum «.:.:.t41'•1U .l~~o }R-"r :-;.~l'l~ury IC4<'Uirtmen' Sl U .-.. ...:li .. r .. U.:~i•~g i.:. ,;e, ~neo lfl ttlf ~ ~ .. ni..fiates tbert tl'lmugh thA.."'k.tolSS ,.ti

as per SA 170 a-lull De conducted aoJ nunirnmn rcdl.JCtioo tn !U"e:a of 351 sll3JI be cmur<d

li} O..'i'Y V-nocob '""""' ,.,. oo per IIU!JPiemtnwy reqmmnent SS ""h impatt values as per UG 84 of Code. Test ~mper:uure shill be lower of MOMT or miua ta•c ( Q•C for SCr-'h Mo) whic:llcver is lower. OriCl\UIIiOn of lt3C bar shall be tr3BSVet$t: (Q tbe direction 0( rollifll.

I oil Bend Tcat u per suppkm<nlal')' require"""" S 14.

SS AND OTHER HIGH ALLOY MATERIAL

(a) All SS lllilerial 000 sffies) sb.all b< In lhe sol~ beal<reottod (tully anocalcd) and pictlod condilloo. All Slabll.t.od grades of SS( SS 321, SS 347 eu:.) lllall be Jl•co ttabillsarion beA<<reulmcOI, in additioa to ..rorion -lin&.

(b) All SS (300 series) pwca sii&U be boc rollod and shall have No.1 finish on boch oidea.

(c) SS 000 .. riel) m.arerials l<lr all componcul.s u1cluding ...,..p.....,.. pons likt baffica, licrodl, at. &hall be procured wilh lhe IOC test as per AST'M A·262 (les< lball be clltricd out, after the rpeelfled beAr <re.ttmenr and se,.ltisarloo per opeclfrcarion) wilh ......,.,..ble conosloo rm and practices u under •

i) For all S<rvic<s ••<CP' nluic: acid lltTVrce, Practice E shall be followed. Specimen aner ••poaurc shall be ben! as per rcquirenw:nt& 111en1101l<d in A262 Pnttice E and lhall be inspected under magnifrcarlon of 200X. Thoe ben• >peclmcn sltlll be me of any crxa or train ctrowin.. The mic:roSlruct~~re sltlll be submincd 10 the Authorised Inspector for approval.

ii) Nitric acid service: Practice C wnb corrosion mte nol arcatcr th!f.n 25 aills per yt>t.

(d) For srraijh< chrome (13!11 Cr.) INUrial , mulmum cvtoon eonten<shall nor exceed 0.08!'. Hardll<$S of UNS no. 541000 and S4100R •hall nor exceed 75 RB and !hat of 540500 shall 001 w:ecd 80 RB

NON-FERROUS MATERIALS

(a) All copper based non-ferrous pious shall ~ pnx:urcd in ani'IC31ed condition.

(b) l'l>l<l for preaaur< pans ahall be IOOll ulltUOftieolly examined. Vendor shall submit lhe procedure for UST tO Aulhorised lospector for approval,

(c) In acldirion ro hydrolest,:lll rubes .tha.U be tddy c:un~ cesced in their (lOll lnne:tled condittoo.

(d) All pipe bcMs shall be 11rcss ~ief IIJl!lealcd afler bendmg.

(e) The paragr>plu NF7 o.ad NFI4 in Pat! UNI' of Code are mand<l<ory.,Tblo applies co non .. ferrOU5 ctaddihg and wdd ovcrtay.

A ENOIN~ERS !NotA UMITEO w NEWDELHI

GENERAl SPECIRCATION FOR

SPECIRCATION REV

H~AT EXCHANGERS 8·15.()()01 PotG*7 el 20 2

I

\

I I

I I I

1.3

2.3.1

2,3.2

2.4

3.0

' -~. ...

,-..,, .•, ,,,,, _ .. -··~·-•-•o.. . L--#-' •• ••• ,,, I ,~1 ._.........,..Jio-:. ........._,~ "'-" ''""''""-~ '"~:!' ••<\• ~·•••"""'''''"'/ _ . ._ , ,,,,.,. •·• ,..,__ • .., •. ''"'••<• <'• •

lO}

(C)

(d)

(e)

(f)

(g)

(h)

pl~<oc::; sh..lll be (Cikd..or. or :::.mfo:aon bc>nde<J tJtc.

Cl;Ki plates :'-hall oc uh:rl."St~o.icJJiy examined it·um the eLo.ddmg. $ U.rf :tt.-,: tn J;;~·vnl:m1_-.:

with S,'\ -57:!. Se:t:miog s.tu.ll te 100~ oft.~~ plate surfuc.e Acceptar:ce st:md:ud Sl-,;t!l be level B. Cl.aJ plait:<; &hall meet the mtpplementary t'equirementll of S1 ot St\.·578. All ultraJ~c>nic testing shall be undertaken after specified beat tt~t l)r clad plate:•.

Both base nwerial and cl:.d rn:LC.erial shall meet the specification of the r~ve materials M stfpula~ in this speeificaliM.

Alloy clad Sleel plates shall be as per SA 263 or SA 264 or SA 265 . ll<lnd berween dadding and the base mec.tl shall be checked for a minimlnn strtngth of l4 kg/nunl in !!hear for alloy clad steel plates, by oonductio.g shear tesl as per applicable material 5petiftcatiou.

for copper- aUoy clad plates, the bond between cla.ddin~~: and base: metal s.haJJ be checked ror a minhnum strength of 10 kg/mml in shear by conductiiug shear test.

During tension test of clad plau:s the cl~ldi.ng shall be removed and the tensile propenics of the ~se matc.rial shall meet the Code material requiremems. ·

For austenitic SS clad plates the SS surface shall be acid picklc:d as per ASTM A~ 380 . .For cbromium steel cl~ .surfaces the pickling sh:lll be ;~s per Vendor's established procedyre. 'J1)c S3.!Tll:· shaJI be submitted to Pureb:tSer or f.IL fo r apProvaJ.

For all clad plates used in Hydrogen or IUS service with design tem;peramre greater tbsn 3SO'C, Hydrogen disbonding teSl shall be carried out. The: tes~ cQndition shall b\l reprt:~<:nl31 ive oflhe ICIUIAl dc:~ign conditions a~ lh<: proc;~urc ~ball be ~l•bro.incd to Aulhorised lnspec•or for approval.

Non pre.ssurt. paru

CS plates ~hall be minimum IS-2062 or SA 283 Gr. Cor equivalent. Pipes $hall be to IS 1239 or SA 53 or cquiv!l.lcnt.

Saddle material shall be same :.J.S th:-&t of shell rQr shell deSign r;:mperaturc greater than 350'C.

The materials for various components in a heal excb.anger shall be as per Purcbaser or EJL•s rcquiromenr. This does 001 preclu.-de use of equivalem or bener ma1erials. However, lhest deviations should be d early jndie::Ued i.O the prescribed ronnat. If an equivalent OO.li!Cfinl sought by the Vendor is 10 a specification. other dun IS or ASTM or ASME, it is necessary for the Vendor to $Ubmit the sped lications or the equivalent awe-rial with .complete details in English for approval.

SUPPLY

Supply shaJI be in accordance with requisition or bid document'i to which this specification Is au.ached. It shall. hi)Wever. include lbe following:

A ENGINEERS INDIA LIMITED w . NEWOEVil

GENERA~ . SPECIFICATION . - FOR

HEAT EXCHANGERS

SPECIFICATIO,III - .flEY

2 6' 16-0001 Pao& 8 Of 20

. . -------------·- ---

3.1

3.3

3 3.1

3.3.2

3.33

3.3.4

33S

3.4

3.S

3.S I

3 S.2

3.S,3

,_, '1!':,r: ~ ... ::r±-f~.: ... .!: u7ti:~i .. tu:;J! •. !4I.Al "'"''1-4 il~C!• wi~etev~• rr:qJJLr'"'l ·I.!U.r t"'! :l""!!l ,......,

'in!.! $U~I~cd by ct~ v .. ~' 1~ SUd:Stt. lltt;.l OiJl c:l."'tt"!'l .;Qt. t>E ihc: .eumrt"'~ >'leld :;;rt:.:iJ :-: :.<;: m.;.:..;;~.kl ...,. )tl.,u.i.m:J i11 ulal.cri.al llnec:aricatk').O Materhl used for f3bnc:ain.C ~ Ju U be of~ qu.alit)l Fot te:mo'Vlblc bunatt wuh rube $tde te:W prc:~i!iure highcc thM ;llell •OJc. dle b\IIYJle ::blll be lcm::d Ot:Uidc IJlt 5bfll, wiUt tub< •id< P<essunsod (or rube 1ide 1<:11 pr=<O 10 cltedlrube 10 ~--jonllleH:lge from the bock~( IUb<.ho<t. t .. t 11Jtnae shall be dessgned 3C<Ordin&ly.

r ... ring assembly COllSiru<tion sh•ll be IIIUfllng box type .. per n,. E-4 U .l o( TEMA. It is prefemd lbollhe u:st ring fl"'ltt dticblea DOl exceed tbe shell <mer flonge lhl<lme<ls, otherwl~ Vrndor 10 providt: ~rate bQltin& tOr asscn1blint test fin& fbn.&c to shttl. Similarly, f<>r""' ~ VtlldoriO check tbat !he studt for ~~Wionary rubcshoet boiling can be used witlt 1cs1 flJtnge. Olh<:rwise sepo...., bollina shall be provided tor :wcmblsr.g lest

flqe.

