BDEP and EPCM Services for TGTU Project at BPCL Mumbai Refinery

S&T HEAT EXCHANGER

(Document No : A710-000-EE-MR-6060)

Page 1 of 193

Click on the Document Title to go to that section of the document

Table of ContentsDocument Number Rev. Document Title Page

NumberA710-000-EE-MR-6060

B S&T HEAT EXCHANGER 4

A710-129-16-46-DS-4001

C ENGINEERING DRAWINGS/SETTING PLAN 9

A710-129-16-46-DS-400102

C ENGINEERING DRAWINGS/SETTING PLAN 10

A710-129-16-46-DS-4002

B ENGINEERING DRAWINGS/SETTING PLAN 11

A710-129-16-46-DS-400202

B ENGINEERING DRAWINGS/SETTING PLAN 12

A710-134-16-46-DS-4003

B ENGINEERING DRAWINGS/SETTING PLAN 13

A710-134-16-46-DS-400302

B ENGINEERING DRAWINGS/SETTING PLAN 14

A710-134-16-46-DS-4004

B ENGINEERING DRAWINGS/SETTING PLAN 15

A710-134-16-46-DS-400402

B ENGINEERING DRAWINGS/SETTING PLAN 16

A710-129-05-45-4013

0 TUBE LAYOUT 17

A710-129-05-45-4015

0 TUBE LAYOUT 18

A710-134-05-45-4431

0 TUBE LAYOUT 19

A710-134-05-45-4434

0 TUBE LAYOUT 20

A710-129-05-45-DS-015

2 SHELL & TUBE HEAT EXCHANGERS-THERMAL DATA SHEET 21

A710-129-05-45-DS-0434

1 SHELL & TUBE HEAT EXCHANGERS-THERMAL DATA SHEET 23

A710-000-16-46-SK-0001

0 JOB SKETCHES 25

A710-000-16-46-SK-0002

0 JOB SKETCHES 26

A710-000-16-46-SK-0003

0 JOB SKETCHES 27

A710-000-06-45-CPS-01

A CP SYSTEM SPECIFICATION 28

A710-000-06-45-CPS-02

A CP SYSTEM SPECIFICATION 38

A710-16-46-TR-6060 B INSTRUCTIONS TO VENDOR/ TECHNICAL REQUIREMENTS 48A710-000-16-46-VDR-6060

A VDR FOR VDR COMPILATION 50

A710-16-46-SP-6060 A MR JOB SPECIFICATION 53A710-16-46-SS-6060 A SCOPE OF WORK AND SUPPLY 60A710-16-46-TL-6060 A GUIDELINES TO VENDOR FOR TUBE LAYOUT 666-15-0001 4 General specification for heat exchangers. 696-15-0003 4 Standard specification for welded tube to tubesheet joints. 886-15-0091 3 Standard specification for hardness requirement of static

equipments (pressure vessels, heat exchanger).97

6-78-0001 0 Specification for Quality Mgt. System Requirements from Bidders 1026-78-0003 0 Specification for Documentation Requirement from Suppliers 1116-79-0013 1 Material requirements for carbon steel components used in sour

service for petroleum refinery environments123

6-79-0015 1 Specification for duplex stainless steel and super duplex stainlesssteel

129

Page 2 of 193

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Table of ContentsDocument Number Rev. Document Title Page

Number6-79-0016 1 Specification for welding of duplex stainless steel and super

duplex stainless steel141

6-81-0001 2 Standard specification for Positive Material Identification (PMI) atSupplier's Works

152

6-81-0009 3 ITP for heat exchangers 1607-15-0001 4 Part details (shell & tube exchangers). 1677-15-0002 4 Types of non standard gaskets (shell & tube exchangers) 1697-15-0004 4 Support for horizontal exchangers (Shell & Tube Exchangers) 1727-15-0005 4 Support for horizontal stack units (shell & tube exchangers) 1747-15-0006 4 Tube hole preparation and roller expanding (shell & tube

exchangers & air cooled heat exchangers)176

7-15-0007 4 Sliding & deflector strips to tube sheet welding details (shell & tubeexchangers)

177

7-15-0008 4 Eye bolt detail (shell & tube exchangers) 1787-15-0009 4 Method of fastening nuts to the tie rods (shell & tube exchangers) 1797-15-0010 4 Jack screw tapping and arrangement (shell & tube exchangers) 1807-15-0011 4 Fixing detail of dowel pins (shell & tube exchangers) 1817-15-0013 4 Lifting lug detail (shell & tube exchangers) 1827-15-0014 4 Davit for shell & channel cover (shell & tube exchangers) 1837-15-0016 4 Earthig Lug (Shell & Tube Exchangers) 1867-15-0017 4 Name plate (shell & tube exchangers) 1877-15-0018 4 Warning plate (shell & tube exchangers) 1887-15-0019 4 Tolerances (shell & tube exchangers) 1907-15-0021 4 Detail of sealing strip assl¿y for two pass shell (shell & tube

exchangers)193

Page 3 of 193

ENGINEERS INDIA LIMITED

R.O.BARODA Client: BPCL

Project: SRU REVAMP PROJECT/TGTU

File Name: U:\A710_MR-6060_Rev B.pdf

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ITEM DESCRIPTION: HEAT EXCHANGER SS-DUPLEX, HEAT EXCHANGER-CS/LAS+SS CLAD

GROUP ITEM CODE: 01CV,01CF DESTINATION: As per Commercial Documents

MR CATEGORY: II DELIVERY PERIOD: As per Commercial Documents

DOCUMENT NUMBER( Always quote the Document Number given below as reference )

02/06/2015 16

JOB NO. UNIT/ AREA

MAINCOST

CENTRE

DOC.CODE

SR. NO. REV. DATE

46

DIVN. DEPT.

ORIGINATOR

NOTES :12

3

This page is a record of all the Revisions of this Requisition.The nature of the Revision is briefly stated in the "Details" column below, theRequisition in its entirety shall be considered for contractual purposes.Vendor shall note the MR category and shall submit his offer in line with therequirements included in attached 'Instructions to Bidders'.

REV. DATE BY CHK. APPD. DETAILS

A

B

08/05/2015

02/06/2015

ISSUED FOR BIDS

REVISED AND REISSUED FOR BIDS

RSR

RSR

SHAIL

SHAIL

SHAIL

SHAIL

MATERIAL REQUISITION (TOP SHEET)

000 EE MR 6060 BA710

This is a system generated approved document and does not require signature.

Page 4 of 193

ENGINEERS INDIA LIMITED

R.O.BARODA Client: BPCL

Project: SRU REVAMP PROJECT/TGTU

File Name: U:\A710_MR-6060_Rev B.pdf

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REQUISITION NO. REV.

BA710-000-EE-MR-6060

SR. NO.TAG NO/

ITEM CODE/ [ ID. NO. ] DESCRIPTION QUANTITY

01.00

02.00

03.00

04.00

05.00

06.00

07.00

08.00

09.00

Code compliance to residual design,procurement & supply of all materials andweld preparation, fabrication, assemblyat shop, painting, inspection , testingat manufacturer's works, packing, seaworthy packing / protection for seatransportation, delivery from vendor'swork to site, supply of mandatory sparesas per clause 3.5 of 6-15-0001 & clause 4of A710-16-46-SS-6060, supply ofaccessories like test rings, test flanges& documentation as per the enclosed EILstandards and specifications,instructions to vendors, jobspecification, data sheets, drawings,etc. and codes and standards attached orreffered

<< DELETED >>

<< DELETED >>

<< DELETED >>

<< DELETED >>

Unit Rates

<< DELETED >>

<< DELETED >>

Drawings and documents as per attachedVendor Data requirement for all suppliesand services covered above in Sr.Nos.1.00to Sr.No.8.00

Lot

Vendors shall quote prices in EIL Price Schedule except for Sr.No.9.00. Price fordocumentation is implied to be included in the prices quoted against Sr.No.1.00 toSr.No.8.00

Vendor to note that the numbers given in square '[]' and curly '{}' brackets arenot for their use and meant for store purpose only. Items shall be tagged as permain equipment Tag No. only.

01.01

01.02

01.03

01.04

06.01

129-E-013A/B/C/D

129-E-015

134-E-431A/B/C/D

134-E-434

PUMP AROUND COOLER

PROCESS GAS COOLER

PUMP AROUND COOLER

PROCESS GAS COOLER

Unit Rates of items for addition/deletion purpose, as per the encloseddoc: A710-16-46-SS-6060.

1 Unit

1 Unit

1 Unit

1 Unit

1

Page 5 of 193

ENGINEERS INDIA LIMITED

R.O.BARODA Client: BPCL

Project: SRU REVAMP PROJECT/TGTU

File Name: U:\A710_MR-6060_Rev B.pdf

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or u

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REQUISITION NO. REV.

BA710-000-EE-MR-6060

LIST OF ATTACHMENTS

SL.No. DOCUMENT TITLE DOCUMENT NO.

REVISION

REV. REV. REV. REV.DATE DATE DATE DATE

Format for Vendor Drawing/Document Submission Schedule

Setting Plan & Section Drawingfor Heat Exchanger 129-E-013A,B/C,D (No. of sheets.2)Setting Plan & Section Drawingfor Heat Exchanger 129-E-015(No. of sheets.2)Setting Plan & Section Drawingfor Heat Exchanger 134-E-431A,B/C,D (No. of sheets.2)Setting Plan & Section Drawingfor Heat Exchanger 134-E-434(No. of sheets.2)

Tube Layout for Heat Exchanger129-E-013 A,B/C,D (No. ofsheet.1)Tube Layout for Heat Exchanger129-E-015 (No. of sheet.1)Tube Layout for Heat Exchanger134-E-431 A,B/C,D (No. ofsheet.1)Tube Layout for Heat Exchanger134-E-434 (No. of sheet.1)Baffle arrangement forshell&tube heat exchanger Itemno: 129-E-015Baffle arrangement forshell&tube heat exchanger Itemno: 134-E-134

Sketch for Lipped FloatingHead Flange.Sketch for Weld Deposit onflanges and pass partitionplate.Sketch for weld deposit fornozzles.

Specifiation for ThermallySprayed Aluminium CoatingSpecifiation for ThermallySprayed Aluminium Coating

Instructions for SubmittingOffers for S&T exchangers

Vendor Data Requirements forShell & Tube Heat Exchangers

1

2

3

4

5

6

7

8

9

10

11

12

13

14

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16

17

18

EIL-1641-1923Rev.1

A710-129-16-46-DS-4001

A710-129-16-46-DS-4002

A710-134-16-46-DS-4003

A710-134-16-46-DS-4004

A710-129-05-45-4013

A710-129-05-45-4015

A710-134-05-45-4431

A710-134-05-45-4434

A710-129-05-45-DS-015

A710-134-05-45-DS-434

A710-000-16-46-SK-0001

A710-000-16-46-SK-0002

A710-000-16-46-SK-0003

A710-06-45-SP-1501

A710-06-45-SP-1502

A710-16-46-TR-6060

A710-000-16-46-VDR-6060

B C

B

B

B

1

1

2

2

3

4

0

0

0

0

0

A B

A

08/05/2015 02/06/2015

08/05/2015

08/05/2015

08/05/2015

21/04/2015

27/02/2015

19/02/2015

26/02/2015

01/05/2015

01/05/2015

02/04/2015

02/04/2015

03/03/2015

13/04/2015

09/04/2015

08/05/2015 02/06/2015

08/05/2015

DATASHEET

DRAWINGS

STANDARD DRAWINGS

SMMS

INSTRUCTIONS TO VENDORS

VDR

JOB SPECIFICATION

Page 6 of 193

ENGINEERS INDIA LIMITED

R.O.BARODA Client: BPCL

Project: SRU REVAMP PROJECT/TGTU

File Name: U:\A710_MR-6060_Rev B.pdf

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Sheet 4 of 5

REQUISITION NO. REV.

BA710-000-EE-MR-6060

LIST OF ATTACHMENTS

SL.No. DOCUMENT TITLE DOCUMENT NO.

REVISION

REV. REV. REV. REV.DATE DATE DATE DATE

Job Specification for Shell &Tube ExchangerScope of Supply & Work forShell & Tube type heatexchangerGuidelines to Vendor Regardingtube Layout Preparation

General Specification for HeatExchangersStandard Specification forWelded Tube to Tubesheet jointSpecification for duplexstainless steel and superduplex stainless steelSpecification for welding ofduplex stainless steel andsuper duplex stainless steelMaterial requirements forcarbon steel components usedin sour service for petroleumrefinery environmentsSpecification for qualitymanagement system requirementsfrom biddersSpecification fordocumentation requirementsfrom suppliersStandard specification forpositive materialidentification (PMI) atsupplier's workStandard Specification forhardness requirement

Inspection & Test Plan forHeat Exchanger

Part Details

Types of Non Standard Gaskets

Support for HorizontalExchangerSupport for Horizontal StackunitsTube Hole Preparation andRoller ExpandingSliding/Deflector Strips toTube sheet Welding DetailsEye Bolt Detail

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

A710-16-46-SP-6060

A710-16-46-SS-6060

A710-16-46-TL-6060

6-15-0001

6-15-0003

6-79-0015

6-79-0016

6-79-0013

6-78-0001

6-78-0003

6-81-0001

6-15-0091

6-81-0009

7-15-0001

7-15-0002

7-15-0004

7-15-0005

7-15-0006

7-15-0007

7-15-0008

A

A

A

4

4

1

1

1

0

0

2

3

3

4

4

4

4

4

4

4

08/05/2015

08/05/2015

08/05/2015

11/08/2010

07/06/2013

07/10/2011

07/10/2011

07/10/2011

04/06/2009

04/06/2009

20/10/2011

05/11/2014

09/09/2013

06/05/2014

06/05/2014

06/05/2014

06/05/2014

06/05/2014

06/05/2014

06/05/2014

JOB SPECIFICATION

STANDARD SPECIFICATIONS

STANDARD INSPECTION TEST PLAN

STANDARDS

Page 7 of 193

ENGINEERS INDIA LIMITED

R.O.BARODA Client: BPCL

Project: SRU REVAMP PROJECT/TGTU

Sheet 5 of 5

File Name: U:\A710_MR-6060_Rev B.pdf

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REQUISITION NO. REV.

BA710-000-EE-MR-6060

LIST OF ATTACHMENTS

SL.No. DOCUMENT TITLE DOCUMENT NO.

REVISION

REV. REV. REV. REV.DATE DATE DATE DATE

In case of any subsequent revision of MR or PR, only revised sheets of theattachments listed above shall be issued alongwith the revision.

GENERAL NOTES:

Methods of fastening nuts totie rods (shell & tubeexchangers).Jack screw tapping andarrangement (shell & tubeexchangers).Fixing detail of dowel pins(shell & tube exchangers).Lifting Lug Detail

Davit for Heat Exchanger

Earthing Lug

Name Plate

Warning plate

Tolerances

Detail of sealing stripassembly for two pass shell(shell & tube exchangers).

39

40

41

42

43

44

45

46

47

48

7-15-0009

7-15-0010

7-15-0011

7-15-0013

7-15-0014

7-15-0016

7-15-0017

7-15-0018

7-15-0019

7-15-0021

4

4

4

4

4

4

4

4

4

4

06/05/2014

06/05/2014

06/05/2014

06/05/2014

06/05/2014

30/09/2011

06/05/2014

06/05/2014

06/05/2014

06/05/2014

STANDARDS

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Page 20 of 193

REV 1 EIL JOB NO. ITEM NO. : 129-E-015

3 2 PROCESS D/S REF. NO. A710-129-03-DS-1404 ,REV.2, DTD 25.03.2015 CUSTOMER : BPCL-MR

3 SERVICE OF UNIT PROJECT : SRU REVAMP-TGTU 1

4 LOCATION:: MUMBAI, INDIA

5 SIZE 387.3 MM X 4000 MM TYPE HORIZONTAL

6 SURFACE PERUNIT m2

SURFACE PER SHELL 21 m2

SHELL PER UNIT ONE

7

8 SHELL SIDE

9 FLUID CIRCULATED

10 TOTAL FLUID ENTERING Kg/hr

11

12 VAPOUR Kg/hr

13 LIQUID Kg/hr

14 STEAM Kg/hr

15 WATER Kg/hr

16 NON CONDENSABLES Kg/hr

17 DENSITY - LIQ/VAP IN/OUT Kg/m3

1.122

18 VISCOSITY - LIQ/VAP IN/OUT Cp 0.021

19 SPECIFIC HEAT-LIQ/VAP IN/OUT Kcal/Kg °C 0.266

20 THER. COND.-LIQ/VAP IN/OUT Kcal/hr m°C 0.028

21 OPERATING TEMPERATURE °C

22 MOL WEIGHT - -VAP/NON COND.

23 LATENT HEAT Kcal/Kg

24 INLET PRESSURE Kg/cm2g

25 NO. OF PASSES PER SHELL

26 VELOCITY m/sec

27 PRESSURE DROP Kg/cm2

ALL : 0.1 CALC : 0.1 ALL: 0.7 CALC: 0.6

28 FOULING RESISTANCE hr.m2.°C/Kcal

29 HEAT EXCHANGED MM Kcal/hr °C

30 TRANSFER RATE SERVICE 237 Kcal/hrm2 °C

31

32 DESIGN PRESSURE Kg/cm2g

33 TEST PRESURE Kg/cm2g

34 DESIGN TEMPERATURE °C T/SHT

35 NO. OF TUBES Thk (MIN) 2 mm LENGTH 4000 mm PITCH 32 mm Layout 90o

36 SHELL/PORT- ID mm SEALING STRIP

37 PITCH 329 (1) mm IMPINGEMENT PLATE NO

38

39 NO. INCH DIA SERIES AND TYPE NO. INCH DIA

40 SHELL 2 8 1 3

41 SHELL COVER 2 8 1 3

3 42 CHANNEL

3 43 CHANNEL COVER

44 FLT. HD. COVER

45 SHELL COVER SHELL TUBE

46 SHELL CHANNEL SIDE SIDE

47 FLOATING HEAD (mm) (mm) TEST RING TEST FLANGE

48 CHANNEL COVER TYPE IS TUBE TO TUBE SHEET JOINT

49 BAFFLES/TUBE SUPPORT THK. 25

50 CORR. 3.0

51 ALL ON KCS TEMA CLASS R CODE ASME SEC VIII DIV.I

52 NOTES :-

53

54

3 55

56

57

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60

61

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7374

01.05.2015 MKM

21.04.2015 MKM

03.03.2015 MKM

DATE BY

Format No. 3-0545-1001 Rev. 0 Copyrights EIL – All rights reserved

TUBE SHEET

TUBES

(4) REFER DRAWING NO. A710-129-05-45-4015 FOR TUBE LAYOUT.

(5) PROVIDE 1.5 TUBE-ROWS OVERLAP FOR DOUBLE-SEGMENTAL BAFFLES.

(1) PROVIDE 6 CROSS PASSES. SEE SHT. 2 OF 2 FOR MORE BAFFLING DETAILS.

(2) SHELL SIDE INLET NOZZLE RHO-VSQ = 983 KG/M SEC2.

(3) DELETED.

(kg)

SDSS

RAW COOLING WATER SERVICE AS PER BPCL-MR.

(11) FOR OTHER REQUIREMENTS, REFER P&ID NO. A710-03-41-129-1043.

ALUMINIUM COATED.

(7) THE UNS NO. OF SDSS MATERIAL FOR TUBES AND TUBE SHEET SHALL BE UNS S32750 (I.E. 2507).

