JOB EXECUTION PROCEDURE

DOC. NO: HDOL/ETP/6907/JP/MECH-TANK-002B /Rev-01

PROCEDURE FORPOST WELD HEAT TREATMENT PROJECT : EFFLUENT TREATMENT PLANT CLIENT : Bramputra Cracker and Polymer Limited CONSSULTANT : Engineers India Limited. CONTRACTOR : Hindustan Dorr-Oliver Limited

PROCEDURE NUMBER

DOC. NO: HDOL/ETP/6907/JP/MECH-TANK- 2B /Rev-01

ABBREVIATIONS:AFC :Approved for Construction

BM:Bench Mark

CI:Cast Iron

CPT:Cone Penetration Test

GI:Galvanized Iron

IBR:Indian Boiler Regulation

Id:Identification

IQI:Image Quality Indicator

IRC:Indian Road Congress

JB:Junction Box

MS:Mild Steel

MT:Magnetic Particle Testing

NDT:Non Destructive Testing

OMC:Optimum Moisture Content

PCC:Plain Cement Concrete

P&ID:Piping & Instrumentation Diagram

PQR:Procedure Qualification Record

PT:Penetrant Testing

PVC:Poly Vinyl Chloride

PWHT:Post Weld Heat Treatment

RCC:Reinforced Cement ConcreteRF:Reinforcement

RMC:Ready Mixed Concrete from Batching plant / external agency

SPT:Standard Penetration Test

U/G:Under Ground

WBM:Water Bound Macadam

WPS:Welding Procedure Specification

CONTENTS

0.0 PURPOSE

2.0SCOPE

3.0REFERENCES

4.0TERMS & DEFINITIONS

5.0RESPONSIBILITIES

6.0METHODOLOGY

7.0 HEALTH, SAFETY & ENVIRONMENT

8.0 QUALITY ASSURANCE & QUALITY CONTROL

9.0 DOCUMENTATION

1.0 PURPOSE

The need for PWHT is driven by code and application requirements, as well as the service environment. In general, when PWHT is required, the goal is to increase the resistance to brittle fracture and relaxing residual stresses .Other desired results from PWHT may include hardness reduction, and material strength enhancements

2.0 SCOPE

This procedure states explicitly in detail the minimum requirement for Post Weld Heat Treatment (PWHT) by the electrical resistance method for nozzles, pipes & piping supports by use of Microprocessor/computer controlled system.

This procedure covers description of the equipment, method of heating, location and type of heating elements temperature measurement and thermocouple location.

Post Weld Heat Treatment (PWHT) shall be in accordance with ASME B31.3,&EIL Specification/Standards.

3.0 REFERENCE DOCUMENTS

1 ) EIL Specification No : 6-77-0001 Rev-3, and 6-77-0005 Rev-1 2 ) ASME Sec. VIII, Div 1 : Boiler & Pressure Vessels code. 3) ASME B31.3 : Chemical Plant and Petroleum Refinery Piping4.0 TERMS & DEFINITIONS

For the purpose of this document the term:

1. Shall, indicate a mandatory requirement and should indicate a

Recommended practice.2. All terms used in the development of this procedure are defined in :

above reference documents.

HSE shall mean Health, Safety & Environment.

EPCC shall mean Engineering Procurement Construction and Commissioning.

QA/QC shall mean Quality Assurance & Quality Control.

ITP shall mean Inspection & Test Plan.

PM shall mean Project Manager.5.0 RESPONSIBILITIES

Following are the responsibilities and reporting structure of personnel involved in the scope of the procedure:

Project Manager-Shall provide all necessary resources to implement this procedure.

Initiate corrective action referred by QA/QC with the production personnel from time to time.

Site Engineer

-Shall report to Project Manager, shall be responsible for day to day

handling of construction and related records.

Shall be responsible for pre-planning of all Structural steel work pre-fabrication & fabrication works activities in sequential method.

Shall execute the work and report as per approved procedure and quality plan.

QA/QC Engineer -1.Shall report to Project Manager.

-2.Shall be responsible for overall control of QA/QC activities,

implementation of Quality and Inspection Test Plan. 3.Shall be responsible for issuing corrective action reports based on periodical audits carried by him6.0 METHODOLOGY6.1 Person handling the PWHT activities Qualification

The basic requirement for PWHT operator shall be that he should either be a science/technical graduate or an electrical apprentice high school graduate with basic electrical knowledge to undertake the heat treatment at the site.

6.2 Description of Required Equipment & Materials

Equipment The equipment shall be of a proper make & it should be bearing proper

electrical power input/output. Power distribution (supply) shall be of 380/440V Ph, with either single phase secondary output or step down transformer secondary output (heat treatment unit) supplying low voltage circuits. The temperature control equipment shall be operated manually or through regulators or it shall be (made) operated automatically with the help of modular controls. The chart type temperature

recorder shall be used for recording temp. The frequency of calibration of temp recorder shall be three months & a proper valid sticker shall be displayed on the temp recorder. Materials

All the connection materials required for the heat treatment, shall be of standard quality & it shall be selected free of defects.

6.3 Surface Conditions

The welds to be heat treated shall be prepared free of greases, lubricants dust and coatings to avoid damage & short circuiting of accessories equipments. During heat treatment it shall be necessary to protect from oxidation the mechanical surfaces line flange faces, threaded holes, threads by the application of coating such as deoxaluminite or any other suitable coating material.

6.4 Method

The procedure for PWHT has to be followed for the various steel grades as mentioned

Basic Requirements to carryout PWHT and the methodology Thermocouples

a) The thermocouples shall be of the type K i.e. nickel-chromium / nickel aluminum type in accordance with BS 1041. Part 4. The thermocouples should have initial calibration check.

All the thermocouple wires should have valid certificate of conformance with a tolerance of