Ac co kl for k:llillg

All ""C"'IfY acc:eJIOfies such u $14)p0ftl. b.lind flanges, lest aukcf$, bolts, nucs etc:. shall be provided atld $Upplied by lbo Vendor for turin& Of beat <J<dl!n&ets, in hb IMp and for " 'bo"l'Jtft u:sting hy Pllr<huer 11 oi~e, whenever rcqyir<d.

Vendor WJI obo $Upllly ue bole., ltvcUinJ shims or intmnediJu: sui)llOn.' lor !lacked unlla. Gasket$, nllls and boles rclatin& 10 Jnre.reonneainJ 00%1les (rube and shell slde) ineludJng ljlVOS Wll bo $Upllli<d hy Vendor. All m..e nomponerws shall be desparclled separately wilh due care having been taken rcprding identirtcl!ion of tbese for ease of iasl.altation,

Earthing Jugs shall be provided on c.acb heat exchanger and •IWI be located in such a way u 10 mrid any louting witlt the exebanaer fow>d>rion bolts a1 si<c.

Vendor 10 tupply one 11t1 o( 1orque wrend!e5 for bois size M4S (I !I ") 10 MS6 (2 \j ") and a scr of boh censioner for boll s izes greater tb:m M56 (lW.•) in cue tbese bolt •l= m beinJ used in excltan&e<1 eovored In !he requl$ition.

Davits, If n:quired as per dcsicn buls or drawings. shall be provided.

Addit'tOOS like ctau for piping. ladder. platform, ioaularion cleats de. wt!Jch may be tCC(IJired II a Inter .1111ge 8haJJ be provided.

Calbodic proccrtion

Wb<nevor oalbodio protec<ioo is specified both sacrificial anodes 'IIIII bxcmal painlins shall be proYided as per ElL Speeif>eation ~201 unless specified odlcrwise.

Spans 10 be suwiJ<d by veodor

BOLTING : 20" $1uds and nucs bul DOl less rllan 4 studs wilh 8 nucs for eaehjol nt.

GASKETS : 400" &»k<U O<her man 1hoso used for bydroleMing >nd despa<cb for ea<:h joint.

Spare bullings and g.,kets wll be provided for all joiJU of ginll ~. ftOatlllS head, ctwmel QOVer, tubclbect, intcrconnocd.na notzles. noxrJcs with blind Oangc etc.

ENGINEERS INDIA LIMITED FOR e GENERAL SP£C1RCATION SPECIRCATION REV

N!W ,_Uti HEAT EXCHANQERS 6·15.0001

'--------------'-------------....1.---- "-9•HO

2

•

. --- -------

' ' . .

4. 1.2

4 .1.3

4. l.4

4.1 .5

4.2

4 2.1

4 .2 .2

4.3

4 .3.1

., . . ··- ........... ... .. - . . r. ~ 1 ''' , ...... ,. .... ·-•• ... "'" _., .... ,.,..,,. .. '<'Hf"""' <'h , ,, ,._. ~ ,,.,. n.n m1ri'lmu\A" rn-;'"' ,..,

~.1~~:·:;:,;·:;:~,:;,:~.~ n:;,:=~~;.g· {l·;~~.;,;~tl~~·~( W~<~ O#P~s--cr.;..b 1;~-lrl•• .J\.lU be (i)lll)W(d by grm.Jing tQ J. ~"lUOOth and regular !WffJCe. Qxy-acetyl~rte fl.unc: t."Uflln.io: shlll be followed by machining QC gooding m dimin.rte any di~>IOJ:.Iliot) ot mattrial affected.

For L.A.~. the <dge.• for welding. shall b< mode by oxy-w:~ylenc tlltlitc culling or by machinirt¥. Cold shearing may be used for cuning lhlck:ness upro 10 mm. Oxy-:leetylen~ flame c:uuins llhall be used with pccheat snd •hall be fol lowed bv maclnning or grindhlJI to ehmin:uc any discoloration or materW affetecd.

For oust<mtie ss. the edses sbalJ be prq>oted uoioa p1>sma = however. cold s1...n., 1111y be l<lop<cd f<lf 111iekDcss uptO IS mm In sll c-.. the cut <dgts slWI be grouoo boc1: ot mxhiocd bod< by 2 to 3 mm.

All weldln& odacs after cutting slWI b< Dye l'<n<tr>nl(DP) or m>gnctic partki<(MP) examined ror laminadons. eratki or stgree:uion. Add1tlonaUy UST shall be c:uried ou1 within twice the nwueriaJ 1hickness of edge (or LAS materials or when rl'le serv1ce is low remperawre or hydrogen or HIC.

The parasraphs NP7 and NF J 4 iD Jl'll' lJNF of Code are rnondotory This sppli<s to nonftrrous tbddina and weld overlay.

Rollloa and dlslW>c or pl.,..

ROLUNO

Rollins !or t><oolns .00 forming or plates will>< In die loo&irudinal direoaion of the pl,.ca. This direction shotll be dcuty m:ul:ed on 1hc places

RerOIIing after weldmg is not norma.lly recommended. However. if for lurge diameter sheila, rerolliJl& of welded shell course i.s ineviuable, procedure for rerollin.g along with extenl or I)On de11tructive tests (NOT) shall be subrnined for appn:waJ of the Authorbcd Jnspeaor. All weldJ on the section to be rerollcd must be ground flush. Al:\er rnollin,a all the welds on the rc·rolled $Ct.1ion must be DP ctM:dtotJ. su~h weiUs sbaU then be suhjoc:ted to radiography ., required by drawi~s am Code.

DISHING

All dt5bed hc>ds shsll ptofcrably be or tingle picc>c c:cl01SINCiioo. Howt'er dished eDia with one chonbl team are acc:epgbk: for $hells with di.Jmetcr grute:r dun I m. In such cues. Ill< dlordal scam tflall p<ermbty b< in die middle ooe-lhlrd or tile blank. Dished <nels slull 1>< torisphericsl (knu<klc radiu• ISlt of outside diam<ter aoo crown radius 80!1 or outSi<le di1flll<er) or 1:1 ellipsowl. Dish.cd heads shall!>< wbjcctcd 10 DP test on ((nuclde ponloO$ (bach in.<tlde tLnd outskJc) and weJd edges aficr hen& 1reatrne1U. Vendor (() ensure ad~llUa.cy or indicated thinning allowance for dished head It nominal thic.kne:ss. indic.,led Is I\Ol acle_qunlc then the nomin.1J d1ickness should be incrells.ed accordingly, keeping minimum thklmcss n.s per hem dr.~.wing . A strnight race or 38 rnm or 3 times the. nom.innl thlck.J.ess of dished ht.lld, whichever is less, shall be provided.

Wddin&

All ~Jdtna .00 weld overlays shall!>< done w1t11 decuodes. fillen and Ouxcs of reputed .-.ate with pro..., reprodutibiluy of roults. Bt>nd..,.,. wll he speeif.ea!ly appro•<d by Autl'loris<d l"'!'CCtO<. FO< CS prossurc poru, tl>< electrodes >ball he of low hydroc<n type

A ENGINEERs INDIA LIMITED w N(WDELH'

GENERAL SPECIFICATION FOR

SPECIFICATION REV

HEAT EXCHANGERS 6 ·15..0001 Page 10 of, 20

2

•

(

(

I • •• ·-· J i ; I . ' -~ 1." •,; ~;; -· li ;; !::; " ..

H li • u ·~ H .~ lA ;~ ~~ ~1 d *• " s '.t u 111 •

II 11i ii •11 ~~ • E a F -ll

:li &1 l~ H t!

·~ H !" ...