(8) ALL COMPONENTS OF CHANNEL SHALL BE THERMALLY SPRAYED

(9) ALL WELD JOINTS AND CONNECTED PIPING SHALL BE STRESS RELIEVED. HARDNESS NOT TO

OUTLET OUT LET INLET

1.6

INLET

45

SS 316L CLAD KCS

KCS (NOTE- 8)

-

KCS (NOTE- 8)

OUT

IN

AS PER CODE

CONSTRUCTION OF ONE SHELL

WEIGHTED M.T.D. (CORRECTED) 22.6

Tube OD 25 mm

70

YES

5.38/FV

200

0.1123

SEA COOLING WATER (NOTE-10)

7,311

21

22,500

PERFORMANCE OF ONE UNIT

PROCESS GAS

CONNECTED IN -

PROCESS GAS COOLER

A710

AHL

NO. OF UNITS ONE

TUBE SIDE

AS PER CODE

AN

D N

UT

S

7

387.3 LONGITUDINAL BAFFLE YES

68

BAFFLES DOUBLE SEG. VERT. CUT

(NOTE-9)

MATERIAL ACCORDING TO ASTM

BO

LT

ING

NOZZLES

CHECK

FULL OF WATER

NOTE- 6, 7

WEIGHT

(6) SDSS CLAD KCS/SDSS.

EXCEED 200 BHN.

REV

1

DESCRIPTION

REVISED AND RE-ISSUED FOR ENGINEERING

2 REVISED AND RE-ISSUED FOR ENGINEERING

3

KK

KKKKBREVISED AND RE-ISSUED FOR ENGINEERING

(10) PROCESS GAS COOLER WAS DESIGNED FOR SEA COOLING WATER SERVICE ON TUBE SIDE.

HOWEVER, IN OPERATION THE ABOVE EXCHANGER WILL BE OPERATED WITH

BUNDLE

150 # WNRF

150 # WNRF

WELDED

SERIES AND TYPE

TUBE SIDE

APPROVAL

KKB

KKB KK

0.27

SS 316L

-

0.0002

3.0

0.265

1.174

22,50022,500

96.5 39

0.024

34

7,311 7,282.2

29

0.018

DOUBLE DIVIDED

GASKET

SIX

0.0004

EMPTY

150 # WNRF

150 # WNRF

SHELL SIDE

%Cut (AREA) 36.6 (NOTE-5)

SHELL & TUBE HEAT EXCHAGERS

Document No.A710-129-05-45-DS-015Rev. No. 3Page 1 of 2

Page 21 of 193

Page 22 of 193

REV 1 EIL JOB NO. ITEM NO. : 134-E-434

4 2 PROCESS D/S REF. NO. A710-134-03-DS-1404 ,REV.2, DTD 25.02.2015 CUSTOMER : BPCL-MR

3 SERVICE OF UNIT PROJECT : SRU REVAMP-TGTU 2

4 LOCATION:: MUMBAI, INDIA

5 SIZE 600 MM X 4000 MM TYPE HORIZONTAL

6 SURFACE PERUNIT m2

SURFACE PER SHELL 58 m2

SHELL PER UNIT ONE

7

8 SHELL SIDE

9 FLUID CIRCULATED

10 TOTAL FLUID ENTERING Kg/hr

11

12 VAPOUR Kg/hr

13 LIQUID Kg/hr

14 STEAM Kg/hr

15 WATER Kg/hr

16 NON CONDENSABLES Kg/hr

17 DENSITY - LIQ/VAP IN/OUT Kg/m3

1.12

18 VISCOSITY - LIQ/VAP IN/OUT Cp 0.021

19 SPECIFIC HEAT-LIQ/VAP IN/OUT Kcal/Kg °C 0.265

20 THER. COND.-LIQ/VAP IN/OUT Kcal/hr m°C 0.027

21 OPERATING TEMPERATURE °C

22 MOL WEIGHT - -VAP/NON COND. 26.78

23 LATENT HEAT Kcal/Kg

24 INLET PRESSURE Kg/cm2g

25 NO. OF PASSES PER SHELL

26 VELOCITY m/sec

27 PRESSURE DROP Kg/cm2

ALL : 0.1 CALC : 0.1 ALL: 0.7 CALC: 0.7

28 FOULING RESISTANCE hr.m2.°C/Kcal

29 HEAT EXCHANGED MM Kcal/hr °C

30 TRANSFER RATE SERVICE 296 Kcal/hrm2 °C

31

32 DESIGN PRESSURE Kg/cm2g

33 TEST PRESURE Kg/cm2g

34 DESIGN TEMPERATURE °C T/SHT

35 NO. OF TUBES Thk (MIN) 2 mm LENGTH 4000 mm PITCH 32 mm Layout 60o

36 SHELL/PORT- ID mm SEALING STRIP

37 PITCH 328 (1) mm IMPINGEMENT PLATE NO

38

39 NO. INCH DIA SERIES AND TYPE NO. INCH DIA

40 SHELL 2 12 1 4

41 SHELL COVER 2 12 1 4

4 42 CHANNEL

4 43 CHANNEL COVER

44 FLT. HD. COVER

45 SHELL COVER SHELL TUBE

46 SHELL CHANNEL SIDE SIDE

47 FLOATING HEAD (mm) (mm) TEST RING TEST FLANGE

48 CHANNEL COVER TYPE IS TUBE TO TUBE SHEET JOINT

49 BAFFLES/TUBE SUPPORT THK. 25

50 CORR. 3.0

51 ALL ON KCS TEMA CLASS R CODE ASME SEC VIII DIV.I

52 NOTES :-

53

54

4 55

56

57

58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

7374

01.05.2015 MKM

21.04.2015 MKM

26.02.2015 MKM

DATE BY

Format No. 3-0545-1001 Rev. 0 Copyrights EIL – All rights reserved

DOUBLE DIVIDED

GASKET

SIX

0.0004

EMPTY

150 # WNRF

150 # WNRF

SHELL SIDE

%Cut (AREA) 37.94 (NOTE-8)

0.024

34

13,725 X 1.1 13,547 X 1.1

178 X 1.1

0.018

56,818 X 1.1

96.4 38.65

0.0002

3.0

0.264

1.205

56,818 X 1.1

0.27

SS316L

26.78

-

SERIES AND TYPE

TUBE SIDE

APPROVAL

KKB

KKB KK

BUNDLE

150 # WNRF

150 # WNRF

WELDED

KK

KKKKBREVISED AND RE-ISSUED FOR ENGINEERING

REV

2

DESCRIPTION

REVISED AND RE-ISSUED FOR ENGINEERING

3 REVISED AND RE-ISSUED FOR ENGINEERING

4

CHECK

FULL OF WATER

(NOTE-4)

WEIGHT

(5) SUPER DUPLEX STAINLESS STEEL (SEAMLESS)

(9) THE UNS NO. OF SDSS MATERIAL FOR TUBES AND TUBE SHEET SHALL BE UNS S32750 (I.E. 2507).

BAFFLES DOUBLE SEG. VERT. CUT

(NOTE-3)

MATERIAL ACCORDING TO ASTM

BO

LT

ING

NOZZLES

AS PER CODE

AN

D N

UT

S

7

600 LONGITUDINAL BAFFLE YES

188

CONNECTED IN -

PROCESS GAS COOLER

A710

AHL

NO. OF UNITS ONE

TUBE SIDE

SEA COOLING WATER

13,725 X 1.1

58

56,818 X 1.1

PERFORMANCE OF ONE UNIT

PROCESS GAS

AS PER CODE

CONSTRUCTION OF ONE SHELL

WEIGHTED M.T.D. (CORRECTED) 16.9

Tube OD 25 mm

70

YES

5.38/FV

200

0.264 X 1.1

SS316L clad KCS

KCS (NOTE-3)

KCS (NOTE-3)

OUT

IN

-

OUTLET OUT LET INLET

1.6

INLET

43

(7) REFER DRAWING NO. A710-134-05-45-4434 FOR TUBE LAYOUT.

(6) ALL WELD JOINTS AND CONNECTED PIPING SHALL BE STRESS RELIEVED.

HARDNESS NOT TO EXCEED 200BHN.

(8) PROVIDE 2 TUBE-ROWS OVERLAP FOR DOUBLE-SEGMENTAL BAFFLES.

TUBE SHEET (NOTE-9)

TUBES (NOTE-9)

ALUMINIUM COATED.

(4) SUPER DUPLEX STAINLESS STEEL/ SDSS clad KCS.

(1) PROVIDE 6 CROSS PASSES. SEE SHT. 2 OF 2 FOR MORE BAFFLING DETAILS.

(2) SHELL SIDE INLET NOZZLE RHO-VSQ = 835 KG/M SEC2.

(3) ALL COMPONENTS OF CHANNEL SHALL BE THERMALLY SPRAYED

(kg)

(NOTE-5)

SHELL & TUBE HEAT EXCHAGERS

Document No.A710-134-05-45-DS-434Rev. No. 4Page 1 of 2

Page 23 of 193

Page 24 of 193

EIL

Pag

e 25

of

193

EIL

Pag

e 26

of

193

Page 27 of 193

SPECIFICATIONS FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-01 Rev. 0

Page 1 of 10

0 13.04.2015 ISSUED AS JOB SPEC. SSP SD NSB

Rev. No

Date Purpose Prepared

by Checked

by Approved

by

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

SPECIFICATION FOR THERMALLY SPRAYED ALUMINIUM

COATING FOR COOLERS AND CONDENSERS

BPCL, MUMBAI REFINERY

(UNIT: SRU REVAMP-TGTU-2)

Item nos. 134-E-431 A,B/C,D

& Item no. 134-E-434

(Specialist Materials and Maintenance Services Department)

Page 28 of 193

SPECIFICATIONS FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-01 Rev. 0

Page 2 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

THERMALLY SPRAYED ALUMINIUM COATING 1.0 SCOPE

The following sections outlines the requirement of supply, application and testing of

thermally sprayed aluminum coatings (TSAC) for corrosion protection of steel components

exposed to sea water.

2.0 ITEMS TO BE THERMALLY SPRAYED

All carbon steel components of channel and floating head alongwith SDSS tube sheet exposed to sea

water including SDSS overlay areas of the flange faces and face under the gasket (i.e. gasket seating

surface) shall be TSA coated.

After fabrication, all damaged TSA coating at all weld areas including HAZ and other locations shall

be repaired by TSA as per approved procedure.

3.0 TSAC REQUIREMENTS

3.1 Surface Preparation

All the parts to be sprayed shall be degreased according to SSPC-SP 1. The absence of oil and

grease after degreasing shall be tested by method given elsewhere in the specification (Refer Sec.

6.7). After degreasing surface shall be tested for presence of soluble salts as per method SSPC-TU4.

Thereafter the surface to be abrasive blasted to white metal finish as per NACE 1/SSPC-SP 5 for

immersion service. Using SSPC VIS 1, it is to be confirmed that the blast cleaned surface meets

requirement of SSPC-SP 5. The clear cellophane tape test shall be used to confirm absence of dust

on the blasted surface.

The blasting media shall be aluminium oxide of suitable mesh size conforming to SSPC-AB-1.

Mesh size shall be required as appropriate to the anchor tooth depth profile requirement and blasting

equipment used. The blasted surface should be having angular profile of 25-35 micron with sharp

angular shape. The profile depth shall be measured according to NACE standard RP 0287 (Replica

Tape) or ASTM D 4417 method B (Profile depth gauge).

For manual blasting one profile depth measurement shall be taken every 10-20 M2

of blasted

surface.

Surface preparation shall be completed in one abrasive blast cleaning operation wherever possible.

If rust bloom (visual appearance of rust) appears on the blast cleaned surface before thermal

spraying, the affected area shall be reblasted to achieve specified degree of cleanliness after which

only thermal spraying shall commence.

Air blasting pressure at nozzle shall be normally maintained at 85-100 psi. Air pressure and media

size should be reduced and adjusted to preclude damage/distortion to thin gauge materials. Blasting

time on work piece should be adjusted to only clean the surface and cut required anchor tooth with

minimum loss of metal. Blast angle should be as close to perpendicular as possible but in no case

greater than 30 0

from perpendicular to work surface. Blasting media must be free of debris,

excessive fines, and contaminants such as NaCl and sulfur salts (Ref. SEC 6.0 of this Spec).

Page 29 of 193

SPECIFICATIONS FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-01 Rev. 0

Page 3 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

3.1.1 Blasting Equipment

The TSAC applicator shall use mechanical (centrifugal wheel) or pressure pot blast cleaning

equipment and procedures. Suction blasting equipment shall not be used. Sec 6.6.2 shall be used to

validate clean and dry air

3.1.2 Feed Stock

The feed stock shall be in the form of wire. The feed stock shall be 99.5% aluminum of

commercial purity grade, its composition shall be in accordance with requirement of BS 1475or

ASTM B833 (wrought aluminum and aluminum alloys, wire).

3.1.3 Thickness Requirement

The nominal thickness of finished TSAC shall be 375 microns having minimum value of 350

microns at low thickness areas (valleys) and not more than 400 microns at peak areas.

The finished thickness shall be measured using SSPC-PA 2 type 2 fixed probe gauge (Magnetic

Gauge).

3.1.4 Coating Bond Strength Requirement

The TSAC coating shall have a minimum tensile-bond strength 2000 psi for arc sprayed

coating.

3.1.5 Porosity

All thermally sprayed metallic coatings will have porosity. For thermally sprayed aluminum

coatings porosity shall not exceed 8% for arc spray coating.

4.0 THERMAL SPRAY APPLICATION PROCEDURE

All carbon steel components under sea water shall be TSA coated by Arc wire method only.

4.1 Equipment set up

4.1.1 Thermal spray equipment shall be set up calibrated, operated (1) according to manufacturer

instructions/technical manuals and also TSAC applicators refinement thereto and (2) as validated by

Procedure Qualification (Sec 7.0 of this specification).

4.1.2 Spray parameters

Spray parameters (see 4.1.3 below) and thickness of each crossing pass shall be set and shall be

validated with bend test (See 6.5 of this Spec).

4.1.3 Spray Parameters

Spray parameters Arc wire spray

Arc voltage 27V

Air pressure 60-80 psi

Steel surface cleanliness NACE-1 white metal/ or Near

white metal

Steel surface profile 65 microns (minimum)

Arc current 150 A-200 A

Coating thickness 375 microns

Coating adhesion > 2000 psi (Total coating)

Coating porosity Less than 8%

Page 30 of 193

SPECIFICATIONS FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-01 Rev. 0

Page 4 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Spray distance (spray Gun

work piece)

6-8”

Spray Pass width ¾” (20mm)

The above parameters to be validated with a bend test by the contractor before start of work (for

details of bend test see Sec 6.5 of this Spec).

4.2 Post Blasting Substrate condition and thermal spraying period.

4.2.1 The steel surface temperature shall be at least 50C above dew point of ambient air temperature.

Steel substrate surface temperature shall be recorded by with a contact pyrometer.

Thermal spraying should commence within 15 minutes from the time of completion of blasting

4.2.2 Holding Period

Time between the completion of final anchor tooth blasting and completion of thermal spraying

for the blasted surface should be no more than four hours. If within this period rust bloom appears,

Sec. 4.4.1 of this specification will apply.

4.3 Pre-Heating

Deleted

4.4 Thermal spraying

Spraying should commence only after validation of equipment set up by procedure qualification test

and spray parameter validation tests described in Sec 7.0 and 6.5 respectively. Thermal spraying

must commence within 15 minutes from the time of completion of blast cleaning

The specified coating thickness shall be applied in several crossing passes. The coating bond

strength is greater when the spray passes are kept thin. Laying down an excessively thick spray pass

increases the internal stresses in TSAC and decreases the bond strength of total TSAC. The suitable

thickness for crossing passes shall be determined by procedure qualification test described in Sec 7.0

of this specification.

For manual spraying, spraying to be done in perpendicular crossing passes to minimize thin spots

in coating. Approx. 75-100 microns of TSAC shall be laid down in each pass.

The surface geometry of the item or area to be sprayed should be inspected before application. The

spraying pass and sequence shall be planned according to following.

- Maintain Gun as close to perpendicular as possible and within 300 from perpendicular to

the substrate.

- Maintain nominal stand off distance and spray pass width as given below:

Spray method Standoff (Inches) Spray pass width

(Inches)

Arc Wire 6-8 1 ½

4.4.1 Rust Bloom (Visual appearance of rust or Discoloration)

If Rust bloom appears on the blasted surface before thermal spraying, the affected area shall be

reblasted to achieve the specified level of cleanliness.

Page 31 of 193

SPECIFICATIONS FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-01 Rev. 0

Page 5 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

If Rust bloom in form of discoloration, or any blistering or a degraded coating appears at any time

during application of TSAC, then spraying shall be stopped and acceptable sprayed area shall be

marked off. The unsatisfactory areas shall be repaired to the required degree of surface cleanliness

and profile.

Blast the edges of the TSAC to provide for 2-3” feathered area overlap of the new work into existing

TSAC.

Then apply TSAC to the newly prepared surfaces and overlap the existing TSAC to the extent of

feathered edge so that overlap is a consistent thickness.

4.4.2 Masking

Masking all those parts and surfaces which are not required to be thermally sprayed as instructed by

purchaser should be inspected by applicator to ensure that they are properly marked and covered by

purchaser.

Complex geometries (flanges, valve manifolds, intersections) shall be masked by applicator to

minimize overspray i.e. TSAC applied outside spray parameters (primarily gun to substrate distance

and spray angle).

Masking shall be done after blasting and before metal spraying. Weld bevel ends of pipe and fittings

provided for future welding shall be masked.

4.4.3 TSAC Finish

The deposited TSAC shall be uniform without blisters, cracks, loose particles, or exposed steel as

examined with 10 X magnification.

5.0 SEALER

Sealant shall be applied after satisfactory application of TSAC and completion of all testing and

measurements of the finished TSAC as per Sec 6.0 of this specification. Sealer shall be applied by

spraying. Since Aluminized surfaces are porous, the first coat of sealer shall be thinned, as per

manufacturer’s recommendation, then applied at a rate of 200 to 400 sq. ft per gallon. The second

sealer coat shall be applied at a min. of 2.5mil wet film thickness for the silicon-based paint.

For shop work, sealer shall be applied immediately after thermal spraying and for field work sealer

shall be applied within 8 hours. The sealcoat shall be thin enough to penetrate into the body of

TSAC.

Silicone alkyd aluminium seal coat shall be applied at a spreading rate resulting in theoretical 38

microns DFT. The seal coat shall be applied in accordance with SSPC-PA 1 and the paint

manufacturer instruction for sealing.

During application of seal coat, complete coverage shall be ensured by visual observation. 6.0 TESTING AND MEASUREMENT SCHEDULE

6.1 Surface Finish

That the blasted cleaned surface meets the required criteria (NACE 1/SSPC-SP 5) shall be visually

inspected using SSPC-VIS 1. The clear cellophane-tape test shall be used to confirm absence of dust

or foreign debris on the cleaned surface.

Page 32 of 193

SPECIFICATIONS FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-01 Rev. 0

Page 6 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

6.2 Blast Profile Measurement: ( In-Process testing during actual production before application of

TSA coating )

The angular profile depth measurement shall be done by profile tape as per method NACE Standard

RP 0287 or ASTM D 4417 method B (Profile depth gauge micrometer). Spot measurement shall be

carried out every 15m2

of blasted surface. At each spot three measurements shall be taken over an

area of 10 cm2 and average of measurements to be recorded and reported.

6.3 TSAC Thickness (In-Process Testing For finished coating during regular production)

6.3.1 TSAC finished thickness shall be measured using SSPC-PA 2 type 2 fixed probe gauge.

6.3.2 For flat surfaces, measurements shall be taken along a straight measurement line; one measurement

line for every 15 m2 of applied TSAC shall be selected along which 5 measurements to be taken at

25 mm internal and average to be reported.

6.3.3 For curved surface or complex geometry, 5 measurements shall be taken at a spot measuring 10 cm2

in area. One spot to be taken for every 15 m2 of applied TSAC area.

6.3.4 The TSAC thickness in surface changes or contour changes, welds and attachments shall be also

measured and reported.

6.3.5 If TSAC is less than specified minimum thickness, apply additional TSAC until specified thickness

range is achieved.