·~ 1' I l,

w.J '-Ui - •'-' ""++ '~ .... 3 !1,1,, n -~dot~• .\i.,oiO:.!U !t '). -~·~U'11;J,/f"." o)f loo;u

;;..Ut...t.~o utd .;•..lUd...;~ ll.l~k :iJ:.t..lll ;d'$ll ~ h-• ' : ~ ....,.. _ ... :_"- •- T~! • ..! ... _ • ..-_ •• ....,. .~ . .;.~-.1 AtaJ·• ct:IMID.. t:\;U<:OJ.tJ ;~._lJ ~ ,~t.;kk:J •ttl\ el.-~,:trt.JU= d1r!t pnxiUCC:: lJl UU$.'f4tic dit•·t~UIJiil tuc;fccj WckJ d.ei)l"-ii HI ~ 1 .. \oi I~'F ,...~.:::; :;i.:!.;!" .. .,;..u_o,•ur-IIOU WCiu oiCfJ'>Slf

4.J.2 All weldma proe«!ures llu!l be ocllnuaal for appmval by Aw!>Qri<O<J lwpoaor giviJ1811ll reJeva01 der•ils. Welding qua!lfu::t~IOI\ recorils sl~:~ll lndicale hardness vlfuao oi wcld mersl, RAZ ;and pueo~ mcu1 and ~fO n::m1ta or in~ te11u when dada.n ll:rl~"'rurc are beft)w

o•c or wbc:o II'C<iriQ!Iy in.!icakd roc ...... w. beina ,.tided. No ....tdmM •Mil be undemken unul me welding procedure an" ""'lder's qtuliftc:llion h3ve btm approved by tbc Authori.ted INj>Cdor. All wddin& procedures and welders shall be ~•a!ifkd for the particular type of welding and Dlllteri>l in aecnrdm:e with lbe ASMP. Surio.~ IX. Vendor sllall be responsible for me qualitY of me wclds perfonned.

4.) .3 Pmsurc boldma?.•w shall be filii penerndon welds. Roo< pus ohingluW. welded joints shall be done wtlh GTAW process. Backing $!:rip tor sinJie side "'elded joinrs is no• permined. For LTCS moterials, b<>th h~Jide m1 outside of w~ldt shall be pound ftuoh or dtes!A!d ~. All imemll welds in me lhell shall be 8f0Und ftush In order IO inserr and r.movetube buodlo, AltO alll)1lt1'n:ll welds shall be p>und 01JOb 10 me Well ortocihtating dnioins of complete equipment, All other weld ""'Y be leA in tile desealed «>ndltion only.

4.3.4 Longirudinal seams shall be •••ggered willllbe circumferential dlSIIUI<C bet-.. me cenues of weld.< beb,g at least $ rimeo the thickness of me lhieker-plate, Weld S<:arns shall be loeored so as to avoid ioterfcrenco with weld...., of noules and utcma1 llladlme11cs.

4.3.5 AUachment 10 pressure pan sbaJl be of same qU3lity as the presow. pan . All LAS weld au.acluntru co pressure retaining eomponenl shall be full penetration weJd and ground to a "mooth coocavc concour. ~f.Uial anxbmeDu like tup. suppons etc. orCS 5tu.JJ not be ~lded dln:c!ly oo high alloy or au.,enh lc SS hear e.•cllJlnier c:ompo!lf<IIS. Tbd< arladunern should be of me same m>ICrial as me hea1 excllan.ger oocnponeOI. U lh~ bi 001 SO, intermediate pad plates or !be samoo mau:rialcype u the heat •"ban&« compooiCO! may be wed. Tbes.: podt sball be a1 I<Ut I OOmm wider and loJ18er rhan I be llltlCitmtnr and sboll be •• l=t 5 mm thick. Wdding of CS or LAS 10 austenitic: SS sball be clone ,.;,h austennic SS dearodes or filter w•rc (AWS-ASTM·F. 309L or E-309 MoL only).

Wrapper plares, reinforcing podt or sdiTen<rl ofhi&h« thickness than II'C<lncd eao be used provided the~ is no cbange lD basic dunens"K)ns and wtth the approval frBm Aurhorised lnspeccor. No sepatate deviation pennit iJ rtquired for the same

4.3.6 P:tnitlon pta<e of CS and 300 series SS CXC<I'I for low l"'11tf11Ul'C sel'!lce, shall be welded 10 ch3nn<ls ere. by continuous fille< weld.< whh minimum size or 6 mm on bo<h sides. For Ill ~r material$ and tor llydtogen and low ,_.lure servl.,.., all weJds involving panioloo plates shall be full penctrari<>n weld. Parti<ion plates dliclter than 10 mm ohlll be IIJlCrcd ro 10 II'Cil a1 panirion groove end eJ<eepl wh<n mentioned o<hcrwlse on dnWil\ll. One weep hole of~ nun diamtltr tbtll M provided at rile ecn!er of eacli honzor•lll pass partilion plate and • S mm radius norch on rop and bonom polnr of each vtrtictl pass p:anltion plate ror all multipus. e~ ror dfeedve veming and dnining.

4,). 7 Weldin& of shell 10 Wllolhbcd ....,..._ st:Wt meet me requlrem<nl$ of COde eonsklering that the tubeshee[ is unsupported

4.3,8 When impact ICSIS ore required on material as per Code or specificat;o, the ~·elds shall •IJo be qualified for impoa IC:SI. In such ~ ... following speci•l requiremtnt sh>U 'I'PIY 10 me welding procedure qualifiCalroo:

i) Qu>lifocat;o, tesU shall be mode on plarcs of the ASMB specif~e01ion ss specined for !he cxch:Ulger us1Jl8 weldlJ18 dectrod .. of AWS or SFA speelfrcauon aed wire &. DUll or rh< speelf~at;on and brand •• are 10 be U.led on Ulc job,

-

GENERAl SPECIACATION SPECtRCATION REV ENGINEERS INDIA LIMITED FOR

NEW DEL.Hl HEAT E:XCI1ANGERS 6·15-o001

L-----------------------~~-----------------------L--------~~··~>0 2

>

' I . -"'• !!!~.! !:-.: ;.' .r••• l!!"'.!!.,... ~~!n;'"':t...., ... ' .. ti ,,...1'!'~1 ,~.-1 .. . ,.,.-,_; .. IY'-' ~;.-.. ,, ..., ,.,..

(;.~ut:al ~i1<l.:u.c::;t . Spect!ia.:J:,·, te!( :::IJ' ·· ,r:all l':c i>..:i-.! :u t:lt~d~·1 1.. ~ !i~J

sttess rt hcf tc:mpc:ratures f\J r appr.lximltt:ly the ~arne le-ngth ot umc a:s Lht hn,.Jl.W n .:hnoger Ftn.tl cooling rate shall bt' appruxlmJte lo lb011 etpectetl fu r the ftnt$hcd exch:lfl8C r,

•• -• ·~ -~ ~:s --~ c-:.•

li H ... ·-jl il u u p fi •I: •, !J -, !: H u ~~ li ll

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iv) Charpy Y·noldl impact rem sb:lll be made on the weld and HAZ uf the t"'t piOie for <Och weklln& pn>«<iure w be qualified. TCSl proo:tdurc sb:lll be .. p.r UG 34 or CC>de Teot t<mp<rorur<: shall not be hish<r than MDMT. lmpac:l energy requonomc:,...$ball be as pee Table 1.15 of SA 20 of ASME Sectioo U Pan A"' UG 3-1 ol Codo "'lud>ever is higber

43.9 WELDOVERLAY

4.3 .9. 1 Weld deposit overlay wll be clone by t qu3lofied weldtng pr«edure and Sllrfu:e shill be properly mtthincd or around tlwb after overlay. Minimum thklcness of linished weld depa~i t shall be as indicated in the drawings or .speclficatioos. In c:ue a h.igher deposition t.hie-kntss 11\d multiple wekllaye£8 Me rtquired to o.chieve the minimum specified und1luccd deposit mc1al, the same shall be done only after Utkina prior approval from Ell. Minimum thic.kne:ss of undilutod finished weld overlay from top shaJI be 2 nun or as specHied in the dr:t•Ni.ngs. For non-ferrous weld deposit, the Iron dilution should be restricted 10 2.$1 (maximum) in the finished undiluted layer (thkkness defined above).

4.1.9.2 Tht weld overlay proc::cdu~ $hall beq.Wified on base rMtal oftbe same ccmposi•~n u the exclwlger eocnpooc01 >nd m<e<ing lbe req.ouemerou of ASME Seetioo IX .

4.3.9.3 lbt wdd _.-lay wll be relative.ty smoo<h "'"' 110 nocchc$ and undcraou tlul .. ould oa as :stress nlstn AU enacts, fiS.!Utes and cireu.lar dtfccu JfQICt th;m 1/16 inch dbmdtr $ball be remo•ed. Repurcd areas >ltall be DP clle<kcd Weld overlay sb:lll be applied w base m«al w~uch hu been gric bla:s.ted 1tJ"ld i:~ .smood1 and dean so a.~ ro ensuR fu ll hoondtOS Welding overlay cladding shall be applied after any notma.H.sing bot befnre the po1U wtld heat treaunc:nt (PWHT). The weld overlay shall consist of at le-ast 2 layers.

4 ,3 ,9.4 The alloy clndding 1hall be C-Ut ~kat all seamll to pennit back·welding o.t the base mcrul. Wdd metal sllllll be ground nus~ ••Ill fu lly ou•ered wiOt the applicable weld deposit. The weJd joil'll 1n bMc plate shall be LOO~ DP cestcd for detection of cracks and Oaws before wdding from clad side. Tht: we-ld deposit shall be at lease as thick .as tbr: cladding.