6.3.6 All locations and values of TSAC thickness measurements shall be recorded in Job Record (JR).

6.4 Tensile Bond Testing ( In-Process testing for finished coating during regular production )

- Tensile Bond strength of the TSAC finish coat shall be determined according to ASTM D

4541 using a self-aligning adhesion tester.

- One measurement shall be made every 50 mm2. If tensile bond is less than 1000 psi for

flame sprayed coating and 2000 psi for arc sprayed coating the degraded TSAC shall

completely be removed and reapplied.

- The tensile bond portable test instrument to be calibrated according to ASTM C 633,

6.5 Bend Tests

Bend test shall be carried out at beginning of each work shift. Bend tests shall also be conducted on

sample coupons before start of thermal spraying work to qualify the following as mentioned earlier

in this specification.

- To qualify spray parameters and thickness of each crossing pass.

6.5.1 Test Procedure

a) Five corrosion control steel coupons each of dimension 50 mm x 150 mm x 1.3 mm

thickness to be prepared.

b) Surface shall be prepared by dry abrasive blast cleaning as per this specification.

c) TSAC shall be applied as per specified thickness range. TSAC should be sprayed in

crossing passes laying down approx. 75-100 microns in each pass.

d) TSAC applied coupons shall be bent 1800 around a 13 mm diameter mandrel.

Page 33 of 193

SPECIFICATIONS FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-01 Rev. 0

Page 7 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

e) Bend test shall be considered passed if on bend radius there is

- No cracking or spalling or lifting by a knife blade from the substrate

- Only minor cracking that cannot be lifted from substrate with a knife blade.

f) Bend test fails if coating cracks with lifting from substrate.

6.6 Tests for blasting media, blasting air

6.6.1 Blasting Media (For every fresh batch of media and one random test during blasting)

a) Blasting Media shall be visually inspected for absence of contamination and debris using

10 X magnification.

a) Inspection for the absence of oil contamination shall be conducted using following

procedure :

- Fill a small clean 200 ml bottle half full of abrasive.

- Fill the bottle with potable water, cap and shake the bottle.

- Inspect water for oil film/slick. If present, the blasting media is not to be used.

b) Soluble salt contamination if suspected shall be verified by method ASTM D 4940. If

present, media to be replaced.

c) Clean blasting equipment, especially pot and hoses, then replace blasting media and retest.

6.6.2 Test for Blasting Air (Once Daily before start of blasting and once at random during blasting)

The air for blasting shall be free from moisture and oil. The compressor air shall be checked for oil

and water contamination per ASTM D 4285.

6.7 Test for presence of oil/grease

The steel substrate after degreasing as per SSPC-SP 1 shall be tested as per following procedure to

validate absence of oil and grease contamination.

a) Visual inspection - Continue degreasing until all visible signs of contamination are removed.

b) Conduct a solvent evaporation test by applying several drops or a small splash of residue-

free trichloromethane on the suspect area especially pitting, crevice corrosion areas or depressed

areas. An evaporation ring formation is indicative of oil and grease contamination.

Continue degreasing and inspection till test is passed.

7.0 TSAC APPLICATOR QUALIFICATION

Following tests to be carried out as part of procedure qualification test for the applicator.

- Thickness measurement

- Coating bond strength

- Porosity test

- Bend strength

Page 34 of 193

SPECIFICATIONS FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-01 Rev. 0

Page 8 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

TSAC applicator’s surface finishing and application process and equipment set up, calibration and

operation shall be qualified by application of TSA on a reference sample which shall be used as a

comparator to evaluate the suitability of application process. Only that applicator will be permitted

to carry out the work when test specimens coated by the applicator meets the desired requirements as

cited below.

The sample shall be made of a steel plate measuring approx. 18”x 18” x ¼” thick. If the actual work

is less than ¼” thick then the sample to be made from material of representative thickness.

The surface preparation, TSAC application shall be made with actual field equipments and

process/spray parameters and procedures as per the specification. The depth profile of blasted

surface, TSAC coating thickness for each cross pass and total thickness range shall be as per

specification.

The surface preparation and thermal spraying shall be carried out in representative environmental

conditions spraying with makeshift enclosure.

7.1 After application of coating, thickness and tensile bond measurements shall be made in

following manner:

- Divide the sample piece into four quadrants.

- Measure thickness along the diagonal line of each quadrant.

- Four each quadrant five in-line thickness measurements at 1” interval shall be

done using SSPC-PA 2 type 2 fixed probe gauge. Thus a total of four “five in line”

thickness measurements to be done for the whole sample.

- One tensile bond measurement using ASTM D 4541 type III or IV portable self

aligning test instrument to be done at centre of each quadrant. Total of 4 measurements for

the sample.

- One porosity evaluation test by Metallographic examination shall be conducted to

demonstrate the achievement of porosity within the limits specified. Sample shall be

prepared for Metallographic examination as per ASTME – 3.

- The procedure shall be considered qualified if thickness and tensile-bond strength

and porosity values meets the specification requirement.

7.2 Bend test: Bend test shall be carried out as detailed at sec. 6.5 of this specification.

Applicators thermal spray equipment set-up, operation and procedure of application

including in-process QC checkpoints adopted during procedure qualification as described

above should be always subsequently followed during entire duration of work.

8.0 DOCUMENTATION

The following information shall be provided by TSAC applicator before award of work.

- TSAC application process consisting of equipment capabilities and their technical

parameters, feed stock material and source of procurement.

- Detailed application procedure and in-process quality control check points for (a) surface

preparation (b) thermal spraying (c) seal coats.

- Type and specification of instruments to be deployed for measurement of blast profile

depth, TSAC thickness and tensile bond.

Page 35 of 193

SPECIFICATIONS FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-01 Rev. 0

Page 9 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

- Paint manufacturer data sheet for the selected sealing coat to be applied.

9.0 RECORDS

- The TSAC applicator shall maintain a job record to record production and QC information.

All the results of the tests and quality control checks shall be entered in the record for each

component/part thermally sprayed. All the result of tests (thickness, tensile bond, bend

tests) and other validation tests (e.g. procedure qualification test, test for surface cleanliness

after abrasive blasting, test for cleanliness of abrasives and air) shall also be recorded and

duly signed by owner.

- All the information mentioned in Sec 8.0 above should also form part of the Job record.

- Any modification affected after procedure qualification in the procedure, QC, spray

parameter, equipment spec to the original information (submitted before award of the work)

must also form part of Job record.

10.0 WARRANTY

The TSAC applicator shall warrant the quality of material used by providing the purchaser with a

certificate of materials used to include

- Spray feed stock: Alloy type/designation, Lot Number, wire diameter, chemical analysis,

name of supplier, manufacturer.

- Sealant : Name of manufacturer, application data sheet.

11.0 SAFETY

The TSAC applicator shall follow all safety procedures required by the purchaser/owner. Owner

shall also give compliance requirement to be followed by applicator. The applicator shall follow

all appropriate regulatory requirements.

12.0 CODES AND STANDARDS

This specification shall apply in case of conflict between specification and following applicable

standards:

AWS C. 2.17 Recommended Practice for Electric arc Spray.

ASTM C 633 Test Method for Adhesive/Cohesive Strength of Flame Sprayed

Coatings.

ASTM D 4285 Method for indicating Oil or Water in Compressed Air.

ASTM D 4417 Test Method for Field Measurement of Surface Profile of Blasted

Steel.

BS 2569 Specification for Sprayed Metal Coating.

NACE Standard RP

0287

Field Measurement of Surface Profile of Abrasive Blast Cleaned

Steel Surfaces Using a Replica Tape.

ASTM D 4541 Test method for Pull-Off Strength of Coating Using Portable

Adhesion Testers.

ANSI/AWS C2.18 Guide for the Protection of Steel with Thermal Spray Coatings of

Aluminum, Zinc and Their Alloys and Composites.

NACE No. 12/AWS

C2.23M/SSPC-CS

23.00

Specification for the application of thermal spray coatings

(Metallizing) of aluminum, zinc, and their alloys and composites for

the corrosion protection of steel.

SSPC Publication The inspection of coatings and linings: A Handbook of Basic

practice for Inspectors, Owners, and Specifiers.

Page 36 of 193

SPECIFICATIONS FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-01 Rev. 0

Page 10 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

SSPC-AB 1 Mineral and Slag Abrasives.

SSPC-AB 3 Ferrous Metallic Abrasives.

SSPC-PA 1 Shop, Field, and Maintenance Painting of Steel.

SSPC-PA 2 Measurement of Dry Coating Thickness with Magnetic Gages.

NACE No. 1/SSPC-

SP 5

White Metal Blast Cleaning.

NACE No. 2/SSPC-

SP 10

Near –White Metal Blast Cleaning.

SSPC-VIS 1 Guide and Reference Photographs for Steel Surfaces Prepared by

Dry Abrasive Blast Cleaning.

13.0 Suggested List of TSA applicators

1) Metallizing Equipment Corporation , Jodhpur

2) Larsen & Tuobro Ltd (Eutectic division), New Delhi

3) Chemtreat India Ltd, Navi Mumbai

4) Deepwater MPE, Malaysia

5) Associated Thermal Spray, Ahmedabad

Other applicators will also be acceptable if they qualify the applicator qualification

procedure given in the specification. If any one of the above suggested applicator is selected,

even then he has to perform the qualification test before commencing of the work.

Page 37 of 193

SPECIFICATION FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-02 Rev. 0

Page 1 of 10

0 09.04.2015 ISSUED AS JOB SPEC. SSP SD NSB

Rev. No

Date Purpose Prepared

by Checked

by Approved

by

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

SPECIFICATION FOR THERMALLY SPRAYED ALUMINIUM

COATING FOR COOLERS AND CONDENSERS

BPCL, MUMBAI REFINERY

(UNIT: SRU REVAMP-TGTU-1)

Item nos. 129-E-013 A,B/C,D

& Item no. 129-E-015

(Specialist Materials and Maintenance Services Department)

Page 38 of 193

SPECIFICATION FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-02 Rev. 0

Page 2 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

THERMALLY SPRAYED ALUMINIUM COATING 1.0 SCOPE

The following sections outlines the requirement of supply, application and testing of

thermally sprayed aluminum coatings (TSAC) for corrosion protection of steel components

exposed to sea water.

2.0 ITEMS TO BE THERMALLY SPRAYED

All carbon steel components of channel and floating head alongwith SDSS tube sheet exposed to sea

water including SDSS overlay areas of the flange faces and face under the gasket (i.e. gasket seating

surface) shall be TSA coated.

After fabrication, all damaged TSA coating at all weld areas including HAZ and other locations shall

be repaired by TSA as per approved procedure.

3.0 TSAC REQUIREMENTS

3.1 Surface Preparation

All the parts to be sprayed shall be degreased according to SSPC-SP 1. The absence of oil and

grease after degreasing shall be tested by method given elsewhere in the specification (Refer Sec.

6.7). After degreasing surface shall be tested for presence of soluble salts as per method SSPC-TU4.

Thereafter the surface to be abrasive blasted to white metal finish as per NACE 1/SSPC-SP 5 for

immersion service. Using SSPC VIS 1, it is to be confirmed that the blast cleaned surface meets

requirement of SSPC-SP 5. The clear cellophane tape test shall be used to confirm absence of dust

on the blasted surface.

The blasting media shall be aluminium oxide of suitable mesh size conforming to SSPC-AB-1.

Mesh size shall be required as appropriate to the anchor tooth depth profile requirement and blasting

equipment used. The blasted surface should be having angular profile of 25-35 micron with sharp

angular shape. The profile depth shall be measured according to NACE standard RP 0287 (Replica

Tape) or ASTM D 4417 method B (Profile depth gauge).

For manual blasting one profile depth measurement shall be taken every 10-20 M2

of blasted

surface.

Surface preparation shall be completed in one abrasive blast cleaning operation wherever possible.

If rust bloom (visual appearance of rust) appears on the blast cleaned surface before thermal

spraying, the affected area shall be reblasted to achieve specified degree of cleanliness after which

only thermal spraying shall commence.

Air blasting pressure at nozzle shall be normally maintained at 85-100 psi. Air pressure and media

size should be reduced and adjusted to preclude damage/distortion to thin gauge materials. Blasting

time on work piece should be adjusted to only clean the surface and cut required anchor tooth with

minimum loss of metal. Blast angle should be as close to perpendicular as possible but in no case

greater than 30 0

from perpendicular to work surface. Blasting media must be free of debris,

excessive fines, and contaminants such as NaCl and sulfur salts (Ref. SEC 6.0 of this Spec).

Page 39 of 193

SPECIFICATION FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-02 Rev. 0

Page 3 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

3.1.1 Blasting Equipment

The TSAC applicator shall use mechanical (centrifugal wheel) or pressure pot blast cleaning

equipment and procedures. Suction blasting equipment shall not be used. Sec 6.6.2 shall be used to

validate clean and dry air

3.1.2 Feed Stock

The feed stock shall be in the form of wire. The feed stock shall be 99.5% aluminum of

commercial purity grade, its composition shall be in accordance with requirement of BS 1475or

ASTM B833 (wrought aluminum and aluminum alloys, wire).

3.1.3 Thickness Requirement

The nominal thickness of finished TSAC shall be 375 microns having minimum value of 350

microns at low thickness areas (valleys) and not more than 400 microns at peak areas.

The finished thickness shall be measured using SSPC-PA 2 type 2 fixed probe gauge (Magnetic

Gauge).

3.1.4 Coating Bond Strength Requirement

The TSAC coating shall have a minimum tensile-bond strength 2000 psi for arc sprayed

coating.

3.1.5 Porosity

All thermally sprayed metallic coatings will have porosity. For thermally sprayed aluminum

coatings porosity shall not exceed 8% for arc spray coating.

4.0 THERMAL SPRAY APPLICATION PROCEDURE

All carbon steel components under sea water shall be TSA coated by Arc wire method only.

4.1 Equipment set up

4.1.1 Thermal spray equipment shall be set up calibrated, operated (1) according to manufacturer

instructions/technical manuals and also TSAC applicators refinement thereto and (2) as validated by

Procedure Qualification (Sec 7.0 of this specification).

4.1.2 Spray parameters

Spray parameters (see 4.1.3 below) and thickness of each crossing pass shall be set and shall be

validated with bend test (See 6.5 of this Spec).

4.1.3 Spray Parameters

Spray parameters Arc wire spray

Arc voltage 27V

Air pressure 60-80 psi

Steel surface cleanliness NACE-1 white metal/ or Near

white metal

Steel surface profile 65 microns (minimum)

Arc current 150 A-200 A

Coating thickness 375 microns

Coating adhesion > 2000 psi (Total coating)

Coating porosity Less than 8%

Page 40 of 193

SPECIFICATION FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-02 Rev. 0

Page 4 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

Spray distance (spray Gun

work piece)

6-8”

Spray Pass width ¾” (20mm)

The above parameters to be validated with a bend test by the contractor before start of work (for

details of bend test see Sec 6.5 of this Spec).

4.2 Post Blasting Substrate condition and thermal spraying period.

4.2.1 The steel surface temperature shall be at least 50C above dew point of ambient air temperature.

Steel substrate surface temperature shall be recorded by with a contact pyrometer.

Thermal spraying should commence within 15 minutes from the time of completion of blasting

4.2.2 Holding Period

Time between the completion of final anchor tooth blasting and completion of thermal spraying

for the blasted surface should be no more than four hours. If within this period rust bloom appears,

Sec. 4.4.1 of this specification will apply.

4.3 Pre-Heating

Deleted

4.4 Thermal spraying

Spraying should commence only after validation of equipment set up by procedure qualification test

and spray parameter validation tests described in Sec 7.0 and 6.5 respectively. Thermal spraying

must commence within 15 minutes from the time of completion of blast cleaning

The specified coating thickness shall be applied in several crossing passes. The coating bond

strength is greater when the spray passes are kept thin. Laying down an excessively thick spray pass

increases the internal stresses in TSAC and decreases the bond strength of total TSAC. The suitable

thickness for crossing passes shall be determined by procedure qualification test described in Sec 7.0

of this specification.

For manual spraying, spraying to be done in perpendicular crossing passes to minimize thin spots

in coating. Approx. 75-100 microns of TSAC shall be laid down in each pass.

The surface geometry of the item or area to be sprayed should be inspected before application. The

spraying pass and sequence shall be planned according to following.

- Maintain Gun as close to perpendicular as possible and within 300 from perpendicular to

the substrate.

- Maintain nominal stand off distance and spray pass width as given below:

Spray method Standoff (Inches) Spray pass width

(Inches)

Arc Wire 6-8 1 ½

4.4.1 Rust Bloom (Visual appearance of rust or Discoloration)

If Rust bloom appears on the blasted surface before thermal spraying, the affected area shall be

reblasted to achieve the specified level of cleanliness.

Page 41 of 193

SPECIFICATION FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-02 Rev. 0

Page 5 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

If Rust bloom in form of discoloration, or any blistering or a degraded coating appears at any time

during application of TSAC, then spraying shall be stopped and acceptable sprayed area shall be

marked off. The unsatisfactory areas shall be repaired to the required degree of surface cleanliness

and profile.

Blast the edges of the TSAC to provide for 2-3” feathered area overlap of the new work into existing

TSAC.

Then apply TSAC to the newly prepared surfaces and overlap the existing TSAC to the extent of

feathered edge so that overlap is a consistent thickness.

4.4.2 Masking

Masking all those parts and surfaces which are not required to be thermally sprayed as instructed by

purchaser should be inspected by applicator to ensure that they are properly marked and covered by

purchaser.

Complex geometries (flanges, valve manifolds, intersections) shall be masked by applicator to

minimize overspray i.e. TSAC applied outside spray parameters (primarily gun to substrate distance

and spray angle).

Masking shall be done after blasting and before metal spraying. Weld bevel ends of pipe and fittings

provided for future welding shall be masked.

4.4.3 TSAC Finish

The deposited TSAC shall be uniform without blisters, cracks, loose particles, or exposed steel as

examined with 10 X magnification.

5.0 SEALER

Sealant shall be applied after satisfactory application of TSAC and completion of all testing and

measurements of the finished TSAC as per Sec 6.0 of this specification. Sealer shall be applied by

spraying. Since Aluminized surfaces are porous, the first coat of sealer shall be thinned, as per

manufacturer’s recommendation, then applied at a rate of 200 to 400 sq. ft per gallon. The second

sealer coat shall be applied at a min. of 2.5mil wet film thickness for the silicon-based paint.

For shop work, sealer shall be applied immediately after thermal spraying and for field work sealer

shall be applied within 8 hours. The sealcoat shall be thin enough to penetrate into the body of

TSAC.

Silicone alkyd aluminium seal coat shall be applied at a spreading rate resulting in theoretical 38

microns DFT. The seal coat shall be applied in accordance with SSPC-PA 1 and the paint

manufacturer instruction for sealing.

During application of seal coat, complete coverage shall be ensured by visual observation. 6.0 TESTING AND MEASUREMENT SCHEDULE

6.1 Surface Finish

That the blasted cleaned surface meets the required criteria (NACE 1/SSPC-SP 5) shall be visually

inspected using SSPC-VIS 1. The clear cellophane-tape test shall be used to confirm absence of dust

or foreign debris on the cleaned surface.

Page 42 of 193

SPECIFICATION FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-02 Rev. 0

Page 6 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

6.2 Blast Profile Measurement: ( In-Process testing during actual production before application of

TSA coating )

The angular profile depth measurement shall be done by profile tape as per method NACE Standard

RP 0287 or ASTM D 4417 method B (Profile depth gauge micrometer). Spot measurement shall be

carried out every 15m2

of blasted surface. At each spot three measurements shall be taken over an

area of 10 cm2 and average of measurements to be recorded and reported.

6.3 TSAC Thickness (In-Process Testing For finished coating during regular production)

6.3.1 TSAC finished thickness shall be measured using SSPC-PA 2 type 2 fixed probe gauge.

6.3.2 For flat surfaces, measurements shall be taken along a straight measurement line; one measurement

line for every 15 m2 of applied TSAC shall be selected along which 5 measurements to be taken at

25 mm internal and average to be reported.

6.3.3 For curved surface or complex geometry, 5 measurements shall be taken at a spot measuring 10 cm2

in area. One spot to be taken for every 15 m2 of applied TSAC area.

6.3.4 The TSAC thickness in surface changes or contour changes, welds and attachments shall be also

measured and reported.

6.3.5 If TSAC is less than specified minimum thickness, apply additional TSAC until specified thickness

range is achieved.

6.3.6 All locations and values of TSAC thickness measurements shall be recorded in Job Record (JR).

6.4 Tensile Bond Testing ( In-Process testing for finished coating during regular production )

- Tensile Bond strength of the TSAC finish coat shall be determined according to ASTM D

4541 using a self-aligning adhesion tester.

- One measurement shall be made every 50 mm2. If tensile bond is less than 1000 psi for

flame sprayed coating and 2000 psi for arc sprayed coating the degraded TSAC shall

completely be removed and reapplied.

- The tensile bond portable test instrument to be calibrated according to ASTM C 633,

6.5 Bend Tests

Bend test shall be carried out at beginning of each work shift. Bend tests shall also be conducted on

sample coupons before start of thermal spraying work to qualify the following as mentioned earlier

in this specification.

- To qualify spray parameters and thickness of each crossing pass.

6.5.1 Test Procedure

a) Five corrosion control steel coupons each of dimension 50 mm x 150 mm x 1.3 mm

thickness to be prepared.

b) Surface shall be prepared by dry abrasive blast cleaning as per this specification.

c) TSAC shall be applied as per specified thickness range. TSAC should be sprayed in

crossing passes laying down approx. 75-100 microns in each pass.

d) TSAC applied coupons shall be bent 1800 around a 13 mm diameter mandrel.

Page 43 of 193

SPECIFICATION FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-02 Rev. 0

Page 7 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

e) Bend test shall be considered passed if on bend radius there is

- No cracking or spalling or lifting by a knife blade from the substrate

- Only minor cracking that cannot be lifted from substrate with a knife blade.

f) Bend test fails if coating cracks with lifting from substrate.

6.6 Tests for blasting media, blasting air

6.6.1 Blasting Media (For every fresh batch of media and one random test during blasting)

a) Blasting Media shall be visually inspected for absence of contamination and debris using

10 X magnification.

a) Inspection for the absence of oil contamination shall be conducted using following

procedure :

- Fill a small clean 200 ml bottle half full of abrasive.

- Fill the bottle with potable water, cap and shake the bottle.

- Inspect water for oil film/slick. If present, the blasting media is not to be used.

b) Soluble salt contamination if suspected shall be verified by method ASTM D 4940. If

present, media to be replaced.

c) Clean blasting equipment, especially pot and hoses, then replace blasting media and retest.

6.6.2 Test for Blasting Air (Once Daily before start of blasting and once at random during blasting)

The air for blasting shall be free from moisture and oil. The compressor air shall be checked for oil

and water contamination per ASTM D 4285.

6.7 Test for presence of oil/grease

The steel substrate after degreasing as per SSPC-SP 1 shall be tested as per following procedure to

validate absence of oil and grease contamination.

a) Visual inspection - Continue degreasing until all visible signs of contamination are removed.

b) Conduct a solvent evaporation test by applying several drops or a small splash of residue-

free trichloromethane on the suspect area especially pitting, crevice corrosion areas or depressed

areas. An evaporation ring formation is indicative of oil and grease contamination.

Continue degreasing and inspection till test is passed.

7.0 TSAC APPLICATOR QUALIFICATION

Following tests to be carried out as part of procedure qualification test for the applicator.

- Thickness measurement

- Coating bond strength

- Porosity test

- Bend strength

Page 44 of 193

SPECIFICATION FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-02 Rev. 0

Page 8 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

TSAC applicator’s surface finishing and application process and equipment set up, calibration and

operation shall be qualified by application of TSA on a reference sample which shall be used as a

comparator to evaluate the suitability of application process. Only that applicator will be permitted

to carry out the work when test specimens coated by the applicator meets the desired requirements as

cited below.

The sample shall be made of a steel plate measuring approx. 18”x 18” x ¼” thick. If the actual work

is less than ¼” thick then the sample to be made from material of representative thickness.

The surface preparation, TSAC application shall be made with actual field equipments and

process/spray parameters and procedures as per the specification. The depth profile of blasted

surface, TSAC coating thickness for each cross pass and total thickness range shall be as per

specification.

The surface preparation and thermal spraying shall be carried out in representative environmental

conditions spraying with makeshift enclosure.

7.1 After application of coating, thickness and tensile bond measurements shall be made in

following manner:

- Divide the sample piece into four quadrants.

- Measure thickness along the diagonal line of each quadrant.

- Four each quadrant five in-line thickness measurements at 1” interval shall be

done using SSPC-PA 2 type 2 fixed probe gauge. Thus a total of four “five in line”

thickness measurements to be done for the whole sample.

- One tensile bond measurement using ASTM D 4541 type III or IV portable self

aligning test instrument to be done at centre of each quadrant. Total of 4 measurements for

the sample.

- One porosity evaluation test by Metallographic examination shall be conducted to

demonstrate the achievement of porosity within the limits specified. Sample shall be

prepared for Metallographic examination as per ASTME – 3.

- The procedure shall be considered qualified if thickness and tensile-bond strength

and porosity values meets the specification requirement.

7.2 Bend test: Bend test shall be carried out as detailed at sec. 6.5 of this specification.

Applicators thermal spray equipment set-up, operation and procedure of application

including in-process QC checkpoints adopted during procedure qualification as described

above should be always subsequently followed during entire duration of work.

8.0 DOCUMENTATION

The following information shall be provided by TSAC applicator before award of work.

- TSAC application process consisting of equipment capabilities and their technical

parameters, feed stock material and source of procurement.

- Detailed application procedure and in-process quality control check points for (a) surface

preparation (b) thermal spraying (c) seal coats.

- Type and specification of instruments to be deployed for measurement of blast profile

depth, TSAC thickness and tensile bond.

Page 45 of 193

SPECIFICATION FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-02 Rev. 0

Page 9 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

- Paint manufacturer data sheet for the selected sealing coat to be applied.

9.0 RECORDS

- The TSAC applicator shall maintain a job record to record production and QC information.

All the results of the tests and quality control checks shall be entered in the record for each

component/part thermally sprayed. All the result of tests (thickness, tensile bond, bend

tests) and other validation tests (e.g. procedure qualification test, test for surface cleanliness

after abrasive blasting, test for cleanliness of abrasives and air) shall also be recorded and

duly signed by owner.

- All the information mentioned in Sec 8.0 above should also form part of the Job record.

- Any modification affected after procedure qualification in the procedure, QC, spray

parameter, equipment spec to the original information (submitted before award of the work)

must also form part of Job record.

10.0 WARRANTY

The TSAC applicator shall warrant the quality of material used by providing the purchaser with a

certificate of materials used to include

- Spray feed stock: Alloy type/designation, Lot Number, wire diameter, chemical analysis,

name of supplier, manufacturer.

- Sealant : Name of manufacturer, application data sheet.

11.0 SAFETY

The TSAC applicator shall follow all safety procedures required by the purchaser/owner. Owner

shall also give compliance requirement to be followed by applicator. The applicator shall follow

all appropriate regulatory requirements.

12.0 CODES AND STANDARDS

This specification shall apply in case of conflict between specification and following applicable

standards:

AWS C. 2.17 Recommended Practice for Electric arc Spray.

ASTM C 633 Test Method for Adhesive/Cohesive Strength of Flame Sprayed

Coatings.

ASTM D 4285 Method for indicating Oil or Water in Compressed Air.

ASTM D 4417 Test Method for Field Measurement of Surface Profile of Blasted

Steel.

BS 2569 Specification for Sprayed Metal Coating.

NACE Standard RP

0287

Field Measurement of Surface Profile of Abrasive Blast Cleaned

Steel Surfaces Using a Replica Tape.

ASTM D 4541 Test method for Pull-Off Strength of Coating Using Portable

Adhesion Testers.

ANSI/AWS C2.18 Guide for the Protection of Steel with Thermal Spray Coatings of

Aluminum, Zinc and Their Alloys and Composites.

NACE No. 12/AWS

C2.23M/SSPC-CS

23.00

Specification for the application of thermal spray coatings

(Metallizing) of aluminum, zinc, and their alloys and composites for

the corrosion protection of steel.

SSPC Publication The inspection of coatings and linings: A Handbook of Basic

practice for Inspectors, Owners, and Specifiers.

Page 46 of 193

SPECIFICATION FOR TSA COATING FOR COOLERS AND

CONDENSERS, BPCL-MUMBAI REFINERY

Spec. A710-06-45-SP-15-02 Rev. 0

Page 10 of 10

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

SSPC-AB 1 Mineral and Slag Abrasives.

SSPC-AB 3 Ferrous Metallic Abrasives.

SSPC-PA 1 Shop, Field, and Maintenance Painting of Steel.

SSPC-PA 2 Measurement of Dry Coating Thickness with Magnetic Gages.

NACE No. 1/SSPC-

SP 5

White Metal Blast Cleaning.

NACE No. 2/SSPC-

SP 10

Near –White Metal Blast Cleaning.

SSPC-VIS 1 Guide and Reference Photographs for Steel Surfaces Prepared by

Dry Abrasive Blast Cleaning.

13.0 Suggested List of TSA applicators

1) Metallizing Equipment Corporation , Jodhpur

2) Larsen & Tuobro Ltd (Eutectic division), New Delhi

3) Chemtreat India Ltd, Navi Mumbai

4) Deepwater MPE, Malaysia

5) Associated Thermal Spray, Ahmedabad

Other applicators will also be acceptable if they qualify the applicator qualification

procedure given in the specification. If any one of the above suggested applicator is selected,

even then he has to perform the qualification test before commencing of the work.

Page 47 of 193

B 02.06.2015 REVISED & RE-ISSUED FOR BIDS RSR SHAIL SHAIL

A 08.05.2015 ISSUED FOR BIDS RSR SHAIL SHAIL

Rev. No Date Purpose Prepared by Checked by Approved by

Format No. EIL 1641-1924 Rev. 1 Copyrights EIL – All rights reserved

SPECIFICATION NO. A710-16-46-TR-6060

Rev B Page 1 of 2

INSTRUCTIONS FOR SUBMITTING OFFERS FOR S & T HEAT EXCHANGERS

SRU-REVAMP (TGTU)

INSTRUCTIONS FOR

SUBMITTING OFFERS FOR

SHELL & TUBE TYPE HEAT EXCHANGERS

Page 48 of 193

Format No. EIL 1641-1924 Rev. 1 Copyrights EIL – All rights reserved

SPECIFICATION NO. A502-16-46-TR-6060

Rev B Page 2 of 2

INSTRUCTIONS FOR SUBMITTING OFFERS FOR S & T HEAT EXCHANGERS

SRU-REVAMP (TGTU)

GUIDE LINES TO BIDDER FOR SUBMITTING OFFER

BIDDING INSTRUCTION (CATEGORY-II)

1. Bidder to note that bid evaluation may be carried out without any post bid correspondence.

2. Bidder shall furnish quotations only for those items , which he can supply strictly as per MR specifications including fulfillment of “Bidder Qualification Criteria” as per MR.

3. If the bid does not include complete scope, technical / performance data, proven track record etc.

required to be submitted with the bid, the offer shall be liable for rejection.

4. Inspection and test plans are attached with the document for guidance. Vendor shall submit inspection and test plans for the approval of visiting Inspection Engineer. The inspection shall take care of all requirements of purchase specifications. Inspection engineer has the authority to modify the plan depending upon the criticality of item.

5. Bidder shall clearly indicate all "deviations and exceptions" (if any) separately at one place with

basis for the same and highlighting the corresponding clauses with respect to attached documents/specifications, standards of this Material Requisition. However, deviations to Material Requisitions are not likely to be considered.

6. Bidder shall have single point overall responsibility for the execution and completion of total job in

accordance with requirements of MR.

7. Bidder shall submit all the required supporting documents with respect to fulfillment of Bidder Qualification Criteria.

8. Subcontracting of the entire / main equipment is not acceptable. Subcontracting of the bought

outs / components should be done to EIL approved vendors only. When no list exists for sub vendors consider only reputed vendors after EIL approval.

Page 49 of 193

VENDOR DATA REQUIREMENTS

FOR

SHELL & TUBE HEATEXCHANGER

A 08-MAY-2015 ISSUED FOR BIDS RSR SHAIL SHAIL

Rev.No.

Date Purpose Prepared by Checked by Approved by

VENDOR DATA REQUIREMENTSFOR

SHELL & TUBE HEATEXCHANGER of 3

Document No.A710-000-16-46-VDR-6060

Rev. A

Page 1

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

Page 50 of 193

VENDOR DATA REQUIREMENTS

The following drawings/documents marked " " shall be furnished by the bidder.

S.NO.

DESCRIPTION WITHBID

POST ORDERREMARKSFOR

REVIEWFOR

RECORD

WITHDATABOOK

(FINAL)

1. GENERAL ARRANGEMENT DRAWINGINDICATING DESIGN DATA FABRICATEDEQUIPMENT WEIGHT, GENERAL NOTES,NOZZLE SCHEDULE, DETAIL OF SHELL,HEADS, SUPPORTING ARRANGEMENT,MAIN WELD SEAMS, NOZZLE ORIENTATIONPLAN, CUTTING LAYOUT ETC.

Duration ofSubmission : 4 Weeksafter LOI

2. TUBE BUNDLE DETAILS Duration ofSubmission : 4 Weeksafter LOI

3. DETAIL OF NOZZLES AND EXCHANGERSUPPORT

Duration ofSubmission : 4 Weeksafter LOI

4. DETAILS OF GASKETS Duration ofSubmission : 4 Weeksafter LOI

5. LIST OF SPARE PARTS WITH DETAILS Duration ofSubmission : 4 Weeksafter LOI

6. MANUFACTURER'S DATA REPORT

7. HEAT EXCHANGER DETAILED DRAWINGSAND PARTS LIST

Duration ofSubmission : 4 Weeksafter LOI

8. PROCEDURE FOR PICKLING &PASSIVATION (FOR SS ITEMS ONLY) @

9. INSPECTION AND TESTING PLAN @ Duration ofSubmission : 4 Weeksafter LOI

10. WELDING PROCEDURES ANDQUALIFICATION TEST REPORTS @

Duration ofSubmission : 4 Weeksafter LOI

11. DESTRUCTIVE AND NON-DESTRUCTIVETEST REPORTS @

Duration ofSubmission : 4 Weeksafter LOI

12. MATERIAL TEST CERTIFICATES @ Duration ofSubmission : 4 Weeksafter LOI

13. RADIOGRAPHIC EXAMINATION REPORTSWITH FILMS @

14. HEAT TREATMENT PROCEDURE AND TIMETEMPERATURE CHARTS @

15. CODE CERTIFICATES (INCLUDINGINSPECTION CERTIFICATE, HYDROSTATICTEST CERTIFICATE, LOCAL CODEREQUIREMENTS, RUBBING OF CODESTAMP AND NAME PLATE ETC.) @

16. PACKING AND FORWARDINGINSTRUCTIONS @

Duration ofSubmission : 4 Weeksafter LOI

VENDOR DATA REQUIREMENTSFOR

SHELL & TUBE HEATEXCHANGER of 3

Document No.A710-000-16-46-VDR-6060

Rev. A

Page 2

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

Page 51 of 193

Notes :

1. "TICK" denotes applicability.

2. Post order, drawing / document review shall commence only after approval of Document Control Index (DCI).

3. All post order documents shall be submitted / approved through EIL eDMS portal.

4. Final documentation shall be submitted in hard copy (Six prints) and soft ( two CDs/DVDs ) in addition to

submission through EIL eDMS.

5. Refer - 6-78-0001: Specification for quality management system from Bidders.

6. Refer - 6-78-0002: Specification for documentation requirements from Contractors.

7. Refer - 6-78-0003: Specification for documentation requirement from Suppliers.

8. All drawings & documents shall be submitted in A4 or A3 paper sizes. Documents in higher paper size shall

be submitted in exceptional circumstances or as indicated in the MR/Tender.

9. Post order- The schedule of drawing / data submission shall be mutually agreed between EIL & the bidder /

contractor / supplier during finalization of Document Control Index (DCI).

10. "@" indicates submission of documents to Inspection Agency.

11. Bill of Material shall form part of the respective drawing.

VENDOR DATA REQUIREMENTSFOR

SHELL & TUBE HEATEXCHANGER of 3

Document No.A710-000-16-46-VDR-6060

Rev. A

Page 3

Format No. EIL-1642-1924 Rev.1 Copyright EIL - All rights reserved

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A 08.05.2015 ISSUED FOR BIDS RSR SHAIL SHAIL

Rev. No Date Purpose Prepared by Checked by Approved by

Format No. EIL 1641-1924 Rev. 1 Copyrights EIL – All rights reserved

SPECIFICATION NO. A710-16-46-SP-6060 Rev A

Page 1 of 6

JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

SRU-REVAMP (TGTU)

JOB SPECIFICATION

FOR

SHELL & TUBE TYPE HEAT EXCHANGERS

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SPECIFICATION NO. A710-16-46-SP-6060 Rev A

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JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

SRU-REVAMP (TGTU)

1. The drawings issued for bids are strictly for quotation purpose. The drawing with revision if required shall be issued along with Purchase Requisition for drawing preparation and fabrication etc. On placement of order the successful BIDDER can proceed with the procurement of major material for ordered items based on the specifications, drawings and requirements of this requisition.

2. BIDDER to quote item wise price. Basis of pricing shall be strictly as per Scope of Work and Supply.

3. All materials required for fabrication, testing and inspection shall be supplied by vendor. No material shall be supplied as "FREE ISSUE" by owner.

4. It shall be entirely the BIDDER's responsibility to ensure compliance to codes specified for residual design, fabrication, testing etc. and to all requirements of Requisition including its specifications / drawings after the order is placed. In view of this, the fabrication drawings prepared by vendor will be reviewed by EIL to the following extent only :

i) Nozzle data, orientation and location, saddle location, dimensions for interfacing.

ii) Pass partitions arrangement, tube layout and bundle detail.

iii) Design data and materials of construction.

iv) Critical details like tube to tubesheet joint detail.

Other details of fabrication drawings submitted shall only be for information/records of EIL and vendor to fabricate, supply equipment based on his responsibility of ensuring compliance to EIL MR/PR requirements including drawings, specifications etc. Vendor to note that approval of documents does not mean approvals of any deviations contained therein. Such deviations if noticed at anytime, even after delivery, same to be rectified as per requisition by vendor.

5. Vendor must ensure that all the vendor documents are thoroughly checked and approved at vendor's end by vendor's competent engineer and responsible engineering office in charge before the same are submitted to EIL for review.

6. The tube bundles for the following items are interchangeable among themselves, and the same shall be checked at the vendor shop prior to dispatch:

Sl. No. Item Nos.

1. 129-E-013 A,B / C,D & 134-E-431 A,B / C,D

7. Test ring assembly shall be stuffing box type in accordance with Fig. E-4.13.2 of TEMA. Drawing for test rings/test flanges shall be furnished by the vendor separately.

Vendor to design and supply test rings/test flanges including all testing accessories separately in accordance with following instructions:

Individual test rings/test flanges as listed against the items (refer sht 2 of spec # A710-16-46-SS-6060).

Common test rings/test flanges for following items:

Sl. No. Item Nos.

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JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

SRU-REVAMP (TGTU)

1. -

2. -

All testing materials /accessories to be provided by vendor, even if not specified in the equipment datasheet.

8. Cathodic protection shall be provided for following items with painting and sacrificial anodes on channel and floating head cover to minimise waterside corrosion.