4.3.9.5 Sheik. coneo and di1hed helds formed from cbod platc:s shall be UST mer lorml111 for a minimum ol lOll or lbe cbod surr.et, intludi!ll 110 Ieos tban one "''''fC feet in d<h 10 square fecc or frxuon tbtrcof. Unbondtd areas dw canooc be C:'I'ICOml'lSScd by a 3 1nth diamet<r c~l< •hall be repaired by weld OYetlay WhM repairs in exreos or 5 ll or lbe toni examined Ilea an requjred., the compltt.t exe-hanacf 1hall be 100,.; UST. Repaired areas and wck1 deposit overlay at weld seams sh1lt be OP examined. UST shaH be repeated lor di<hed he:tds after heat trearmem. All UST shnll be In accordance with SA 518 S6 lor spot exa.mimuion aOO SA 578 S7 for 100% e~~:eminJu ion.

4.3.9.5 All wdd overlays shall be 100% DP examined In ncc:orda.nce witb the mc:•bod described in ASTM·8· 165. 11te butier layer shall be IOOll examlrtod. Wben !he OYerlay Involves multiple pu.ses (layers) and the procedure usa an lntcnncdillte heat treatment with cool ill& to room temperature prior 10 applying the subsequent Layer. each layer shaH be eumioed. Where ovrrlay is to be machined such as for ftance laei111, madtined sur lace shall be 100 S eumined al\er (111&1 PWHT. II 100$ ol overlay IS <Ulllloed prior tO tit< final PWHT. o,·erla) lllall be '90' eumioed (noc less th>n lOll of lbe surlatt) after heat trearmeno

- ENGINEERS INDIA LIMITED GENERAl SPfCtFICATION

FOR S PECIFICATION REV

HEAT EXCHANGERS 6·1 5~001 • NEW PI!LHI P<t911 12 of 20

~---------------~--------------~----~~~~--~ 2

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hll ca. I! r"fP"" N we~ ng RX;.:j,J, ~It •}( nt; d~emJCl! .!JUJYSil uh.1?l ~ ... 1 ill!'.muu'"' on

,11..~"t!:C!'1~ !.-.sy .. t.l.vl (ut avpcuvai

4.).9. 7 For all wdd ovetlilYS ll!ed in hydrogen or H2S ll:I'Vi(:C wirb design ~r.uure g~ tban 35Q•c. H)<borcn dlmndlfl& tesc :hall be c.arrled •>~Jt . Tbe test cc.~OtJn)()n sball be repreo;c:nuuive. of the at:tual dc•ign coudicioot and dx procedure "Sb.tJI be s:ublniuod (() Audlonled Inspector for "'''lrovo!.

4.J. IO PToducuon '""coupons (P'TQ ore required for CS welds above SO nlltl lhi<*nes$. for LAS weld.• above 25 mm or when l'l:qUired by th: Code. The iollowma $ball •pply:-

a) Two PTC. reprcstOI:atiYC: ot one lon,&iwdinal and another c1rtumfercnuaJ seam shall be provldcd for each proetdure. po&ilion and lhick:nes.s.

b) PTC shall he from maltrial of the wne heat •nd thickneso u o1 par<n< mcul. Durin& ond lftcr Mldln& PTC shall be subjecced co •am• he3t ,,..1men1 u and together wilh lhc oourse lhey n:present, excn PTC shall be praervol 10 calte care of evClliUality of tt1o:su.

c) The ICSU mendonccl below sllall be carried om u per metllods of ~ing in Co)de:

I) One transverse tcn.non lest

li) Two side bend lCiit.S wich weld located in lbe ccmer of bend-

uij One ban:lllt:!S C«t on PTC weld and HAZ. The acctplahlo: llmiiS "'" 200 BHN for CS, 225 BHN foe P3 and P4 materialS and 235 B HN for PS as per 6-15-0091.

IV) Micro and macro examirwlon of welds.

v) For CS, <harpy V ootc~ ccsu on weld and HAZ slull be canied ouc. For MOMT below O' C. impacc 1e11 c~racure shall be MDMT. For MOMT greater lb4D or equal 10 o·c. th: .... ,_....,. ohall b< o•c. The ac:eepco.nce criteria for i.,..,.ct enersy shall be II$ per table a 2 .15 of SA 20 of ASME Section II part A or UG-84 of C>de whichever i11\iJj>c:r.

vi) For LAS, clttrpy V DOitb...,.. on weld ond HAZ IJtall be carried our for 25 mm lbiekness and abave or when speeificd in requl.sition. Ta r tempctanlTc and a<:cql(ance criteria shall be u per <louse 2 2.2 (d) (II) above

4 .4 Tube ro tubesbeo< jolms

Requiremonrs of 6-15-0003 shall be C<lm!)lied wilh for •-elded rube 10 IUbcJI>e<r join«s and mac of 6-15-0004 shall be eomplied wich for expanded cube 10 IUbcshecc joinu.

4.S Hardnw Umitadons

1-brd.ntss limitation for maic:ri.:ll.s wherever spcti(ltd on drawrngs or duasheeft an! LAS materiW shall be as per Spce. 6-1~1 . Hardness lim!cariQn for tube to tubeshcec weld in& shall be -.tablished on a mock-up with JimulW<>n heal trea<m<nr. Hud..,s of suslgllt dtrome malcrials in rho eold formed mre, H"Z and welds ah•ll not exceec:J 88 RB.

A ENGINEERS INDIA UMITED w NEWOEUtl


SPECIACATION REV

HEAT EXCHANGERS 6·1 6-0001 Ptffl 1~ol 20

2. '

I •

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L;

4.6.2

4.6.2.1

4.6.2.2

4.63

4.7

4.7.1

4.7.2

4.7.3

4.7.4

4. 7.5

Of.:c."'f.i •~t :-ortrw -:>e ;.;.;:~ ... ;. di •• ko:.Ji,}n.;. JriUin,ti. (Jdmt Jn..-1 tol-;:;:.n·.c~ (¢•· ::.:;;::~!.: lla!l~e:; Ffnrl blir.d "'"~ts i f ti'qnir-rl\ sh:i:U be a:;. per ;-\SME B 16 5 (foe $i'u uptc 24" :-rm ~c ASME B 16.4'1 Serle$ B (for SIZr".S. ;~bove 2.4" NB) far d'e respecuve d:•ss~ Weld overlays, wherever specified oc required, st\::1:11 be in addiuoo to the duckne:s~ J:i pet" thc::se stantlard$. Bolt holes on these nozzle tlsoge\: snnn $traddle ptiac.ipal venical and borizomat cc:nu:r lines of equipment. Jf !he co~t to whicb noz:zJes are atti!Ched i$ sub&equently stress relieved, il shall be: Vendor's tesponsibilicy to maintain true gasket faces by m:JChinln.g or otherwise. If distOrtion expected is coosidcrnblc. final machining operation shollld be done after stress relieving; sufficient m:acbiuing allowance for this purpose should be available. G>Skoc•, lor flanges 10 ASME B l6.5 ml 816.47. shall be as per ANSI 8!6.20.

NOZZLES

Nozzle pipes shall be attaclled to the heat exchanger component." hy full penetration welds. A!W:Iunc!\1 welds ming n•~Y inner and outer fill<1 w<l<l:l arc IIQI pcnniutd. Unless otherwise indicated on the da.tii.Sht:et..'i or drawing,!, 1leclcs of all nozzles sh.:all be flush with chc if)Side of the heal exchanger component. ln.'lide comers of nonle pipes ar shell and channel inside diameter shall be radtused. All nozzles 2" NB and b<:low, except long weld neck, shaJl have two stitTencr11 (30 mm x 6 mm) at right angles,

Whenever noztle i11.$idb is required lObe overlayed, these slt:IH be done by weld ove-rlay or cladding. Minimum nozzle ID before weld depositing to be SO nun in such cases. Liners an: not acceptable.

REINFORCING PADS AND TESTING

Reinforting p3ds whe:ncveT required as per drawings or Code shall be Qf tbe $3ffiC material or equivalent as the beat exch1tngcr component to which it is welded. AU reinforcing pads ;hall 1>< ptovided wirh two 1/8. (3 m.m) NPT tallPed hole:!! loe:ued 180" aparr ror air ~oap solution test with a pressure or 1.25 kg/cnY!g). This test shall 01Jso be requ:ir¢1.1 to bt: carried out for slip Oil flanges. Higher test pressures are no« recommended because or accompanying cisks and also because tbe sonp bubbles have a chance to biow off. Tell-tale boles in d1e rein!orting ~s shall be plugged with bard grease uoii!".')S otherwise indicated after the hydrotest of the e.x_ch.anger.