Sl.No. Item Nos.

1

2

3

4

Vendor must submit anode test reports as required in the anodes specification for EIL-SMMS’s approval before start of the anodes manufacture. This shall be “HOLD” point for Inspection.

9. While preparing fabrication drawing it shall be endeavored to cover all fabrication details in minimum number of drawings, not exceeding 5 in any case. There shall be a separate drawing for gaskets. Preparation of fabrication drawing will also include developing tube layouts as under.

o Based on enclosed tube layouts.

Based on indicative tube layouts and Guide lines issued with this requisition.

The indicative tube layouts for the items covered in this requisition are issued to the vendor for developing detailed tube layouts in line with the Guide lines issued. The detailing will call for providing tie rods, spacers, sealing strip/sliding strips, seal rods, eye bolts, plugs for eye bolts, inserts for eye bolts in case of clad tube sheets etc. Vendor is expected to consider the aspects and base his quotation accordingly. No extra cost shall be admissible on this account.

10. BIDDER is expected to quote strictly in accordance with the requirement of the requisition.

11. ACCEPTABLE ALTERNATIVES:

(I) SA 516 Gr 70 is also acceptable in place of SA 516 Gr 60 for following items nos.

a) Shell side only

XX-E-XXX A/B

b) Tube side only

c) 129-E-013 A,B / C,D, 129-E-015, 134-E-431A,B / C,D, 134-E-434

d) Both Shell & Tube sides

XX-E-XXX A/B

(II) Forgings can be used in place of plates or pipes wherever the stress values are same or higher.

(III) Higher thickness for reinforcement pad, stiffeners and non-pressure parts shall be acceptable

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JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

SRU-REVAMP (TGTU)

(IV) For IBR items SA192 tubes instead of SA179 tubes are also acceptable, provided

a) Tubes shall be procured in cold drawn condition.

b) Hardness of tubes shall be limited to 72 HB maximum

12. Vendor shall comply with clause 1.2.2 of 6-15-0001 in respect of following items falling under the purview of IBR.

Sl. No. Item Nos.

1 -

13. Hardness limits of various material for nozzle flange & RTJ gaskets are as follows:

FLANGES GASKET

MATERIAL HARDNESS (BHN) MATERIAL HARDNESS

(BHN)

C.S 140 (Min) SOFT IRON 90 (Max.)

1 Cr TO 5 Cr 150 (Min) 5 Cr- ½ Mo 130 (Max.)

9 Cr 160 (Min) 5 Cr-½ Mo, 9 Cr-1 Mo 140 (Max)

SS 304, 316 150 (Min) SS 304L, SS 316L 160 (Max)

SS304L,316L 140 (Min) SS 304L, SS 316L 160 (Max)

SS321,SS347 170 (Min) SS 321L, SS 347 160 (Max)

14. Positive material identification (PMI), vendor shall ensure that all alloy steel and stainless steel materials are properly identified and finally check tested by a PMI analyser before dispatch of equipment as per 6-81-0001.

15. Metric threads shall be used for all non-standard flanges. However ASME flanges may have threads as per American standards.

16. For the items where tube bundles are interchangeable, it is vendor’s responsibility to ensure all the materials; dimensions of the tube bundle are same. In case of any discrepancy, vendor shall bring the same to EIL notice and EIL decision shall be final and binding on the vendor.

17. During welding of nozzles in exchanger, if back gouging is required, gauging electrodes should be used instead of grinding to avoid / minimize the reduction in the thickness of nozzle pipe.

18. All the reinforcement pad tell-tale holes should be tapped properly and plugged with hard grease. No grub screws to be provided.

19. Vendor shall ensure that all data folder documents including the “AS BUILT DRAWING” are updated & complete in all respect & incorporate all suggestions/correction informed by EIL-Inspection while obtaining certificate of completeness from Inspection.

20. Vendor shall furnish list of drawings/ documents with schedule of submission of drawings for approval by EIL. The same shall be submitted to EIL immediately after placement of order. Drawing index duly updated to be submitted with each submission of documents.

21. Refer clause 4.6 of spec.6-78-0003. Final documentation shall be submitted in soft copy in CD form in 2 sets in addition to the specified requirements of documentation.

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SRU-REVAMP (TGTU)

22. All mandatory spares & Commissioning spares shall be listed separately along with description, item no., detailed specifications, name of supplier etc.

23. Note-1 on exchanger setting plan drawing is not relevant to vendor.

The heat exchangers should have free movement at sliding end on the supports to avoid any restriction during thermal expansion. The saddle of the exchanger should be at centre of the foundation bolt slot during erection. Only SS shims shall be used for equipment alignment. Sliding end of exchangers shall be painted as “CAUTION-SLIDING END” in black on the primer coating in the shop. Only SS shims shall be used for equipment alignment.

24. Torque values required for tightening of bolts shall be specified in vendor documents.

25. Nozzle schedule/thickness indicated on the drawings are minimum required. It shall be fabricator’s responsibility to select the nozzle schedule so that no shrinkage or warping occurs during weld overlay.

26. Where ever expanded tube to tubesheet joint are specified and vendor is not able to meet the Fr value in mock up, EIL reserves a right to ask vendor to provide strength welded tube to tubesheet joint without any cost & delivery implication.

27. The clause no. 2.4 of specification 6-15-0001 for ‘Equivalent Material’ stands deleted.

28. Wherever stress relieving is mentioned in mechanical datasheet, same shall be considered PWHT.

29. Wherever PWHT is required in fixed tubesheet type Heat exchanger, temperature requirement shall be maintained as per clause 6.2 of specification 6-15-0001.

30. All Carbon Steel components on channel side along with SDSS tubesheet exposed to sea water including SDSS overlay areas of the flange faces and face under gasket (i.e gasket seating surface ) shall be TSA coated as per specification attached elsewhere in the MR.

Minimum 2 nos. Lifting lug shall be provided for all vertical fixed tubesheet type heat exchangers as per std. spec. 7-15-0013. Lifting lugs shall be suitable for heat exchanger erection weight.

31. Vendor must ensure minimum thickness of undiluted finished weld overlay as per spec. 6-15-0001 and shall take special precaution to ensure the same. Vendor to take suitable allowance on machining in this regard so that minimum undiluted thickness is guaranteed after machining. Vendor to qualify WPS/PQR and submit documents to the inspecting authority for approvals before proceeding with the fabrication.

Also Refer clause 4.3.9 of EIL specification 6-15-0001. The following additional requirements shall also be complied. “All weld overlays shall be tested for iron pick-up after each pass during welding in addition to other tests stipulated. In case of weld overlay failure due to poor workmanship while in service during the warranty period, the affected component shall be replaced by vendor without any cost and delivery implication”.

32. Wherever Duplex / Super Duplex metallurgy is specified vendor to comply all requirements of specification no. 6-79-0015 & 6-79-0016.

33. For CS/LAS equipment only:

All production welding shall be examined by RT. In case vendor want to perform UT by TOFD technique in lieu of RT the same is acceptable subject to the following: a) Thickness of plate is greater than 38mm.

b) With Code Case 2235, Automated UT incorporating TOFD and pulse echo probes or

TOFD and Phased Array mounted on the same chassis that automatically traverses

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JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

SRU-REVAMP (TGTU)

along the joints to be inspected and displaying both results simultaneously on a single screen may be considered in lieu of RT.

c) Calibration block of similar material/thickness shall be used. Calibration block shall have

suitable notches to simulate longitudinal as well as transverse cracks on outside and inside surface. Setup should be capable of detecting defects on outside as well as inside while scanning from one surface only.

d) The system that is proposed to be deployed in lieu of radiography shall be submitted along with the track record prior to use for EIL review. The vendor shall demonstrate successfully the capability of AUT machine and the defects evaluation in the same screen during the site visit of EIL inspector/EIL representative. Based on which, the approval of the parties and their AUT system shall be given.

e) Qualified NDT persons shall be deployed to perform UT.

34. Equipment(s) having length more than 20 meters and / or forming “Gross Vehicle Weight” (weight of equipment(s) & weight of vehicle clubbed together) more than 49 Metric Tones shall be transported on Hydraulic axles only with compliance to all statutory norms of authorities concerned.

Suppliers / Transporters to check the requirements as per latest guidelines issued by ministry of surface transport before shipping the equipment.

35. For consignments, a GPS tracking system should be installed to monitor movement of

consignment if the equipment(s) / equipment sections meets any of the below criteria: a) Overall diameter (dimension) inclusive of nozzle projection exceeds 5.5 meters. b) Length more than 25 meter. c) Weight over 100 Metric Tones.

36. When spot radiography is specified the extent of radiography defined in Clause 5.3 of EIL

specification 6-15-0001 shall be replaced as follows:

Each category A or B pressure containing weld shall be spot radiographed in accordance with ASME Section-VIII Division-I, paragraph UW-52 as a minimum requirement. Each Spot radiograph shall be a minimum of six inches (150mm) in length and minimum one spot shall be selected in each circumferential & longitudinal seam. Additionally at least one T-joint in each circumferential seam shall also be selected. Welds from each welding procedure, welded/welding operator shall be examined.

37. SUBCONTRACTING OF THE ENTIRE/MAIN EQUIPMENT IS NOT ACCEPTABLE. SUBCONTRACTING OF THE BOUGHT-OUTS/COMPONENTS SHOULD BE DONE TO APPROVED VENDORS ONLY. WHEN NO LIST EXISTS FOR SUBVENDORS CONSIDER ONLY REPUTED VENDORS AFTER EIL APPROVAL

38. INSPECTION

Inspection requirements are as mentioned hereunder.

All materials including those used for internals shall be procured with stage-wise inspection. Stage wise and final inspection of equipments and its components shall be carried out by following:

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JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

SRU-REVAMP (TGTU)

a) For foreign Vendors: Stage wise & final inspection of the equipment including all components and internals shall be carried out by third party inspection agency. Quoted price shall include for the same.

b) For indigenous Vendors: EIL shall be inspection agency for equipments and

its indigenous components. Incase internals/forging/plates etc. are procured from abroad, the inspection shall be carried out by third party inspection agency. Quoted price shall include for the same. Charges for EIL inspection to be borne by the OWNER.

c) The acceptable third party inspection agencies are BV/ DNV/ TUV/ CEIL/ LRS/ SGS/ GLI/ MOODY/ BAX COUNCIL/ BHARAT QUALITY ENGINEERS.

Also refer commercial conditions.

IBR items to be inspected by IBR or Agency approved by IBR. All cost towards IBR inspection shall be borne by the vendor.

39. TECHNICAL DOCUMENTATION REQUIRED WITH BID

The technical part of the bid document shall contain following:

o Duly filled-in, signed and stamped comment/query sheet.

o Deviation Schedule Technical, duly filled-in, stamped and signed.

o Any other documents as required in the MR.

Unpriced Price Schedule (with prices left blank) must indicate following:

Items quoted Refer Scope of work & supply Spec. No A710-16-46-SS-6060

Name of third party inspection agency.

INDICATES APPLICABILITY.

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Format No. EIL 1641-1924 Rev. 1 Copyrights EIL – All rights reserved

SPECIFICATION NO. A710-16-46-SS-6060 Rev A

Page 1 of 5

SCOPE OF WORK & SUPPLY FOR SHELL & TUBE HEATEXCHANGERS

SRU-REVAMP (TGTU)

SCOPE OF WORK & SUPPLY FOR

SHELL & TUBE HEAT EXCHANGERS

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SCOPE OF WORK & SUPPLY FOR SHELL & TUBE HEATEXCHANGERS

SRU-REVAMP (TGTU)

SCOPE OF WORK AND SUPPLY

Bidder’s scope of work and supply shall be as follows and price shall include the following.

1. Residual design & engineering. 2. Complete equipment supply (total shells as specified) as per requirements of MR. 3. Supply of test ring & test flange as per requisition. 4. Supply of Mandatory Spares

i. Gaskets 400% ii. Bolting 20% (Minimum 4 Studs and 8 Nuts per joint).

5. Supply of torque Wrenches for item no. XX-E-XXX A/B as per clause 3.3.3 of spec. 6-15-0001. Cost of same shall be included in base price of each item. Quantity of Torque wrenches shall be considered per Tag basis.

6. The weights indicated on EIL engineering. Drawings do not form the basis for offer, since these are approximations only.

7. Carrying out design calculations as per IBR & obtaining approval, for IBR Items. 8. Inspection as per General Purchase Condition. 9. Complete documentation including submission of design calculations, As-Built dossier, QAP etc. 10. Any other requirements specified in requisition.

EQUIPMENT SCHEDULE

SL NO

ITEM NO.

QUANTITY

NO. OF UNITS SHELLS PER

UNIT NO. OF TEST

RINGS NO. OF TEST

FLANGES NO. OF DUMMY

SHELLS REMARKS

1 129-E-013 A,B/C,D

TWO TWO FOUR - - QUOTED/NOT QUOTED

2 129-E-015 ONE ONE - - - QUOTED/NOT QUOTED

3 134-E-431 A,B/C,D

TWO TWO FOUR - - QUOTED/NOT QUOTED

4 134-E-434 ONE ONE - - - QUOTED/NOT QUOTED

NOTES:

1. The submission of prices by vendor shall be construed to mean that he has confirmed compliance with all technical specification of the corresponding item (s).

2. Vendor shall submit the above equipment schedule duly filled in with his offer.

Vendor’s Name :

Vendor’s Signature

With Seal/ Stamp :

Date

:

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SCOPE OF WORK & SUPPLY FOR SHELL & TUBE HEATEXCHANGERS

SRU-REVAMP (TGTU)

PRICES FOR FUTURE ADDITIONS / DELETIONS OF CLEATS ETC.

DESCRIPTION PRICE LIST

1. Indicate charges for the following for future addition/deletion of cleats etc. with material

:

External support clips per Kg. Basis : :

IS: 2062 Gr B :

SA 516 Gr. 60 SA 516 Gr. 70

:

2. Change in size of SRWN nozzles per Kg basis

SA 105 : SA 105+Monel Weld Deposit :

3. Change in size of LWN nozzles per Kg basis

SA 105 : SA105+SS316L Deposit :

The schedule of rates for addition / deletion of nozzles shall also be submitted as per sheet 4.

Vendor’s Name :

Vendor’s Signature With Seal/ Stamp

:

Date :

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SCOPE OF WORK & SUPPLY FOR SHELL & TUBE HEATEXCHANGERS

SRU-REVAMP (TGTU)

SCHEDULE OF RATES FOR ADDITION/DELETION OF NOZZLES MATERIAL: KCS

CLASS 150

(WN RF FLANGE) CLASS 300

(WN RF FLANGE) CLASS 600

(WN RF FLANGE)

Nominal Size Without

Blind Flange With

Blind Flange Without

Blind Flange With

Blind Flange Without

Blind Flange With

Blind Flange

1 ½"

2"

3"

4"

6"

8"

10"

12"

14"

16"

18”

20”

24”

26”

28”

30”

32”

NOTES:

1. MATERIAL SPECIFICATION FOR NOZZLE COMPONENTS SUCH AS NOZZLE NECK, FLANGE. REINFORCEMENT PAD, NOZZLE STIFFENERS, STUDS, NUTS AND GASKETS SHALL BE IN ACCORDANCE WITH ENGINEERING DRAWINGS. NOZZLE REINFORCEMENT AND PROJECTION DETAIL CAN BE WORKED OUT BASED ON DATA AVAILABLE IN EXCHANGER DRAWINGS IN THIS REQUISITION.

2. SCOPE OF SUPPLY OF NOZZLE COMPONENTS SHALL BE AS PER MATERIAL REQUISITION. 3. THE RATES QUOTED SHALL INCLUDE SUPPLY OF NOZZLE NECK, FLANGE STIFFENER, STUDS, NUTS

AND GASKETS (WHEN SUPPLIED WITH BLIND FLANGE) AND ASSOCIATED FABRICATION AND TESTING. 4. PRICES, IF VARYING, FOR VARIOUS NOZZLE NECK WALL THICKNESSES SHALL BE INDICATED CLEARLY. 5. VENDOR MUST FILL-IN ALL THE COLUMNS MENTIONED ABOVE.

Vendor’s Name :

Vendor’s Signature With Seal/ Stamp

:

Date :

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SCOPE OF WORK & SUPPLY FOR SHELL & TUBE HEATEXCHANGERS

SRU-REVAMP (TGTU)

SCHEDULE OF RATES FOR ADDITION/DELETION OF NOZZLES

MATERIAL: KCS+SS 316L CLAD/WD

CLASS 150

(WN RF FLANGE) CLASS 300

(WN RF FLANGE) CLASS 600

(WN RF FLANGE)

Nominal Size Without

Blind Flange With

Blind Flange Without

Blind Flange With

Blind Flange Without

Blind Flange With

Blind Flange

1 ½"

2"

3"

4"

6"

8"

10"

12"

14"

16"

18”

20”

24”

26”

28”

30”

32”

NOTES:

1. MATERIAL SPECIFICATION FOR NOZZLE COMPONENTS SUCH AS NOZZLE NECK, FLANGE. REINFORCEMENT PAD, NOZZLE STIFFENERS, STUDS, NUTS AND GASKETS SHALL BE IN ACCORDANCE WITH ENGINEERING DRAWINGS. NOZZLE REINFORCEMENT AND PROJECTION DETAIL CAN BE WORKED OUT BASED ON DATA AVAILABLE IN EXCHANGER DRAWINGS IN THIS REQUISITION.

2. SCOPE OF SUPPLY OF NOZZLE COMPONENTS SHALL BE AS PER MATERIAL REQUISITION. 3. THE RATES QUOTED SHALL INCLUDE SUPPLY OF NOZZLE NECK, FLANGE STIFFENER, STUDS, NUTS

AND GASKETS (WHEN SUPPLIED WITH BLIND FLANGE) AND ASSOCIATED FABRICATION AND TESTING. 4. PRICES, IF VARYING, FOR VARIOUS NOZZLE NECK WALL THICKNESSES SHALL BE INDICATED CLEARLY. 5. VENDOR MUST FILL-IN ALL THE COLUMNS MENTIONED ABOVE.

Vendor’s Name :

Vendor’s Signature With Seal/ Stamp

:

Date :

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SCOPE OF WORK & SUPPLY FOR SHELL & TUBE HEATEXCHANGERS

SRU-REVAMP (TGTU)

SCHEDULE OF RATES FOR ADDITION/DELETION OF NOZZLES MATERIAL: KCS (HIC RESISTANT)

CLASS 150

(WN RF FLANGE) CLASS 300

(WN RF FLANGE) CLASS 600

(WN RF FLANGE)

Nominal Size Without

Blind Flange With

Blind Flange Without

Blind Flange With

Blind Flange Without

Blind Flange With

Blind Flange

1 ½"

2"

3"

4"

6"

8"

10"

12"

14"

16"

18”

20”

24”

26”

28”

30”

32”

NOTES:

1. MATERIAL SPECIFICATION FOR NOZZLE COMPONENTS SUCH AS NOZZLE NECK, FLANGE. REINFORCEMENT PAD, NOZZLE STIFFENERS, STUDS, NUTS AND GASKETS SHALL BE IN ACCORDANCE WITH ENGINEERING DRAWINGS. NOZZLE REINFORCEMENT AND PROJECTION DETAIL CAN BE WORKED OUT BASED ON DATA AVAILABLE IN EXCHANGER DRAWINGS IN THIS REQUISITION.

2. SCOPE OF SUPPLY OF NOZZLE COMPONENTS SHALL BE AS PER MATERIAL REQUISITION. 3. THE RATES QUOTED SHALL INCLUDE SUPPLY OF NOZZLE NECK, FLANGE STIFFENER, STUDS, NUTS

AND GASKETS (WHEN SUPPLIED WITH BLIND FLANGE) AND ASSOCIATED FABRICATION AND TESTING. 4. PRICES, IF VARYING, FOR VARIOUS NOZZLE NECK WALL THICKNESSES SHALL BE INDICATED CLEARLY. 5. VENDOR MUST FILL-IN ALL THE COLUMNS MENTIONED ABOVE.