6olt"i, studs ttt. and tapped boles

All inch bolting and threading slull conform 10 ANSI B 1. 1 excepl (or $i-Ze l" and above wh.t.re h shall be 8 threads per iach. Metric bolting and threading shall confonn to ISOR26J e.xcepr for size M24 and above. where it stull have 3 nun pitch.

Sruds shall extend beyond !he 1\U! by aboo1 I 0 mm and shall lx: threaded full leog1b excep1 when square ends are required (or use with bolt t¢1\Slooer. In which case the extension shall be as per bolt tcnsioner manufaciUret's reconunendarion. The studs for ~xteoded tubesheers and the u uds for use with connecting piece shall aLiio have square ends.

All nuts sh.all be of heavy series only a!ld nut searing face.s sbaJI be madlinod or spot f~M::ed.

Threads on e.xrenud bOldng, plugs e(C. shall be lubricated with graphiu: grease. for working temperan.re upc_o 200•c ;~nc:l with Molybdenum Disulphide for higber cemper.JtureJ.

Tapped holes drilled on '"' channet side face of cllld lube sbce" for rtmov•ble bundles sh.oll be fitted wi(h plugs of a rruuerial similar to channel side material in cont!l<:t wi(h tubeside nuid, For CX(ended rubesh«ts, r~ppod holes shall be provided for ginh bolting.

I a ENGI,..EERS INDIA LIMITED l,. NEW 0£1.!11


HEAT EXCHANGERS

SPECIFICATION

6·15..()001 P-ag" 14 of 20

2

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V~r .).i._aU bt ft'.Jpoll.liibte Cot uk:mg 001.:Quat~ prc'lm£1\lc Jl.lt.::.l.SW'CS w tefli&Ure the qualily tOO finiih of mareru!s ~ to 3.votd. any N:ling

4.S .2 S..it;al>le onetbod o( lll&lunent l!ko dowell«<. •11>11 be provided for prq>er asaembly of ch2rmel, chaMe1 covers. suuionary tubeshcet ecc.

4.8. 3 Sucked c<&:h:lllgers shall be assembled in die worbbop for a trial fit. Speci>l <>re >ball be eu:rrisl:d il'! maina up cor;ocetina noz:zJe flangei.

4.8.4 ·r· .merever 1ndi<11ed on drowins;s. d<ntXes m.1ld1 nwt for wanl>ly and Wil be: puncbed on all maling pam

4 .8.5 Lifting 1111' shall be provided u per SWitl.'lTd for limns of clulnne.ts, <lultmet covers, shell covers, teat rinas. ttsc flanges etc.

4.8.6 In case or removable bundles t1v: f<~llowing are noquired:·

(a) Slalionary lube sbecu lball be drilled and lapped •• venical (0') poririon for auaching eye bolls: or a lifting Jua or lde<jlllle lhid<ncss ohall be waded Wldl 2, mm (minimum) diamc<et bole.

(b) Orillinc ond tapping as above ohall be carried oul on Ooollng IUbeshcc<.

(c) LMI suppon plate shall be drilled (lS mm diAmelcr hole) for lifllng. LO<l\l suff<rung may be neces.nl}' 10 adequately suppon !he bundl<.

4.8. 7 Pulllng eye boles INde rrem fMpl CS shall be fi!O'Iided for All removable bundles. The•• shall be provided loose.

4.8.8 SuliOnal}' rubes'- shall be drilled and lapped for de rods. C... sbould be talten 10 enoure lhot holes .,. 001 drilled tl!rouih.

4.8 9 l~eabl• and 180' rorauble bundles •hall have conlmon p...,_p4.Udon aroove amngcmel\l in lbc reopective WbeS~ For uchangcn wbere bundles are •pocifted 10 be lmttthanaeable, !he same shAll be ensured •• the Vendor's shop by OCtUlUy ins<nin& !he bundles or U5lng a 1empla<e c:onsWlna 4 IWI d"-er baffles. eadl spaced " a di!Unce equol "' the blme pitch.

4.8.10 Jack sorews ohall be provided on •U ,ginh flanaes.

4,9 Dl:scalina. pick! ina and ~·lvadon ohall be done [or all ss pam or heal -..hangers in occordonce with ASTM A·380. The Vendor shall >11pply d<l<lils of the J><OCc:dure for approval co the Aulhoriscd lnspec:wr.

4. 10 No disconion wb:ll.soever sJ:u.Jl be pcrm.;ned on tbc gask-er. ~ina surfaces due ro rube ro rubcoheet woldmg, sbell to tube•h<:et weldmg. PWHT <1<. If distoned, !he s:uae >bAll be 1110<hlned subeequ<t'dy

4.11 I The climeosional IOierlllCCI shall be within Lbe limits indlwc:d on ElL drawinSJo and standard$. }Vhere rolc:ranec.s are noc specifted, these shall be in accordllncc w1th the rcquir<men~s or TEMA and Code.

'

A ENGINEERS INDIA LIMITED w NEWDCI.Jfl

GENERAL SPeCIFICATION FOR

SP€CIACATION REV

HEAT EXCHANGE.RS 6·U.0001 P~• 161'1• ?n 2

\

I

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• • ·--.......... -.. I I I lhe t!'.!£p:::.DVU ~.-..;t ... -.c o....u .1 :\.o -. -.•1 '~"'·' ......J ~·~·~ .. ~~; ~ ::=.!:".!~ ~~''!!!:.,~ !!'.!!

tt:mng t,)\. e:tLii:UiaJO:~ :jil.llt lK ~.,.~u LV h"'f'"='-r";-1\ hf L'l~ A ult.vtt.;..J. l..lS'".,...x-• .~r "" ~iti-.;;r. r.; 111\]' ir~pection te<;ui."ed by 11'\(: !!p~if.ed. O >oJr- Of by local authow •cs haY'ing i••• L,d.l..tl,ln o"Ytf the tnstall<uion

7 . I l hupcaoon shall be arncd ""' botb ~ r.btictlion and before dclivay and also for sutordered maten:lls, 1! :t.ny. In addition to fina.lmspe~;tion aAJ cert1ticadon by Aulhorised lmpcctor dutina tile <GW$0 Of manufotturo, Au<honsed Inspector'& wriuen opproval sb:IJI be oblain«l by 1he V.OOor •t vorlollS Sl>ges or f•briauion. For this purpn<O, Vendor shall prepare his Quality Assurance Plan. defining the $tages or fabricatiOil, hold pohus for his o-n inspcc:r1on .00. lhaE by the Ao:tborized fNpeetioo or Code or starut:ory Authorities lnspcaion c«: The Quali<y Assurance Plan sbalJ be dlscussed wilb .~ud!onsod <nsp«~or befon: Sian or job and lllUIU>IIy agreed The variooH sages of fabricalion 10 be onspcacd (by Vcn<br or 1be AUihori'"'d lmpc«or) •hall include bul not limited 10 <he following:

(:a) raw material identiflc:uioo and verifkallon of mill 1es1 certiftcllte.

(b) edt< prq>anlioo for ,.ddq. inolud1111 visual tbccll for l:uniJI>Iions.

(t) alj&f'Jmcnt of longirudhul :aad circumrercntial scams.

(d) roRin.g tolerances on individual socdon.

(c) al~l and fn up of ...,lOll$ and_..

(0 rooc PQ!IJ dearan.ce tJcrore welding and cltaning.

(g) pronlc and lhiMing of dlall<'l ends Jnd wrkonical pioccs after fonning.

(b) chcckrna of lllbc:sl>oOI >1\<r drillins indudiJla .,.w tbccll for lamo..,..,.

(i) rubesbcct (0 shell $C1 up ror ftxed rubeshee( exchangcn, prior ro welding opera(ion.

(j) tube to tubcsheet joint expansion or welding.

(I!) visual choek of shell ""ode and rul>e bundle ms.t1ion.

(I) welding of expan.,inn bellows or joiniS. If rcquircd.

(en) review of NOT repons

(o) rtYitw of hat <!<>lmCOI <Jwts,

(O} fU"Ol vttual and dimensloMI iospec•ion,

(p) wimcnlng of hydrlllest.

7. 1 l The preornce of <be AUihonscd lllspca.>r ohall no< modi f)' or ""'""' dlc oblia>~-o( dlc Vendor to carry Of.ll hjs own CQU and conuol. Shc>ufd any maccnaJ :and/or equipment bt round n01 in co•u.pliance with lhe requirements specified. the AUihori3ed ln:lpector or his delegate stl.a.ll be emilled 10 Irrevocably reject them, even lr suck non COR'()Iian<:e has not bcco evidmee<l in the course or i~pections and/or tests.

7. 1 4 1bt Aulhonscd lnspec10f .,.,11, a.t 1be time of hiS initial vtsu, a.et up \With che Vendo«' I(NIJ dccails of irup¢~ion stages to be:: wirnessed or c:aTTied out; the schedule of tuUJrc visits :~nd

a ENGINE£RS INDIA liMITED w ~WDflHI


SPECIFICATION REV

2 HEAT EXCHANGERS 6-16-0001 '-a• 11 of 20

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" • 5 Tbe Vendor Sholll T\llflty tJl.! 1\uthor\s.:d Jo\-:wt•)( StJt'tltlt:t.!!.h 1:134-::;••·· ... "•! flO. .. .. .. .._ ~r..=..-::1:-~ :U V"--'lu~~ U,Ud W .atnve at tne Vc=ndM'S &hop 1n tim e (0 Wi(I)C:Sl lhl~ t\f.,_, 'ltiort<

7.1 6 The Vmlof !!WI pt<Mdc to !he Amllcris<d ln!it>«•or, free aeo:esa 10 hi$ shops 01 olltinlol. He •boll aJ:;n illlpply all r.»!Jllld bel<lcs 10 !he ~ lnspcaor ro. csrrymg out che itrfptatOD. 1be Vender ~hall also arrange for sunililt flttiU!es !11 his sub-cootrxwr·s s.OOpa

1 I 7 The Vendor m"'' satisfy the Autflorio<d ln.pec:tor that U>e W<kting proco31ra, wel<lers, e:Jectrodc:s. ftua,~ ~wires etc. &re in accordmce Wilh the tequiremCIUS Of tbe Codt and specificatio~. Funher the weiJea • • qual if u::.Woo test ft1U5.l be carried oul i_n the prcsmce of !he Authoru<d lnopc:ctor.

7.1.8 Pnor 10 fin.tl inspection. all Sl"8, weld spat..,looseS<ate, dirt, &rit. poiot,arease. oil and Clhfr forei&n maa<r <hall he """'ved In onlcr 10 f.acoli!Jlle inopection. All reinforcing pads and sl1p on type flange wckb shall be pressure u.l<d ...W. air and ""'P solUiion before and aft<r boar ..........,. (if ony) and befo"' final hydroo!Jltic lese.

7 . 1.9 A dimensional cheekcng of equipmenoubnll be carric<l ooctaldng inco ucoun~lhe colmnces •hown on jol:> drawings and mndards, design opec:irtcatlons or Cede. tho mo"' '"'"ll'"' values •hall govern. t>imcnsiorull ~heek.s are 10 be tak.m of !he ku<rnal meuu..,.,.. or equ;pm.ru •.,..met with otern.tl ones and che,. nre 10 be rec<lrded on a c:opy of the drawinas as being the • As Sui.lt" dirnensiolll.

7.2 Hyctr .. cadc ,..,.

7.2. 1 Hyd-...,. shall he wilnes!<d by the AU!ltorised IMp«(Or, When ilydJ·c.ta&ic teiiLS Ire pcrfQmled tho rndicatlna sauae sbnll be connected 10 the upper 111011 pen of !be equopmffl. Tts•in&"""" shall be clean po!Oble water. Sea water shall not be 111ed. For SS cquipmenl, w11er used for che8e tests slull IICM tonlaln more INn 1S ppm chloricles. Minimum mccal temperature during hydroouuic , .. ,. shoJI be 20'C. T.,c pr,.SUTc:$ $ball he maincaulcd foe ;u least ono hour. Shell lU'd Q.lbt Ji.de4 sh:dl be teSted separately. anlc::ss orherwisc men1ioncd on the drJwing. For tuhe$hec:t.s d"'lgn<:d for diffcrelllial pressure, special care shall he oaken duriJll cesllng. Equipmonl dtlwinss •hall clearly indicate by a nolO, if ruhe$htell h•ve bc<n designed [Or diff.,ntial pte$!Ure. Drying OUl U per clause 9.1 -<hall he ClUried 001 imrnedoately atltr h)'dJOICSl.

7.2.2 All vmic:aJ exchangers sball be lt!led In vcnical po; ition, Altecn.11ivety. e)l-tban&ef 0\ay bt: tested in horizontal position with rest pressure modified with prior approv:tl or Designer.

7 2.3 SliCked c.u~w>&m wilb nou:les interconnected shall be hydro<esled In sut<k<d condicion except when the h.ydrote.~' pressure or the lndivkluaJ w:hanJcr i1 dlffcrenc

8.0 STAMPING, NAME PUTilS A-~ WARNING PLATES

8.1 Each excNl!8er shell shall he fined with an SS name pt•••· 8.2 Warning plates, if required. shall be provided.

8 l The following ex<:h>nger pa"" sh•ll have ohe hero nurubef stamped •=pc for heat cxchangen in low tc:mpcnrure service in wbk:h cascl:be uem oornber shall be marked with nOtt·nmovable ink:

Sholl Sirlh flanges, shell cover flange, channel Jinh llanJes, flat channel cover. n•uonary al1d n-in& rubeshe<u, flootmg head cover flange, floating head backing ring, COilllCCtiAg pieces. te.llc rinas, test Oanges and ~r main rtnlCWlble parts.

A eNGINEERS INDIA LIMITED w N£'W ~-.Uti

GENERAL SP'ECIACATION FOR

SPECIFICATION REV

HEAT EXCHANG~RS 6·15.0001 hoe ,. of :10

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Dry ~~ shalt 1>e rk'm" sttlll-dt~~~ :usly r .. 1 t:l•'oi:h shell and '1.-.l."t' side'> Aile .. fiNir•g 1h;. ~qu1pmeru :.haJJ be i:rged and fi!l.e<l with dry N.,. ar 0. 25 kg/cn)l. The eQufp~;n; sh:~!t be ptovidcd with pre~'Ure gauge to moniror N~ pressure,. and Jh • nonMcccurn V3lve. All threaded boles, Other ttu:1 tell tale holes for tesung. WU be suitably protected wittl uetl bar plug$ . All nozzles not prov~ wirh blind Oange :i.halll.x: provided with :«eel covers and teiDPorary gaskets and bollS.

9 "2 Shop painting

AJJ CS and U\S t:uernal surfaces Cldlcr than gasket ftl<::d and other m.acltin·ed surfaces sh~t1 be given one coat of primer paint. Surtaces to be painted shaJI be pn:pared for painting by removing loose mill scale, IOO$e rust, oil. grease aod Olhet fll.ms or subs~ harmful ro th.e adhesion of paim by an approved 01tlh<>d such as shot blast cleaning. The surface shall be plfl)at<d 10 n<i!r while finish as per SSPC-SP-10 [ SA 2 'h Swedish Sl9ndard (SIS<05• 5900)1. The sbop primer shall be inorgan~ zinc silicate @ 65-75 microns dry film thickness. unless stated otherwise ..

9.3- The equipment item number, Purchase Order (PO) number and Purchaser name al'\d address ~hal l be painted in bold white paint leuers wriuen with stencil. on the beat exchanger.

9 "4 Oesfl'lldl of equ; pm..ut

No heat exchanger shall be released for $.hipcnent uncil it has been approved by the Authorised Inspector. Heat e:~chaagers shall be dcspatchc:d after the oper:1.rtlon! as requited by clauses 9.1 , 9.2 and 9.3 bave been carried out and shall be despatchrd in aHested 0011dition. In c"-"e stacked exchanger shells ate despatched sepanuely the Vendor Sh:\11 provide adcUtional set of gasket!l far ll'lte-reonn«ted nozzles other than the gaskets included in q>ares. Heat exchangers sh:dl be sc:eurdy anchored for despaich in order to prevent any slliftirs.g and damage during tr:ansport::tion. Expansion joints and bellows, wherever used shall be suit~ly protected against any possible damage by providing de bars b¢fore bo.xing up. Packaging shall be suitable for rail or road transport and also sea worthy if tramponcd by ses. Spares shall be despa.cched sep:mu.cly in a bo~ and marked with PO nqmber. item number and Purchaser's name and address.

Sling marlc identification shall be provided by Vendor on all heat exchangers with cespecc to cente( of gravity of the equipment.

No equipmem shall be despatched umil a written clc:1.ranc<: is obtained from Purchaser or Cll re8arding Piping CHps and Structural Cleats on individual equip~nents.

10"0 VENDOR'S GUARANTEI!S

The Vendor shall be completely responsjbJe fO( the compl iance to Cod~ requiremenl:s. re$idual design. detailing, fabricalion, mare rials and workmanship of the c:xchanger-1 as per the stipulalions of the requisition and its attachments. In this regard. it may be noted that re\•iew by Purctw:er cc £It stull not relieve the Vendor of b.is responsibiUty of meeting all requicemcnt.s and ensuriog satisfactory performance or the equipment. Guarantee period shall be as per Cicneral Purchase Conditjon of .Purchaser.