Vendor’s Name :

Vendor’s Signature With Seal/ Stamp

:

Date :

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SPECIFICATION NO. A710-16-46-TL-6060 Rev A

Page 1 of 3

GUIDE LINE TO VENDOR REGARDING TUBE LAYOUT PREPARATION

SRU-REVAMP (TGTU)

GUIDE LINE TO VENDOR

REGARDING TUBE LAYOUT PREPARATION

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GUIDE LINE TO VENDOR REGARDING TUBE LAYOUT PREPARATION

SRU-REVAMP (TGTU)

SCOPE

Vendor shall develop detailed tube layout drawings based on the tube layouts, the guidelines given below and other attachments of the specification. Contractor can proceed with drilling of tubesheets, baffles, and support plates only after the detailed tube layout drawings have been reviewed by EIL in writing. Any conflict between the tube layout/guidelines/other requirements of the requisition shall be brought to EIL's notice and EIL's decision on the same shall be final and binding on the vendor without any cost/time implication after the order.

GUIDELINES

1. Sealing strips shall be as indicated on the drawings. Sealing strips minimum width to be 25mm, however minimum clearance between tube OD to sealing/sliding strip to be 5 mm. The actual width of the sealing strips to be calculated based on a minimum clearance of 5mm between tube OD and the baffle OD. The sealing strips shall extend from first to last baffle unless when they are required to hold the bundle (i.e. there is no tie rod placed within 50 mm distance of the sealing strip), in which case they shall extend from stationary tubesheet to last support plate. Ensure that sealing strips/tie rods do not obstruct nozzle opening. Attachment to stationary tubesheet shall be as per EIL Standard 7-15-007. Sealing strip thickness shall be 8 mm (min). However the sealing strip thickness shall not be less than twice corrosion allowance. Sealing strips shall extend up to baffle OD and shall not be extended up to shell ID.

2. Impingement plate shall be held by tie rods/sealing strips/sliding strips. Extra tie rods shall be provided if necessary to hold the impingement plate. Impingement plate may be welded to shell in fixed tubesheet exchangers only. In such case impingement plate in material shall be same as that of shell. Width of impingement plate shall be as indicated in the tube layout. Length of impingement plate along the shell, if not specified in the Setting Plan drawing shall be taken as nozzle ID + 50mm.

3. In case of 45o & 90o tube patterns, through clear lanes shall be provided for cleaning outside of tubes and no tie rod, seal strip/seal rod/sliding strip shall interface with these lanes.

4. The notches in baffle for sealing strips/sliding strips shall be the strip thickness + 0.5mm.

5. Width of sliding strips to be maximum keeping a gap of 5 mm between the tube and sliding strip. However, minimum thickness & width of sliding strip shall be as given in Table-1. Any change in minimum width and thickness shall be brought to EIL's notice and EIL's decision shall be final. The sliding strip shall extend from last support plate to stationary tubesheet. Attachment of sliding strip to tubesheet shall be as per EIL STD 7-15-007. To facilitate bundle insertion/withdrawal a maximum of 0.8mm clearance between the shell ID and sliding strip to be provided.

6. For removable bundles, eye bolts shall be provided on the channel side face of stationary tubesheet and located approximately diametrically opposite. In case of four eye bolts, these shall be spaced along the circumference of tube sheet at approximately diametrically opposite ends. For cladded tubesheets on channel side, alloy base plugs as per standard drawings shall be used. Eye bolt size shall be as per EIL Standard 7-15-0008 and shall be selected based on a bundle pulling force of 1.5 times bundle weight. Eye bolt holes shall not be drilled through the tubesheet thickness. Location to be such as to distribute loads on tube sheet evenly.

7. The ligament between eye bolt hole edge and tubesheet edge/tube hole shall be minimum 6 mm.

8. For 'S' & 'T' type exchangers, support plate shall be provided with maximum cuts at top & bottom to clear top/bottom row of tubes and encompassing full width of the sliding strips. The window cut in the middle shall be such that at least 50% of the total numbers of tubes are supported. The minimum ligament between the tube OD (top/ bottom row) and the support plate cut shall be 15 mm.

In case of `U' tube exchangers, the support plate, if required near `U' bend, shall be located on the straight length portion, 50 mm from tangent line of `U' tubes.

For `G', `H' type exchangers, support plates shall be provided at the centerline of shell nozzle and shall be provided with notches as indicated below.

For `K' type exchangers, full support plates without cuts and notches shall be provided at a spacing not exceeding 85% of the maximum unsupported tube length given in TEMA.

Page 67 of 193

Format No. EIL 1641-1924 Rev. 1 Copyrights EIL – All rights reserved

SPECIFICATION NO. A710-16-46-TL-6060 Rev A

Page 3 of 3

GUIDE LINE TO VENDOR REGARDING TUBE LAYOUT PREPARATION

SRU-REVAMP (TGTU)

9. Pass lane width given in the tube layout are from tube centre to tube centre across the pass partition lane.

10. The dome height specified in the tube layouts is the minimum distance to be maintained from shell ID to the top of impingement plate (or top of tube if there is no impingement plate).

11. Baffles/support plates shall be provided with 900 top and bottom notches with width given below:

Shell ID (mm) Notch width (mm)

Less than 300 : 6

300 to 600 : 10

Greater than 600 : 12

12. Where tie-rods have been considered without spacers, then tie-rods shall be welded to baffles/support plate.

13. For LAS tubesheets, do not weld any attachment like sealing strips, dowel lugs/jack screw lugs to tube sheet. These shall be attached by screw connections.

TABLE - 1 MINIMUM SIZE OF SLIDING STRIPS

Shell ID (mm) Width (mm) Thickness (mm)

Less than 432 -- --

433 to 812 50 16

813 to 1092 60 18

1093 to 1524 70 20

1525 & above 100 25

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STANDARD SPECFICATION ENGINEERS FOR WELDED INDIA LIMITED

) IA Govt of India UndenakIng) TUBE TO TUBESHEET JOINTS

STANDARD SPECIFICATION No.

6-15-0003 Rev. 4 Page 1 of 9

(Q ,1611 ZaTeZ •71) {CPR TrriW 'WU

STANDARD SPECIFICATION FOR WELDED

TUBE TO TUBESHEET JOINTS

4 07.06.13 REAFFIRMED AND REISSUED AS STANDARD SPECIFICATION

3 28.01.08 REAFFIRMED AND REISSUED AS STANDARD SPECIFICATION

REVISED AND REISSUED AS STANDARD 2 01.09.99 HN PK SPECIFICATION

RKT/SC DM

AKM

RKA AS

KA PK

VC

1 04.05.89 ISSUED AS STANDARD SPECIFICATION RKA BSG VKM RNS

Rev. No. Date Purpose Prepared Checked

by by

Standards Standards Committee Bureau Convenor Chairman

Approved by

Format No. 8-00-0001-F1 Rev. 0

Copyright EIL — All rights reserved Page 88 of 193

ENGINEERS STANDARD SPECFICATION STANDARD SPECIFICATION No.

INDIA LIMITED FOR WELDED 6-15-0003 Rev. 4 IA GOVT. of

in" Undertaking) TUBE TO TUBESHEET JOINTS Page 2 of 9

0ll6iel Ogee

Abbreviations:

API ASME AWS OD TEMA TIG

American Petroleum Institute American Society of Mechanical Engineers American Welding Society Outside diameter Tubular Exchangers Manufacturers' Association Tungsten inert gas shielded arc

Static Equipment Standards Committee

Convenor :

Members:

Mr. R K Trivedi

Mr. K Anjaneyulu Mr. Tarun Kumar Mr. Tarun Goyal Ms. R K Singh Mr. G K Iyer Mr. Ratan Lal Mr. S Ghosal

Copyright EIL — All rights reserved Format No. 8-00-0001-F1 Rev. 0 Page 89 of 193

ENGINEERS STANDARD SPECFICATION Igar 22egWv INDIA LIMITED FOR WELDED

IA Govt of InOta Undertaking) TUBE TO TUBESHEET JOINTS

STANDARD SPECIFICATION No.

6-15-0003 Rev. 4 Page 3 of 9

CONTENTS

1.0 SCOPE 4

2.0 APPLICABLE CODES AND STANDARDS 4

3.0 WELDING PROCESS AND JOINT DETAIL 4

4.0 WELDING PROCEDURE QUALIFICATION 4

5.0 WELDERS QUALIFICATION 6

6.0 PREPARATION OF TUBES AND TUBESHEET 6

7.0 WELDING 6

8.0 EXAMINATION OF JOINTS 7

9.0 TUBE EXPANDING 7

10.0 REPAIRS 7

11.0 TEST AND REPAIR REPORTS 7

APPENDIX-1 - JOINT DETAILS

APPENDIX-2 - DETAILS OF TEST SPECIMENS

Format No. 8-00-0001-F1 Rev. 0

Copyright EIL — All rights reserved Page 90 of 193

ENGINEERS STANDARD SPECFICATION STANDARD SPECIFICATION No.

fameg INDIA LIMITED FOR WELDED 6-15-0003 Rev. 4 IA Govt of Ind a Undertaking) TUBE TO TUBESHEET JOINTS Page 4 of 9

1.0 SCOPE

1.1

This specification covers minimum requirements for the welding and testing of tube to tubesheet joints of shell and tube heat exchangers and air coolers. It is the Fabricator's responsibility to furnish sound, leak free joints. For the purpose of this specification, the terms "joints" shall be construed to mean "tube-to-tube sheet joints".

2.0 APPLICABLE CODES AND STANDARDS

The latest edition of the following codes and standards shall be complied with:

a) ASME Section VIII Division I b) ASME Section V c) ASME Section IX d) TEMA for tubular exchangers e) API 661 for aircoolers f) AWS

3.0 WELDING PROCESS AND JOINT DETAIL

3.1 Manual or automatic Tungsten Inert Gas shielded Arc (TIG) welding shall be used. All joints shall be made by using minimum two weld passes. The first pass should be preferably made without filler wire to ensure root fusion. The second or final pass shall be with filler wire. Any other welding process can be used only after obtaining written approval from the Authorised Inspector.

3.2 Joint detail shall be as indicated on the Purchaser drawings by giving reference to figure numbers in Appendix-1 of this specification. In absence of any Purchaser drawings or indication regarding type of joint, Figure 2 or Figure 3 shall be used depending upon whether tube thickness is > 2 mm or < 2 mm respectively.

4.0 WELDING PROCEDURE QUALIFICATION

4.1 Welding Procedure Specification shall be compiled by the Fabricator and submitted to the Authorised Inspector for approval before the qualification tests are performed. Mock up test shall commence only after approval is obtained from the Authorised Inspector.

4.2 Welding procedure qualification test is required to be carried out if :-

a) Authorised Inspector requires the test to be carried out.

b) There exists no previous qualification tests within last three years for the proposed combination of tube and tubesheet P number and group number (as per ASME Section IX), tube outside diameter (OD), tube thickness, tubesheet thickness, tube pitch, tube pitch pattern, welding procedure and joint detail. All other factors remaining same, the procedure test need not be repeated if the job tubesheet thickness exceeds 40 mm and qualification exists for 40 mm or higher tubesheet thickness.

For plug type air coolers additional procedure qualification test is required to be performed for any of the following conditions:

i) The job has lower clearances between tube and any of the header plates like top/bottom/end/stiffener/pass partition plate compared to earlier tests.

ii) The job has lower plug size for the same tube size compared to earlier tests.

Format No. 8-00-0001-F1 Rev. 0

Copyright EIL — All rights reserved Page 91 of 193

STANDARD SPECIFICATION No.

6-15-0003 Rev. 4 Page 5 of 9

ei ENGINEERS STANDARD SPECFICATION ligar Offleu INDIA LIMITED FOR WELDED

IHIen rircoft Cavan) IA Govt of Indo Undertaking) TUBE TO TUBESHEET JOINTS

iii) The job has higher plugsheet thickness compared to earlier tests.

c) Code or requisition or bid document requires the test to be carried out.

4.3 If required as per 4.2 above, the Fabricator shall perform a procedure qualification test, at least two weeks before the scheduled beginning of production. Procedure shall be qualified for the same hand position as is being proposed for production. Procedure test shall consist of the welding of nine tubes for square pitch and eight tubes, (three, two and three tubes per row arrangement) if on a triangular pitch. This shall be done for each set of combination of tube and tubesheet P number and group number, welding procedure, joint detail, tube OD, tube thickness, tube pitch, tube pitch pattern, tubesheet thickness. Additionally for air cooler, tests shall be done for each tube size with lowest plug size, lowest clearence between tube and any of the header plates, and the lowest plugsheet thickness to be used on the job. Thickness of the tubesheet used for procedure testing shall be same as used for job, except that for carbon steel and austenitic stainless steel materials, it need not exceed 40 mm, unless otherwise indicated. Refer Appendix-2 of this specification for test specimen details.

4.4 The following data report (six copies) shall be furnished for review to Authorised Inspector with the weld samples as outlined below.

a) Complete details of welding procedure employed indicating various machine settings, welding rods, inert gas composition & purities, flow rate, weld sequence etc.

b) Mechanical properties and chemical composition of tubesheet, tubes and filler metal.

c) The hardness of the weld, the tube, the tubesheet heat affected zone and the tubesheet base metal after each pass.

d) The complete test sample shall be cut (by sawing) as per Appendix 2 of this specification. These shall then be subjected to various tests etc. as outlined below:

i) Section 1 shall be polished, etched and microphotographed for examination of depth of weld, penetration and definition of boundaries. The minimum leak path of each weld shall be not less than the nominal thickness of the tube. The weld leg shall also be measured and shall be minimum 1.4 times the nominal thickness of the tube.

ii) Section 2 (two specimens) shall be subjected to tear test. These specimens shall be tongue bent to show the extent of weld penetration. The underside of the weld shall show evidence of adequate & uniform weld penetration.

iii) A section 10 mm thick containing the tube end welds shall be sawed from section 3 and radiographed for weld quality. The radiograph shall be submitted to Authorised Inspector. No cracks or crack like or visual defects are acceptable. Acceptance shall be as per Appendix 4 of ASME Section VIII Division 1. In case the radiograph is not acceptable, welding procedures shall be suitably modified so that proper weld and acceptable radiographs are obtained. These shall be proved by retests.

iv) Section 4 shall be etched and polished and given to Authorised Inspector.

e) A tension strength test shall be carried out as per ASME Section VIII Division I Appendix A. This strength test shall be performed at room temperature for each combination set of tube and tubesheet P number and group number, tube OD, tube thickness and joint detail. The breaking loads shall be at least equal to the load required for breaking the tube using the minimum specified ultimate tensile strength

Copyright EIL — All rights reserved Format No. 8-00-0001-F1 Rev. 0 Page 92 of 193

" ENGINEERS STANDARD SPECFICATION kiVeGVIW' INDIA LIMITED FOR WELDED

(#11"9122mweinJW,R) (A Govt of India Undertaking) TUBE TO TUBESHEET JOINTS

STANDARD SPECIFICATION No.

6-15-0003 Rev. 4 Page 6 of 9

of tube as indicated in certificates issued by the tube supplier. When tube material is to a specification which does not call for mechanical tests to be performed, ultimate tensile strength of the tube material shall be considered as four times the allowable stress at room temperature as indicated by the ASME Section II Part D, or other relevant code. Failure of the test piece at the weld shall not be a cause for rejection in case the minimum strength is attained, but the fracture should be examined for any evidence of faulty workmanship.

4.5 Fabricator is advised to satisfy himself that the procedures employed are the best for the job and would enable him to give workmanship guarantee for the equipment. Authorised Inspector's approval shall in no way relieve the Fabricator of his responsibility and guarantee to supply the equipment as per the conditions of the purchase order.

5.0 WELDERS QUALIFICATION

The purpose of this operator qualification test is to demonstrate that both the welding operator and the welding machines are capable of producing satisfactory joints. Once welding procedures have been qualified as above, welding operators employed on welding shall be required to prove their ability by making test samples similar to that prescribed above for welding procedure qualification. Welding operators may be qualified based on para 4.4 d (i), 4.4 d (ii), and 4.4 d (iii) above only, provided same welding machines & welding procedures are used. This welding operator qualification test should also be carried out if the welding operator has not executed similar welding six months prior to production. Repeat tests may be called for in the course of manufacture to determine the consistency of operator or machine to produce sound welds.

6.0 PREPARATION OF TUBES AND TUBESHEET

6.1 Tubeholes shall be to special close fit tolerance as per TEMA for shell and tube exchangers and as per API 661 for air coolers. Tube holes shall be free from any burns and the bundle side edge of tube holes shall be chamfered or radiused. Tube holes shall have smooth finish to 63 AARH.

6.2 Prior to assembly, the tubesheet and tube ends (inside and outside for a distance equal to the tubesheet thickness + 30 mm) shall be cleaned and degreased to free from dirt, grease etc. It is essential that the solvent used for degreasing be chloride free and sulfide free and non residue forming. The solvent should not lead to any possible fire hazard.

6.3 The tubes shall be positioned in the tubesheets by 30° tapered drift pin.

6.4 Before welding tube to tubesheet, the tubesheets shall be heated to a temperature as required to remove any last traces of moisture or solvent which may remain after the cleaning operation. Any specific requirement for application of preheat shall be established as a part of the welding procedure qualification test and should account for increased restraint offered by the larger assembly during production.

7.0 WELDING

Tubes shall be individually welded, using the procedure approved by the Authorised Inspector. Systematic welding procedure shall be adopted so as to result in minimum tubesheet distortion. All tubes are to have initial pass completely cleaned as necessary, visually examined and tested as per para 8.1 below, if required, before subsequent layers are applied. Welds shall be suitably finished and any spillage or spatter on tubesheet removed. Spillage of weld metal into the bores of tube is not permitted.

Format No. 8-00-0001-F1 Rev. 0

Copyright EIL — All rights reserved

Page 93 of 193

ENGINEERS STANDARD SPECFICATION og-ar 02ft 1W INDIA LIMITED FOR WELDED

Govt of Indo Undertaking) TUBE TO TUBESHEET JOINTS

STANDARD SPECIFICATION No.

6-15-0003 Rev. 4 Page 7 of 9

8.0 EXAMINATION OF JOINTS

8.1 Joints shall be subjected to air-soap solution test after first weld pass with air at 1.25 kg/cm2 (g). Procedures outlined in ASME Section V, Article 10 shall be followed.

8.2 After completion of welding, the tubesheet face, the welds and internal tube surfaces to a distance of 25 mm beyond the fusion line must be cleaned thoroughly by wire brushing and examined carefully for surface defects. Defects such as cracks, surface breaking porosity, slag inclusions and lack of fusion are not acceptable.

8.3 After the visual inspection, a liquid penetrant examination in accordance with ASME Section VIII Division I, Appendix-8 & Section V, Article 6 shall be done. Before conducting this test, the faces of the carbon steel tubesheets shall be cleaned thoroughly by wire brush and solvents to remove all weld slag, rust and scale.

8.4 When specified on the drawings or requisition, a halide test shall be performed after the tests as per para 8.1, 8.2, and 8.3 above have been successfully completed. Procedures for halide test shall be as per ASME Section V, Article 10, Appendix - III Halogen diode detector probe test.

8.5 After the final tube expanding (refer para 9.0) has been completed, the liquid penetrant examination as outlined in para 8.3 above shall be repeated.

8.6 Whenever a halide test has been specified, an envelope test shall also be done as a further test for leaks after final tube expanding. For this test, tubesheets shall be securely wrapped in plastic sheets and the shell allowed to remain under test pressure with halogen tracer, for a period of 10 to 12 hours. Then with the detection set at a maximum sensitivity, the probe shall be inserted through the plastic cover at the bottom of the tubesheets and readings taken to observe if any leakage has occurred.