" -ENGINEERS INDIA LIMITED I w - ·N£W 0€1.HI

GENERAL SPECIFICATION • FOR "

HEAT EXCHANGERS

SPECIFICATION I " REV

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'"' N INfERS INDIA lJMiocD WELDED e f G

- STANDARD SPECIFICATION FOR

N(W OEl.H> TUBE TO TUB.ESHEET JOINTS

SPECIFICATION REV

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i: 2.0 APPLJCABLE CODES AND STANDARDS

,.:il 3.0 WELDING PROCESS AND JOINT DETAIL . " ~~ ~~ 4.0 WELDING PROCEDURE QlJALIP!CATION .ill

~ ~ ~0 WELDERS QUAL!FICA TlON

li 6.0 PREPARATION OF TUBES AND TUBESHEET ~I H 7.0 WELDING p

8.0 ~~ EXAMINATION OF JOINTS

rJ 9 .0 TUBE EXPANDING ·l ! s 10.0 REPAIRS

~ ~ ':!J 11 .0 TEST AND REPAJR REPORTS

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u APPENDIX· I

JOINT DETAJLS . ~ APPEND!X·2 ~.

h DETAILS OF TEST SPECIMENS &J

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STANDARD SPECIFICATION FOR SPECIACATION REV G ENGINEERS INDIA LIMITED WELDED NEW D£U.l TUBE TO TUBESHEET JOINTS 6-1 6 ·0003 2

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2.0 APPLICABLE CODI?S AND STANDAlUJS

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The lakSI «111Joo O( lbe lllllowlnt codes ond NncUrdl ollall 1>: complied with:

a) ASME See1lon Vlll Ot•isioo I b) ASME Scctioo V c) ASM E Scclloo IX d) TEMA for !Ubular exd>onge"' e) A PI 661 for alr<:c»ler• I) AWS

3 0 WELDING PROCFSS AND JOIN!' DETAIL

3 I M:u~ual or au1oma1ic Tunasra> laert G .. shielded Are (TJG) welding shall b< used. All joinrs shall be made by usio& minimum IWO weld pa.s .... Tile firol pa•s should be preterably nl:lde withool filler win 10 """''" rooc fus.lon. Tbe oecoad or final pass shall be wilb filler win:. Any other v.·e1dinJ p~ can be u&cd only after obUiinina wriuen approval t'tom the Authorised Inspector.

3.2 loiru d<tail &hall be .. indicul«l on the Purtlwer dtaw~n&s by civina ... - 10 UJU"' numbc.n in Appt'l\dix·l of this apedtic:ttion In ibse~ of any Purtb.uer drawrngs oc 1n<hcatlon regarding lype or joim, Figure 2 "' fiJ!Ure 3 ihliJJ be usod dependin& IIJlQCI Wllclhcr tUbe tbkkne$$ is .;a. 2 mm or < l mrtl rupa::dvety.

4.0 W£LOING PROCEDURE QUAUncAnON

4, I Weldin& PrOCedure SpcclCICallon 511:111 be ~iltd by lbe Fabricalor ond submined to the AuthoriJod laspeelor for approval be(orc !he quallfi.c:otlon ICSI> are performed. Mock up I(St •hllll commence only afier awroval i:1 ob<Jined from lbe Aulhorisod l•sp«ror

4, 2 Weldin.& procedure qualification test is required to be carried out if :-

a) A-uthorised Inspector requires the te$t co be carried out

b) There exiats no prevlous qu.alifico.tioo tests within I&Jil three years t« the propo.'ICd combination or lube ond m~ P oumber and SJOUP number (as per AS Mil Sccuon IX), tUbe ou~>ide 4iamttor (00), rube llllckness, tubt$1\ccl thickn<.ss, rube piiCh, tUbe pilch PJUtern, weldin& proeedore andjolnt detaU , All ocber t.:mrs remaloing same, lbe pr<»«<ur< ""' oced DCX be repeated if lbo job lubeshe<:l thickness exoeeds 40 mm ond qualification exlsu lor 4() mm or hlch<r 1ubeobt<t dllctneso.

For plug type ~air coolers additional procedure quaJifkadon tat is CU{Uitod to b: perfomal ro• any or the lol"""ins oondorions.

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The joO has iO""" clear..us - lUbe ond any or lbe bead<r plore. Ilk• toplbottomfend/a:liffcncr/pa.'l.S partition pl1ue CC.lrf'IP<~ff:d to c:arJieJ' lesu.

Tbe JOb has I0\1.-et plug .site for the same rube s-tze c:ornp•red 10 earlier ft".Sts.

a ENOINEERS INOlA LIMITEO STANDARD SPECIFICATION FOR SPECIFICATION 'l REV

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!:' re~\J.!r;.-.! ?.S p~ I . l. Jbc··'~ . !he f<;)brx:~wr ~r.a!i prrf1."'!m :1. prr ... 'C~re c:cl.l :t:-.;:~th.:n ~e:lt . :.:! !e:t.S: two weds bt'fo~ fho: ~~lt~:t.!u!ed be-ginnifl$-t of producllOl\. Procedure :sh.JH be qu!lii6t"'l fot the same hand posicion as is being pro0posed foe production Procedure resl sh.aii coruiSJ oi ttl€ welding of nine lllbcs for squ~re :pti.Ch and e~gilt lUbe'S, {U\n:e, two and three rubes per row •rrtUl~fAknt) if .:>n a triru1gutar pircb. This shall be dooe for ea.ct, set of combiu::uion of rube aod rubesbeet P number ~nd group number, wddiog procedure:, joim deulil. rube 00. cube thickness. tube pitch, tube pitch pattern. tubesheet tl1ictoess. Additionally for air cooler, rests shall be done for t".IIC·h tube siu with lowest plu~ site, lowe$t clearence between tube and any of the heao.:h:r plates, and t1te lowes.:r plugsheet thickness robe used on the job. Thickness of the rubt:sbeet usee.J for procedure 1es1ing sb3.ll be= samt !tS U:ied for job, cx.cc:pt that for t:lrbon :iteel and austenitic st:tinless st~l materials. it need nor ellceed 40 nlm, unless otherwiSt: indjc21ed. Reter AppeodixM2 of this specification tOr test specimen de!ails.

The following (!3[3 repcm (~ix copies) sho:ll be furnished fer review to Authorised ln.'ipeclot with the weld $iimpl<i >< outlined below.

a) Complete details of weldln.g procedure employed indicating varioos m.achine seuings welding rods. inerl gas composition & puri1ies, flow r.lte, weld sequence etc.

b) Mechantcal prope:n ies and chemical compositinn of rubesheet. tubes and fi ller metal.

c) The ha.-dnes..~ of tile weld, the tube, the rubesheet heat affected zooe and the rv.besheet base metal after each pass .

d) Tht romptete 1.e3t sample shali be CUI (by sawing) as per Appendix 2 of this !tpeeif:caticn. These shaJJ then be wbjetted to \'1rioo:s test! etc. as outlined below:

il Section I sllall be tXllisbed; erchoo and microphorograpbed for cxaminalion of depth of weld~ peneuarion and definition of boundaries. The minimum leak palh of each weld sh~ll ~ not less 1han me nominal thickness of the tube. The weld leg shaJI 1\bG be ll\e3$Urtd :and shall be minimum 1.4 times the nornirml thicknes$ of the-tube.

ii) Sec.tion 2 (two speCimens) shalt be subjected 10 tear 1es.r These $pecimens shall be 1ong·u~ ben! to show the extent of weld penetration. Tbe underside of t.he weld shall show eYidence of adequate & uniform weld penetratiOI'I.

iii) A section lO nun thick: conuaio.ing the tul;le end welds shall be sa\\'ed from seccjon 3 and rll(liqgrilJlhtd for weJd quality. Tbe radiograph shall b¢ $Ubmitted co Autbori~ ]nspector. No cracks or crack: like or visuaJ defects are acceptable. Accept;m;e shaU be llS p~;:r Appendilt 4 of ASME Section VIII Division L Jn case the radiograph is not acceplable, weldjng procedures shait be suitably modified so lhat proper weld and acceptable radiographs are obtained. These shaH be proved by relcsts.

iv) Sec-tion 4 sb.ill be etched 1rrd polished and :.iven 10 Authorised Inspector.

e) A tension ~tn:na,th test shall be carried out JS per ASME Section Vlfl Division I Appendix A. This strc:ng1h teSt shall be performed at room temper3rure for each combination set of tube and lUbesheet P number and groop number. tube 00. wbe thJcknes.s and joint decai.l , The· breaking loads shalt be at leasl equal to the load req-uired fo r break:ing lhe tube using the minhoom specified ultimate tensile strength of cube as indicated in ccrt.iflcates issued by the tube supplier. When tu~ material is 10 a spc:c:iOcation which does not c._ll (or tn(:(:hal'\jcal teslS to be performed. ultim~~tc tensile

~- ENGINEERS INDIA LIMITED 'W N£WOEI.HJ

STANDAI!P SP~CIFICATION FOR SPECIFICATION • REV WELDED f----::-cc::-:=-=-- +-···

TUBF. TO TUBESHEET JOINTS 6 •1S·0003 . 2 Pe~e4of 8 .__ __________ J......._ ..

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4 . .S Fabricacor islldviSOd to utisiy lumsell mr.t lbe prccedures c:mp!oyed are the IJe•• for tl"' Joe :uld ""'"ld <nable hitn to alve workmallllhip au:u~ for 1be oqulpmed<. Alllllo<isal lft!pcao<'s llllP<oY>I sboll in no w:ay t<l.,..lhe Flbncaor olhis respo!!$ibili<y nnd auar•n•oe 10 :lllpply me equapmcnr 33 per the coodiflons of t.ht purcba.se ordt:r

.S.O W€LD£RS QUA.LIF1CA110N

The purpose ollbis operotor qualilicatioo cc.. Is 10 dtmoos~me lbst both tllC " cldlng operator :ond lbe weldin& rnad>UI<S m eopol>lc or producing salisfac<ory Joints. Once wcldioJ prcceduRS have been qualified u above. wetdin& opc:nu>r1-\oyed oo welding $boll be requcred co provo cbelr ability 1>y ~nakina cell samples similar co dull pre!Ciibed above for ....Wma proccdut¢ qu>litication. Welding opet1IIQI1 may be qualified based on para ~.4 d (i). 4.4 d (li). and 4.4 d (IIi) above only, provided """" welding 1111Chin<1 & welding proc<dlir<S arw ll.l<d. This ~ldina operalt>t qualllicadon lest obould also be carried out if tlJe weldinJ operator has noc executed sirnilor welding sla moncb.• prior 10 prodllCIIM. R<pca<...,. may be tailed for in lbe course of rnanufacalre to determine the COtUim.ncy of operntor or f'h;Jchlne to produce SQU.nd welds.

6.0 PREPARATION OF TUBES A-ND TUBfSH.EET

6 I Tubeholes sb>ll be ro opecial clooo fit !Oio::raaco as per TEMA (or sbell and rube exchangers a11d as per API 6<11 lor air coolers. Tube hoi"' shall be free lrom any burns and lhe bund~ side ed&e of rube hole$ 1holl be chamfered or radlu$<d. Tube holes shall have smooch finisJI <o 63 AARH.

6. 2 Prl<)r co as.<embly, cbe IUbtobeec :ond rube ends (inside :ond outSide ior a d•swcc equal to the rube$hect chlcknesa + 30 nun) !ball be cleaned and degreased ro free from~ Itt, ,,.... et< lc 1$ W'Jllild lllat tbe solvent used for dqreaslna be cbJoridc ~and sulflde free <nd non rt<tdue fonnlna. The solvenr should noc lead to a.ny JlOIISiblc fire ha!Jird.

6 3 Tho rubes sball be positioned in cbc cub«beet> by 30' tapered driR pin.

6.4 Before weldiiiJl rube 10 tubetilleet, lbe wbeih<ets shall be bcued co a lt04"'<awn u required 10 remo\'t any lUI t:nc:a of mobwre or solvent Whicb may remain ;~fter tbe c:l~nina ope: ration. Any specific requirtmentle< appliatioo of preli<:U sb>ll be <mblished u a pan~ tbe weld.ln& procedure qualification cesr and should 110001101 for lncrea:!td l'e$tralnt offered by tbe larger assembly during produelion.

7,0 WELDING

Tubes $lUll be individually welded.uaing lhe prooedun: approved by cbe Aucl1ori!led l~peccor. Sysremar!c weldin,c procedure shAll be adopted so as ro resuh in minimum rubnberc" dlitonion AJI rube$ uc co have lnirial pus C0£1'1)letely cleaned u nectssary. vi5ua1Jy examined and te~aed • • per para 8. 1 below. If required, before subseq..,tlayen areopplied. Welds s!lall be suilably fmlshed lind my spillage OO'sparter on tube<heelromoved. SpillAge ol wei~ ""'"'l inro UJc hon:s of robe Is n01 penniucd.

REV A ENGINEE~S INDIA LIMITED ...,. NEWOEI.HI

STANDA~D SPECIACATION FOR SPECIACATION WELDED 1--""='"'==-=--+--l

TUBE TO TUBES HEfT JOINTS B·1 S.OO~! 5 ol 8 2

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~....,. ~ "" ol •I A .;:.....fF -.a· •• l.ol \,: }infl.l~ ; tbtl ~ j,.,. 1. ~~ •

3.2. ,\,U:I .. vo>ll)lcu\Jd u( w~IJ1U)!, t.llt ru00b«( f.x.c, t!'IC wciJ~ Wll.l uttenut rube .m·f.ll.\."1 iu .t

dJ.stai!Ce or 2S mm beyuod tbc iuswn line mu~' bt ( le;utcll tbocougbly by wire brll.:il'lin& ::ukl ex.tmiocd .. :arefully folr surface llefects. D..!f.::Cl'l &U:Ch ~~ <:mck:;, surt':K:e b~ting poruslty, s.l.li inclusioM and lack of fusion are not llctepll\blc.

8.3 Atler the vi.sunl in~tJ()O, a liqui<l penelr•m eJmmltunlon m acc6rdancc w1th ASMI: Scctlon Vln Oivi.Jlon I. Appendix 8 & Section V, 1\nic:le 6 'hi ll be doot. Before conductin, this t« t. lbe faces 01 me a rl)r)n 5t.c:cJ wbc:sheeu !halt be t lelnod lborougbiy by wtre brush and ~I vent< co renlOve all ~ld slaJ . rust aod seal~.

8.4 Wb<n specified on tlx dn.,iags or requisirioa. • IWJdc 1<>1 sball b< per1crm<d '""' tlx O<SIJ .. per para 8. 1, 8.2. and 8 .3 ...,._ bave been ......, .. ~Jiy ~-- PrOCCO!res for llolicto:,... shill bt ll per ASME Sec!Joo V. Anicle 10. Appendll • lll llalogeo diodecl<!leclor probe ldl

8.5 After lhe final Nbc expanding (refer pant 9.0) has bten completed, cbe liquid penetrant ex.~~.mination as outlined in para 8.> ~bovc:: 8hall be rept:~ted .

8.6 Whenever n halide test has been specitied, an envelope t.:M shall aJso be done as a further test for le3ks after t1na1 tube expJnding. For this ttS1, tubesh«t.s shaiJ be: securely wnpptd m plastic !hteU and fhe shell allowed to rero~in undtr test pressure with halogen tracer. for a period or lO to ll hours. Then with L~ deu~etion se1 a1 a maxtmum Jetuitivit)', the probe 5h.lll be cnsencd tbrougb the plastic cove:r 11 the boOOm of Lhc: tut!Qheets &Dd reldings take~~ to observe if any ~ ba> OCCUrt<d

8.7 F1nal accq>UnC< hydnuh< P""""' lest slull b< condlloltd ofa:r wb< ·~ a1 h~ p=urt ror 01 It~ Oil< bour.

9.0 TUBE EXPANDING

After chc rc.st:s l'lo\ltllne:d in 8.1 , 8. 2, 8.3, and 8.4 have been su~cssfuliy complet.ed and all !coking weldJ repoirod. the Wbe! shall be ·contact c>l)'lllded" with a PARALLEL type expander. Contact expanding is int·ended co brlng the tube 00 into contacc with the mbc hole ContaCt cxp:tndin~ &hall begin 12 rnm fl"am the rubeshCf:t far;e and extend tO l nun (rom the back f3Cc: . Tile CCXIIOCI expansion shall have lhlnnllli Of 3-5$ wbkb sl!atl be <""'red b) m:asurint: the Inside diameter of rubes,

10.0 REPAIRS

If leaks are found durin& IDY o( lhe ~e tt1olin& proccdurn lbe:Jc shall be rq»>O'Ud CO It~ Aulhoriled lnspe<IDr and alter ob'"ln!ng his "''''roval. reptlti Wll bt ~by removini lhe defects down tO sound parent meal and repc:auna the quaJified weld prcxedures. All weld repairs shall be retdted in ::K.COCdatx:e with procedures w tlincd in para 8.0 abo\le.

II .0 TE!iT AND REPAIR REPORTS

Test and repair reports shall be included in the OtUI Folder. These repon:s sb•ll also indicate the number of leaks dlliCO\'tred oo: each cesc and che txtenr or the: rep~ir dOne.

~ ENG!NE.ERS INDIA LIMITED w HEWOELHI

REV STANDARD SPECIFICATION FOR SPECIFICATION WELDED f---:;6:-:. 1:-:;5~.0;:;0:;;0:;3:---t---!J

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FIG·13 FOA PLUG TYPE AIRCOOLEI'lS

FIG-14 FIG-16

LECENO 1. FOR MICROPHOTOGRAPHIC EXA""'"TION 2. FOR TEAR rEST 3. FOR RADIOGRAPHIC FXAMINA.TION

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ST ANDAAD SPECIFICATION FOR ENGINEERS INDIA LIMrT£0 WELDED 1--------l---J

NeW DGJ< TUBE TO TUBESHEET JOINTS

SPECIFICATION REV.

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inspection and test plan for heat...

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