8.7 Final acceptance hydraulic pressure test shall be conducted after tube expansion at hydrotest pressure for at least one hour.

9.0 TUBE EXPANDING

After the tests outlined in 8.1, 8.2, 8.3, and 8.4 have been successfully completed and all leaking welds repaired, the tubes shall be "contact expanded" with a PARALLEL type expander. Contact expanding is intended to bring the tube OD into contact with the tube hole. Contact expanding shall begin 12 mm from the tubesheet face and extend to 3 mm from the back face. The contact expansion shall have thinning of 3-5% which shall be ensured by measuring the inside diameter of tubes.

10.0 REPAIRS

If leaks are found during any of the above testing procedures these shall be reported to the Authorised Inspector and after obtaining his approval, repairs shall be made by removing the defects down to sound parent metal and repeating the qualified weld procedures. All weld repairs shall be retested in accordance with procedures outlined in para 8.0 above.

11.0 TEST AND REPAIR REPORTS

Test and repair reports shall be included in the Data Folder. These reports shall also indicate the number of leaks discovered on each test and the extent of the repair done.

Format No. 8-00-0001-F1 Rev. 0

Copyright EIL — All rights reserved Page 94 of 193

FIG-2

D = 1.6t TO 2t

FIG-6

W= t R = t

D = t FOR t<3 AND

= 0.6t FOR t >3

APPENDIX 1 - JOINT DETAILS

w i t

FIG-1

W t

FIG-3

FIG-5

FIG-7

FIG-4

t or 3 WHICHEVER IS MORE

Ig'-ar „151PG, ENGINEERS STANDARD SPECFICATION INDIA LIMITED FOR WELDED (A Govt of India Undettaking) TUBE TO TUBESHEET JOINTS

STANDARD SPECIFICATION No.

6-15-0003 Rev. 4 Page 8 of 9

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 95 of 193

30 30 * *

I I

O

It

It

O

FIG-12

STANDARD SPECIFICATION No.

6-15-0003 Rev. 4 Page 9 of 9

el 5igat Rift

1***clecrnetv3*,,,*)

ENGINEERS STANDARD SPECFICATION INDIA LIMITED FOR WELDED (A Govt of Indla Undellakeng) TUBE TO TUBESHEET JOINTS

APPENDIX 2 - DETAILS OF TEST SPECIMENS

* - - EDOG O+W+ * Act

FIG-11

* 1

NOTE:-

THE MOCKUP ASSEMBLY SHOULD HAVE THE DIMENSIONS/THICKNESS MARKED AS PER JOB

*

*

BUNDLE SIDE

FIG-13 FOR PLUG TYPE AIRCOOLERS

I I I

FIG-14 FIG-15

LEGEND 1. FOR MICROPHOTOGRAPHIC EXAMINATION 2. FOR TEAR TEST 3. FOR RADIOGRAPHIC EXAMINATION

Copyright EIL — All rights reserved Format No. 8-00-0001-F1 Rev. 0 Page 96 of 193

1 26.03.04 REAFFIRMED AND REISSUED AS

STANDARD SPECIFICATION

Rev. No

Date Purpose

Copyright EIL — All rights reserved Format No. 8-00-0001-F1 Rev. 0

VB RKG AKM N.DUARI

NSK PK SSA SKG

RV SSA RKA AS

Prepared by

Checked by

Standards Committee Convenor

Standards Bureau

Chairman

Approved by

3 05.11.14 REVISED & REISSUED AS STD. SPEC.

2 29.06.09 REAFFIRMED & REISSUED AS STD. SPEC.

0 15.03.96 ISSUED AS STANDARD SPECIFICATION

l511

£;12e5 man ,roxt asTararr,

STANDARD SPECIFICATION STANDARD SPECIFICATION No. ENGINEERS

INDIA LIMITED FOR HARDNESS REQUIREMENT 6-15-0091 Rev. 3

OF STATIC EQUIPMENT(PV & HE) Page 1 of 5

if[R4

r(N-R 4-11-ich

STANDARD SPECIFICATION FOR

HARDNESS REQUIREMENT OF

STATIC EQUIPMENTS (PRESSURE VESSELS, HEAT EXCHANGER)

Page 97 of 193

STANDARD SPECIFICATION STANDARD SPECIFICATION No.

Og—a[ f&if51 2.12ErreM1.3.7..11

Page 2 of 5

Abbreviations:

ASTM

BHN

HAZ

PWHT

American Society for Testing & Materials

Brinell Hardness Number

Heat Affected Zone

Post Weld Heat Treatment

Static Equipment

Convenor : Mr.

Standards Committee

R.K. Trivedi

Members : Mr. Mr. Mr. Mr. Mr. Mr. Mr.

K. Anjaneyulu Tarun Kumar Anish Trehan R.K. Singh (Inspection) G.K. Iyer (Construction) Ratan Lal (Project) S. Ghosal (SMMS)

ENGNEERS FOR HARDNESS REQUIREMENT INDIA LIMITED 6-15-0091 Rev. 3 (A Go. of tnd Und.tak.9) OF STATIC EQUIPMENT(PV&HE)

Copyright EIL — All rights reserved Format No. 8-00-0001-F1 Rev. 0

Page 98 of 193

STANDARD SPECIFICATION STANDARD SPECIFICATION No. ENGINEERS FOR HARDNESS REQUIREMENT INDIA LIMITED 6-15-0091 Rev. 3 A GoN of Undertaking) . OF STATIC EQUIPMENT(PV&HE) fg-ar fal51-g

Page 3 of 5

CONTENTS

1.0 SCOPE 4

2.0 HARDNESS REQUIREMENTS 4

3.0 WELDING QUALIFICATION TEST 4

4.0 PRODUCTION TEST 4

5.0 APPROVAL 5

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 99 of 193

441, rs'enl L151,7,77.1

STANDARD SPECIFICATION STANDARD SPECIFICATION No. ENGINEERS FOR HARDNESS REQUIREMENT INDIA LIMITED 6-15-0091 Rev. 3

GoA of haaundertakog) OF STATIC EQUIPMENT(PV&HE) Page 4 of 5

1.0 SCOPE

This specification covers general requirement of hardness of base metal, weld and heat-affected-zone (HAZ) and is applicable to all C-% Mo, Cr-Mo steels and other materials whenever asked for in drawings/ specifications/standards. All testing shall be done after PWHT.

2.0 HARDNESS REQUIREMENTS

Hardness in base metals, weld and heat affected zone as per ASTM E 10 shall not exceed the following:

For P1 materials - 200 BHN For P3 & P4 materials - 225 BHN For P5 & P6 materials - 235 BHN

3.0 WELDING QUALIFICATION TEST

3.1. For each welding procedure qualification six tests shall be made, three in weld metal and three in HAZ. Hardness requirements shall be as per cl. 2.0 above.

3.2. In addition to the requirement of 3.1 above, Vickers Micro hardness test shall be made on a full cross-section at 25 mm intervals beginning at 3 mm from the top surface with 5 kg load or with a load approved by the authorized inspector. Tests shall be made at each level for each of the following locations as per ASTM E 92:

Three tests shall be made in the weld metals, two tests in HAZ and one test in the base metal in accordance with Fig.1 and the hardness shall not exceed the following in base metal, weld metal and HAZ.

For P1 materials - 210 VHN For P3 & P4 materials - 237 VHN For P5 & P6 materials - 247 VHN

4.0 PRODUCTION TEST

4.1 All pressure containing weld metals are to be checked for hardness of weld and HAZ after PWHT but before hydro-test. The hardness shall not exceed the value stipulated.

4.2 Each longitudinal seam shall be checked both internally and externally near the center and at one end.

4.3 Each circumferential weld shall be checked at four locations approximately 90°apart, both internally and externally.

4.4 Each nozzle weldments shall be checked at two locations, 180° apart, both internally and externally.

Copyright EIL — All rights reserved Format No. 8-00-0001-F1 Rev. 0

Page 100 of 193

ON CROSS SECTION (TYP)

HEAT AFFECTED ZONE

HEAT AFFECTED ZONE (TYP)

"I‘

3(TYP)

VICKERS HARDNESS TEST

STANDARD SPECIFICATION STANDARD SPECIFICATION No. ENGINEEFZS FOR HARDNESS REQUIREMENT gz:11 INDIA LIMITED 6-15-0091 Rev. 3 IA Govt ~la Unctertak.g) OF STATIC EQUIPMENT(PV&HE) 4,1 3.1U./

Page 5 of 5

5.0 APPROVAL

In case the hardness as obtained on production test is more than the limit specified in 2.0 above, the vendor shall submit the corrective procedure to lower the hardness in writing to EIL and/or authorized inspection agency for review/approval.

BRINELL HARDNESS TEST

FIG.1- HARDNESS REQUIREMENT ON TEST COUPONS

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01We?Sg7k1t5tr,

ENGINEERSINDIA LIMITEDA Got of India undertaking)

MATERIAL REQUIREMENTS FORCARBON STEEL COMPONENTS

USED IN SOUR SERVICE INPETROLEUM

REFINERY ENVIRONMENT

STANDARD SPECIFICATION No.6-79-0013 Rev. 1

Page 1 of 6

tirecrrt Rtoi it1 cimicitu i TrTK tirchiTRYITru trk A-r4 chick tack,' aNzgl

timul aTerw

MATERIAL REQUIREMENTS FORCARBON STEEL COMPONENTS USED

IN SOUR SERVICE INPETROLEUM REFINERY

ENVIRONMENTS

1 07.10.11 SPECIFICATION AR SG PPL DM0 07.10.04 ISSUED AS STANDARD SPECIFICATION GM VRK KKM SKG

Standards StandardsRev. Prepared Checked Committee BureauNo Date Purpose by by Convenor Chairman

Approved by

REVISED & REISSUED AS STANDARD

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reservedPage 123 of 193

In$jg",C1T 'Meg.

ENGINEERSINDIA LIMITEDIA Govl of India undertaking)

MATERIAL REQUIREMENTS FORCARBON STEEL COMPONENTS

USED IN SOUR SERVICE INPETROLEUM

REFINERY ENVIRONMENT

STANDARD SPECIFICATION No.6-79-0013 Rev. 1

Page 2 of 6

Abbreviations:

ANSI : American National Standards Institute

API : American Petroleum Institute

ASME : American Society of Mechanical Engineers

ASTM : American Society for Testing and Materials

ISO : International Organization for Standardization

NACE : National Association of Corrosion Engineers

SMMS Standards Committee:

Convener: Mr. PP Lahiri

Members: Mr. A AminMr. GS HegdeMr. R ChaudhuryMr. S GhosalMr. P SahaMr. R Nanda (Piping)Mr. AK Gupta (HMTD)Mr. S Mukherjee (Construction)Mr. R Muthulingam (Inspection)Mr. Raj Kishore (Pipeline)Mr. AR Purushottam (POSD)Mr. MP Jain (Projects)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 124 of 193

1511*Zret:te ENGINEERSsig7 wegwINDIA LIMITEDIA earl of India Undenakurp)

MATERIAL REQUIREMENTS FORCARBON STEEL COMPONENTS

USED IN SOUR SERVICE INPETROLEUM

REFINERY ENVIRONMENT

STANDARD SPECIFICATION No.6-79-0013 Rev. 1

Page 3 of 6

CONTENTS

1.0 SCOPE 4

2.0 REFERENCED CODES/STANDARDS 4

3.0 GENERAL REQUIREMENTS 4

4.0 MATERIAL SPECIFICATION 5

5.0 PRODUCT SPECIFIC REQUIREMNTS 5

6.0 POST WELD HEAT TREATMENT (PWHT) AND HARDNESS REQUIREMENT 6

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 125 of 193

Salfazrei$1@l729.egi INDIA LIMITED

IA Gan ol Intha undedakingl

MATERIAL REQUIREMENTS FORCARBON STEEL COMPONENTS

USED IN SOUR SERVICE INPETROLEUM

REFINERY ENVIRONMENT

STANDARD SPECIFICATION No.

6-79-0013 Rev. 1Page 4 of 6

1.0 SCOPE

1.1 In general, for refinery services, NACE Standard MR 0103 shall be applicable. For services

where HIC (Hydrogen Induced Cracking) resistant carbon steel is specifically mentioned inthe Process Documents, this specification shall be followed.

1.2 This specification lays down the requirements related to the chemical composition,manufacture, fabrication and testing requirements for carbon steel components intended to beused in sour service in petroleum refinery environments. These requirements are specified inorder to make the carbon steel component resistant to the various forms of material damage ina sour environment, such as Sulfide Stress Cracking (SSC), Hydrogen Induced Cracking(HIC), Stress Oriented Hydrogen Induced Cracking (SOHIC), Blistering etc. Theserequirements can be used for resisting Alkaline Stress Corrosion Cracking (ASCC) also. Thisspecification is applicable for corrosive petroleum refining facilities.

1.3 The service medium is defined as "Sour" when the service environment conforms to one ofthe following conditions, as defined in NACE Standard MR0103.

Service environments containing free water (in liquid phase) and:

>50 ppmw dissolved H 2 S in the free water.

Free water pH < 4 and some dissolved H 2S present.

Free water pH >7.6 and 20 ppmw dissolved hydrogen cyanide (HCN) in the water andsome dissolved H 2 S present.

>0.003 MPa absolute (0.05 psia) partial pressure H2S in the gas in processes with a gasphase.

2.0 REFERENCED CODES/STANDARDS

NACE MR 0103 ASTM A 694 ASTM A 770NACE RP 0472 ASTM A 216 ASTM A 370NACE Publication 8X194 & 8X294 ASTM A 106 ASTM A 578NACE TM 0284 API 5 L ASME SEC II PART CASTM A 20 API 6 A ASME SEC VIII-DIV.IASTM A 516 ASTM E 18 ASME SEC IXASTM A 105 ASTM E 45 ANSI B 16.34ASTM A 234 ASTM E 92 ANSI B 31.3

All ASTM Standard designations shall be applicable for corresponding ASME designationswhich would be read as ASME SA XXX instead of ASTM A XXX.

3.0 GENERAL REQUIREMENTS

3.1 The steel for sour service shall be manufactured by either basic oxygen or electric arc furnaceroute and shall be fully killed and fine grained.

3.2 Carbon steel shall not contain intentional additions of elements such as lead, selenium orsulphur to improve machinability.

3.3 Carbon steel shall be used in one of the following heat treatment conditions.

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I5ilfaZre?at ENGINEERSs'gar Ea rew INDIA LIMITED

MATERIAL REQUIREMENTS FORCARBON STEEL COMPONENTS

USED IN SOUR SERVICE INPETROLEUM

REFINERY ENVIRONMENT

STANDARD SPECIFICATION No.

6-79-0013 Rev. 1

Page 5 of 6

Hot-rolled;Annealed;Normalised;Normalised and tempered;Normalised, austenitised, quenched and tempered;Austenitised, quenched and tempered.

3.4 All material after cold forming shall be thermally stress relieved to meet a hardnessrequirement of 200 BHN maximum.

3.5 All products shall be free of low temperature transformation microstructures such as bainitebands or islets of martensite.

4.0 MATERIAL SPECIFICATION

All items are required to conform to the chemical composition of the respective specificationas listed below.

Plate: SA-516 Gr.60

Pipe: SA-106 Gr. B or SA-333 Gr.1 or 6

Forgings: SA-105 or SA-350 Gr.LF1 or LF2 or SA-266 Class 1

Fittings: SA-234 Gr. WCB or SA-420 Gr.WPL6

Castings: SA-216 Gr. WCA, WCB or WCC or SA-352 Gr. LCA, LCB or LCC

Tubing: SA-179 or SA-214

5.0 PRODUCT SPECIFIC REQUIREMNTS

5.1 Plates and rolled products

All rolled products such as plates and sheets and fittings / pipes made of rolled products shallmeet the following specific requirements.

5.1.1 The steel shall be made through a clean steel making route and shall have minimum ofinclusions.

5.1.2 The sulphur level shall be restricted to 0.003 wt%.

5.1.3 The steel shall be calcium treated for inclusion morphology control and the Ca/S ratio shallbe in the range of 2 to 3. When sulphur content is less than 0.0015%, then Ca/S ratio is notapplicable and calcium can be present up to 50 ppm.

5.1.4 For plates including and above 25mm thick, through-thickness tensile testing shall be carriedout in accordance with ASTM A770, with minimum reduction in area being 35% asdetermined in accordance with ASTM A370, on one plate per heat.

5.1.5 No repair welding shall be permitted on plated.

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tillaZleTeell ENGINEERSsigzir tatReglite INDIA LIMITED

IA Gent 01 Intha undeftakingi

MATERIAL REQUIREMENTS FORCARBON STEEL COMPONENTS

USED IN SOUR SERVICE INPETROLEUM

REFINERY ENVIRONMENT

STANDARD SPECIFICATION No.6-79-0013 Rev. 1

Page 6 of 6

5.1.6 When the fabrication of the components from the previously HIC tested plates involves noheavy wall thickness reduction or material flow, such as bending, spinning or welding, nofresh HIC test would be required on the final product. However, for fabrication of productswhere heavy reduction of thickness and heavy flow of material is encountered while formingsuch as like forging, extrusion or drawing, metallographic examination of the final productshall be required to be carried out to ensure absence of elongated inclusions.

5.1.7 The plates shall be procured only from pre-qualified manufacturers.

5.2 Pre-qualification criteria for vendors with prior experience track record

Vendors/manufacturers who have proven track record of supplying materials for sour serviceapplications in petroleum refineries to any of the reputed operating companies/EngineeringConsultants or Process Licensors such as UOP/ IFP/ EXXON/ BP/ CHEVRON/ IOCL/ HPCL/BPCL/ EIL will be considered as 'pre-qualified vendors/manufacturers', on production of therelevant Purchase Orders and test certificates, certified by a witnessing third party inspectionagency such as DNV/Lloyds/BV/ABSTECH/TUV/SGS/CEIL for the conformance of thematerials to the respective materials specification of the mentioned operators / engineeringconsultants. For pre-qualified vendors, Clause No.5.4 is not applicable.

5.3 Pre-qualification criteria for New Vendors with out track record

A vendor who has no track record of supplying sour service materials to any of the reputedengineering consultants/operators, as mentioned in Clause 5.2 above, shall be considered as anew vendor and shall be required to carry out HIC test as detailed out in Clause 5.4 for pre-qualification by any one of the reputed third party inspection agencies like Lloyds, BV, CEIL,DNV or TUV etc..

5.4 Hydrogen Induced Cracking (HIC) Test

The requirements for HIC test shall be as follows.

This test is required for vendor pre-qualification only.

This test shall be performed on a set of three specimens representing each productionbatch/heat of rolled products in accordance with NACE TM 0284 with the followingacceptance criteria:

Crack Length Ratio (CLR) 10.0%Crack Sensitivity Ratio (CSR) 1%

(iii) In case of failure of any one of the specimens, three more specimens from the sameproduct shall be retested and all the specimens shall meet the acceptance criteria. In caseof failure of any retest sample, the material shall be considered unacceptable.

6.0 POST WELD HEAT TREATMENT (PWHT) AND HARDNESS REQUIREMENT

All the weld joints, irrespective of thickness, shall be given a post weld heat treatment. Thetemperature range for PWHT shall be 595-650°C. Other aspects such as rate of heating,holding time etc. for PWHT shall be as per ASME Sec.VIII, Div.I /ANSI B31.3 requirements.The hardness of the weldment after PWHT shall be 200 BHN maximum.

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SPECIFICATION FORDUPLEX STAINLESS STEEL AND

SUPER DUPLEX STAINLESSSTEEL

01'4216a ENGINEERSSig2:11€01-duNi101 INDIA LIMITED

eo,gezill,A1911 IA Gov't of India uneenatng)

STANDARD SPECIFICATION No.6-79-0015 Rev. 1

Page 1 of 12

1-14-€€ 141 1 4 I I KORTAM€ ch I 1 tzi 4(11d

Thmg reibi

SPECIFICATIONFOR

DUPLEX STAINLESS STEEL ANDSUPER DUPLEX STAINLESS STEEL

41444 #6daAr_1 07.10.11 REVISED & REISSUED AS STANDARD

SPECIFICATION SKM SG PPL DM0 28.12.04 ISSUED AS STANDARD SPECIFICATION SG VRK KKM SKG

Standards StandardsRev.No Date Purpose Prepared

byChecked

byCommitteeConvenor

BureauChairman

Approved by

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ILi1Prire?

5g-elkreg)SPECIFICATION FOR

INDIA LIMITEDENGINEERS DUPLEX STAINLESS STEEL ANDIP Govt of India Underlakingi

STANDARD SPECIFICATION No.

6-79-0015 Rev. 1Page 2 of 12

SUPER DUPLEX STAINLESSSTEEL

Abbreviations:

ABS : American Bureau of ShippingASME : American Society of Mechanical EngineersASTM : American Society for Testing and MaterialsBV : Bureau VeritasCEIL : Certification Engineers International LimitedCPI : Chemical Process IndustryCSC : Chloride Stress CrackingDNV : Det Norske VeritasDSS : Duplex Stainless SteelHAZ : Heat Affected ZoneISO : International Organization for StandardizationMSS : Manufacturers Standardization SocietyNACE : National Association of Corrosion EngineersPREN : Pitting Resistance Equivalent NumberSDSS : Super Duplex Stainless SteelSSC : Sulphide Stress Cracking

SMMS Standards Committee:

Convener: Mr. PP Lahiri

Members: Mr. A AminMr. GS HegdeMr. R ChaudhuryMr. S GhosalMr. P SahaMr. R Nanda (Piping)Mr. AK Gupta (HMTD)Mr. S Mukherjee (Construction)Mr. R Muthulingam (Inspection)Mr. Raj Kishore (Pipeline)Mr. AR Purushottam (POSD)Mr. MP Jain (Projects)

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SPECIFICATION FORDUPLEX STAINLESS STEEL AND

SUPER DUPLEX STAINLESSSTEEL

lalfaeldia ENGINEERSbfba-fir OIRes NW INDIA LIMITEDGovl of India lffideftlion9)

STANDARD SPECIFICATION No.

6-79-0015 Rev. 1Page 3 of 12

CONTENTS

1.0 SCOPE 4

2.0 CODES AND STANDARDS 4

3.0 STEEL MANUFACTURE 5

4.0 HEAT TREATMENT 5

5.0 APPLICABLE REQUIREMENTS FOR DSS AND SDSS 5

6.0 PRE-QUALIFICATION CRITERIA FOR MILL / MANUFACTURER 8

7.0 CORROSION TESTS FOR PRE-QUALIFICATION 9

8.0 REQUIREMENTS FOR PRODUCTION TESTING 11

9.0 QUALITY SURVEILLANCE AND INSPECTION 12

10.0 DOCUMENTS TO BE SUBMITTED 12

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SPECIFICATION FORDUPLEX STAINLESS STEEL AND

SUPER DUPLEX STAINLESSSTEEL

ENGINEERSs'g7galeg W INDIA UMITED

(A Gave DI i,tea UndellakON

STANDARD SPECIFICATION No.

6-79-0015 Rev. 1Page 4 of 12

1.0 SCOPE

1.1 This specification covers the specific requirements for manufacture, inspection, testing and

supply of duplex stainless steels conforming to UNS No.(s) S 31803, S 32205 or equivalentand super duplex stainless steel conforming to UNS No.(s) S 32760, S 32750, S 39274, S32550, J 93380 or equivalent. DSS and SDSS material shall be considered acceptable whenthey meet the pre-qualification criteria mentioned in this specification.

1.2 This specification shall be read together with the corresponding product specificationsmentioned in the relevant piping material specifications or the equipment data sheets/designdrawings intended to be used in sour and/or chloride containing environments, as applicable.

1.3 In case of conflict between this specification and the referred material codes/standardspecifications, the requirement of this specification shall govern.

2.0 CODES AND STANDARDS

The manufacture, inspection, testing, marking and supply of the item covered by thisspecification shall follow the latest editions of the following codes and standard specifications:

ASTM A 182

ASTM A 240

ASTM A 276ASTM A 351

ASTM A 370ASTM A 743

ASTM A 744

ASTM A 789

ASTM A 790ASTM A 799

ASTM A 815

ASTM A 923

ASTM A 928

ASTM E 18ASTM E 562ASTM G 36

ASTM G 48

ASME B 16.34ASME Sec.VMSS-SP-55

Forged or rolled alloy steel pipe, flanges, forged fittings and valves andparts for high temperature serviceHeat resisting chromium and chromium - nickel stainless steel plate, sheetand strip for pressure vesselsStainless steel bars and shapesCasting - austenitic, austenitic-ferritic (duplex) for pressure containingpartsStandard methods and definitions for mechanical testing of steelCastings - iron-chromium-nickel-base corrosion resistant, for generalapplicationCasting - iron-chromium-nickel-base corrosion resistant, for severeapplicationSeamless and welded ferritic/austenitic stainless steel tubing for generalserviceSeamless and welded ferritic- austenitic stainless steel pipeSteel castings-stainless instrument calibration for estimating ferritecontentWrought ferritic, ferritic-austenitic and martensitic stainless steel pipefittingsStandard test methods for detecting detrimental intermetallic phase inwrought duplex austenitic/ferritic stainless steelsSpecification for ferritic/austenitic (duplex) stainless steel pipe electricfusion welded with addition of filler metalRockwell hardness testing of metallic materialsDetermining volume fraction by systematic manual point countPerforming stress corrosion cracking tests in a boiling magnesiumchlorideStandard test methods for pitting and crevice corrosion resistance ofstainless steels and related alloys by use of ferric chloride solutionValves- flanged, threaded, and welding endNon-destructive examinationManufacturers Standardization Society of the Valve and Fitting IndustryStandard — Quality Standard for Steel Castings for valves, flanges, andfittings and other components (visual method)

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SPECIFICATION FORDUPLEX STAINLESS STEEL AND

SUPER DUPLEX STAINLESSSTEEL

1510 zi ah ENGINEERS51. Et2eGlit INDIA LIMITED(A Govt ol moa unaeoakingi

STANDARD SPECIFICATION No.

6-79-0015 Rev. 1Page 5 of 12

NACE MR0175/ISO 15156Part 1:Part 3:NACE MR0103

NACE TM0177

SNT-TC-1A

Petroleum and natural gas industries-Materials for use in H2S-containingenvironments in oil and gas production:General principles for selection of cracking-resistant materialsCracking-resistant CRAs (corrosion-resistant alloys) and other alloysMaterial resistant to Sulfide Stress Cracking in corrosive petroleumrefining environmentsLaboratory testing of metals for resistance to sulfide stress cracking andstress corrosion cracking in H2 S environmentsPersonnel qualification and certification of nondestructive testingpersonnel, American Society for Nondestructive Testing (ASNT)

3.0 STEEL MANUFACTURE

3.1 The steel shall be manufactured / produced by the following or as specified in the applicablematerial specification:

3.1.1 The steel shall be made by one of the following primary steel making processes:

- electric arc furnace,- electric induction furnace.

3.1.2 The steel shall be subjected to tertiary steel refining treatments such as vacuum oxygendecarburization (VOD)/ argon oxygen decarburization (ACID), and vacuum arc degassing(VAD) to minimize dissolved gas contents, inclusions content and to meet the chemicalcomposition with close tolerances.

4.0 HEAT TREATMENT

4.1 Duplex Stainless Steel (DSS)

All the finished product forms shall be solution annealed by holding it at 1020-1100°Cfollowed by a fast cooling procedure. The duration of homogenizing treatment is dependent onthe product forms and thickness, but shall be not less than 20 minutes per 25 mm of thickness.For product thickness is less than or equal to 10 mm, forced air cooling shall be carried outwhile for thickness greater than 10 mm, water quenching shall be carried out. All hotworking/forging operations shall be carried out within a temperature range of 1020-1100°C.No hot working/forging operations shall take place at temperature less than 1020°C.

4.2 Super Duplex Stainless Steel (SDSS)

All the finished product forms shall be supplied in solution annealed condition. The productshall be homogenized at 1050-1120°C followed by a fast cooling procedure. The duration ofhomogenizing treatment is dependent on the product forms and thickness, but shall be not lessthan 20 minutes per 25 mm of thickness. For product thickness is less than or equal to 10 mm,forced air cooling shall be carried out while for thickness greater than 10 mm, waterquenching shall be carried out. All hot working/forging operations shall be carried out withina temperature range of 1050-1120°C. No hot working/forging operations shall take place attemperature less than 1050°C.

5.0 APPLICABLE REQUIREMENTS FOR DSS AND SDSS

5.1 Chemical Composition

Chemical composition of DSS and SDSS shall be as per Clause Nos. 5.1.1 and 5.1.2respectively.

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5g:zrr W.aG,ENGINEERSINDIA LIMITEDIA Govt of India Undettaongl

SPECIFICATION FOR STANDARD SPECIFICATION No.DUPLEX STAINLESS STEEL AND 6-79-0015 Rev. 1SUPER DUPLEX STAINLESS

STEEL Page 6 of 12

5.1.1 DSS

Element

Carbon (C)Manganese (Mn)Silicon (Si)Sulphur (S)Phosphorus (P)Chromium (Cr)Nickel (Ni)Molybdenum (Mo)Nitrogen (N)Copper (Cu)Tungsten (W)

5.1.2 SDSS

Wt%

0.03 (max.)2.0 (max.)1.0 (max.)0.02 (max.)0.03 (max.)21.00 - 23.004.50 - 6.502.5 - 3.500.15 - 0.200.50 (max.)0.50 (max.)

Element Wt%

Carbon (C)Manganese (Mn)Silicon (Si)Sulphur (S)Phosphorus (P)Chromium (Cr)Nickel (Ni)Molybdenum (Mo)Nitrogen (N)Copper (Cu)Tungsten (W)

0.03 (max.)1.0 (max.)1.0 (max.)0.2 (max.)0.3 (max.)24.0 - 27.06.0 - 8.03.5 - 4.50.20 - 0.350.75 (max.)1.00 (max.)

5.1.3 If any other elements are proposed to be added, such proposals shall be submitted to Companyfor specific written approval. Copper (Cu) and Tungsten (W) additions exceeding the limits asspecified above shall be acceptable, provided the weldability and freedom from undesirablemetallurgical constituents are ensured.

5.2 Pitting Resistance Equivalent Number (PREN)

5.2.1 PREN shall be calculated by the following formula:

PREN = % Cr + 3.3 x (%Mo) + 16x (% N)

5.2.2 PREN for DSS

The pitting resistance equivalent number of the duplex stainless steel materials shall be greaterthan 35, when calculated as mentioned in Clause No.5.2.1.

5.2.3 PREN for SDSS

The pitting resistance equivalent number of the super duplex stainless steel materials shall begreater than 40, when calculated as mentioned in Clause No. 5.2.1.

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STEEL Page 7 of 12

15irdzIellft ENGINEERSSg-Lit la2egiiiVINDIA LIMITED

EA Got of India Undertaking)

5.3 Microstructure

5.3.1 DSS

The duplex stainless steel shall have approximately equal proportions of austenite and ferritephases and the ferrite content shall be in the range of 40-55% in the austenite-ferrite matrix.

5.3.2 SDSS

For super duplex stainless steel, the ferrite content shall be in the range of 35-55% in theaustenite-ferrite matrix.

5.3.3 Ferrite content measurement for DSS and SDSS material shall be carried out for each heat bymetallography method in accordance with ASTM E 562.

In case ferrite-scope is expected to be used during fabrication/erection for the ferritemeasurement, then the testing at shop shall be carried out by the ferrite-scope also, and thecorrelation between the results from the two methods shall be established for future use.

5.3.4 For DSS and SDSS products, either in the as-supplied condition, solution annealed condition,or in the as welded condition, the microstructure shall not reveal the presence of any carbideor any intermetallic phases to the extent that are detrimental to the toughness and corrosionresistance of the material. The detection of the detrimental intermetallic phases in the wroughtproducts shall be carried out in accordance with ASTM A 923. The intermetallic phases shallnot be more than 1%.

S4 Mechanical Properties

5.4.1 DSS and SDSS

The material in the solution-annealed condition shall conform to the mechanical propertiessuch as ultimate tensile strength, 0.2% & 1% offset yield strength, % elongation, hardnessapplicable for the respective UNS No. of the material. The tensile test shall be carried out asper ASTM A 370.

The hardness test method shall be in accordance with ASTM E 18. If any other methodsincluding portable hardness tester are to be deployed for checking production welds, then thecorrelation between the qualification method and the production method shall be establishedand the calibration graph shall be generated for use at the field/shop.

5.4.2 Impact energy (Charpy V-notch) for DSS and SDSS

The impact test shall be carried out as per ASTM A 370.

Wrought materialsat 20°Cat -30°C

Cast materialsat 20°Cat -30°C

120 J (Average)/ 90 J (Minimum)100 J (Average)/ 75 J (Minimum)

75 J (Average)/ 55 J (Minimum)60 J (Average)/ 40 J (Minimum)

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ti at ENGINEERSazzlErAeglIVINDIA UMFIED

6.0 PRE-QUALIFICATION CRITERIA FOR MILL / MANUFACTURER

6.1 The DSS and SDSS material components shall be procured from a pre-qualified supplier. Thesupplier shall be qualified for specific TINS No. for which the mill was pre-qualified. Anychange in UNS No. shall require a fresh pre-qualification.

6.1.1 Pre-Qualification Criteria for Vendors with Prior Experience Track Record

Vendors/manufacturers who have proven track record of supplying DSS and SDSS materialsfor sour service and chloride containing environments in chemical process industries (CPI) toany of the reputed operating companies/Engineering Consultants or Process Licensors such asUOP, IFP, EXXON, BP, CHEVRON, IOCL, HPCL, BPCL, and EIL shall be considered as`pre-qualified vendors/manufacturers', on production of the relevant Purchase Orders and testcertificates, certified by a witnessing third party inspection agency such as DNV, Lloyds, BV,ABS, TUV, SGS, CEIL, and EIL for the conformance of the materials to the respectivematerials specification of the mentioned operators / engineering consultants. For pre-qualifiedvendors, Clause No.6.1.2 is not applicable.

6.1.2 Pre-Qualification Criteria for New Vendors without Track Record

A vendor who has no track record of supplying DSS and SDSS materials for sour service andchloride containing environments in chemical process industries (CPI) to any of the reputedengineering consultants/operators, as mentioned above in Clause No.6.1.1, shall be consideredas a new vendor. The chemical, the mechanical and all the corrosion tests shall be carried outas mentioned in Clause Nos. 5.0, 7.0 for pre-qualification by any one of the reputed third partyinspection agencies like Lloyds, BV, CEIL, DNV, TUV, and EIL.

6.2 The corrosion tests for DSS and SDSS in accordance with the Clause No. 7.0 shall beconducted for the pre-qualification of the manufacturers/mills.

6.3 All the tests reports including the corrosion tests shall be based upon the tests conducted onthe product specimen drawn from a single heat, and shall bear the same heat number.

6.4 In case the manufacture(s) had already conducted all the corrosion above tests on a product ofthe same material in the past, and has an approved quality assurance system in place, and thetest results are certified by a witnessing a third party inspection agency approved by theCompany, the test results shall be furnished by the bidder, along with his bid, for Company'sreview.

The manufacturer(s) shall be qualified based on the satisfactory review of the submitted testresults. The Company's decision in this regard shall be final and binding on the bidder.

While selecting and procuring the duplex stainless steel and super duplex stainless steelmaterials for a specific project, care shall be taken to use the same UNS No. for the entiresystem. Bidder shall note that, subsequent to qualification, a change in combination ofmill/manufacturer and UNS No. shall call for a fresh qualification exercise to be conducted.

6.5 Examination for DSS and SDSS Castings

6.5.1 Visual

All castings for valves, flanges, fittings and other components of DSS and SDSS shall bevisually examined in accordance with the quality levels mentioned in MSS-SP-55. Theprocedure for visual examination and the acceptance criteria shall be as per MSS-SP-55.

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SPECIFICATION FORDUPLEX STAINLESS STEEL AND

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151fraeg ifa ENGINEERS@.ti Ciir INDIA LIMITED

IA Gov't of India uneenatmg)

STANDARD SPECIFICATION No.

6-79-0015 Rev. 1Page 9 of 12

6.5.2 Radiography

Radiography examination shall be performed on all DSS and SDSS valve castings (inaccordance with ASME B16.34 with the acceptance criteria mentioned therein) and flanges,fittings and other components of DSS and SDSS in accordance with Article 2 of ASMESection V. The operator's certification to SNT-TC-1A or equivalent is required.

6.5.3 Penetrant Test

Wet fluorescent penetrant examination shall be performed on the exterior and accessibleinterior surfaces of all DSS and SDSS valve castings (in accordance with ASME B16.34 withthe acceptance criteria mentioned therein) and flanges, fittings and other components of DSSand SDSS in accordance with Article 6 of ASME Section V. The operator's certification toSNT-TC-1A or equivalent is required.

7.0 CORROSION TESTS FOR PRE-QUALIFICATION

7.1 Sulphide Stress Cracking (SSC) test as per Clause No. 7.2, Chloride Stress Cracking (CSC)test as per Clause No. 7.3, Pitting Corrosion test as per Clause No. 7.4, Crevice Corrosion testas per Clause No.7.5, are mandatory when DSS and SDSS steel materials are intended to beused for sour service and chloride containing environments.

If DSS and SDSS materials are intended to be used for chloride containing environments only,the SSC test as per Clause No.7.2 shall be waived off. The remaining corrosion tests specifiedin this section shall be carried out for DSS and SDSS materials meant for use in the chloridecontaining environments.

The corrosion tests applicable for DSS and SDSS materials shall be as furnished in thefollowing paragraphs:

7.2 Sulphide Stress Cracking (SSC) Test

7.2.1 DSS

SSC test on duplex stainless steel shall be carried out by using the following test solutions andtest conditions:

i) a) Test solutionTest temperatureStress value

d) Acceptance criteria

ii) a) Test solutionTest temperatureStress valuePartial pressure of H2SAcceptance criteria

7.2.2 SDSS

NACE TM017724° C350 N/mm2test sample failure at or after 720 hours.

NACE TM017790° C325 N/mm216 barstest sample failure at or after 720 hours.

The Sulphide Stress Corrosion Cracking tests on super duplex stainless steel shall be carriedout by using the following solutions and test conditions:

i) a) Test solutionTest temperatureStress value

d) Acceptance criteria

: NACE TM0177: 24° C: 425 N/mm2: test sample failure at or after 720 hours.

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SPECIFICATION FORDUPLEX STAINLESS STEEL AND

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el ENGINEERSs'Ig7 WesWe'S INDIA LIMITED(A Gait of India Untie/10mM

STANDARD SPECIFICATION No.

6-79-0015 Rev. 1Page 10 of 12

Test solutionTest temperatureStress valuePartial pressure of II2S

e) Acceptance criteria

: NACE TM0177: 90° C: 390 N/mm2: 16 bars: test sample failure at or after 720 hours.

7.3 Chloride Stress Cracking (CSC) Test

7.3.1 DSS and SDSS

The CSC tests shall be conducted on representative specimens of DSS and SDSS, inaccordance with the testing procedure mentioned in ASTM G-36, in aerated, boiling40% calcium chloride (CaCl 2) solution at 100°C with the pH of the solutionmaintained around 6.5.

Acceptance criteria: stress to cause rupture in 500 hours shall exceed 0.85 times theactual ultimate tensile strength values of duplex stainless steel and super duplexstainless steel material individually.

7.4 Pitting Corrosion Test

7.4.1 DSS

The pitting corrosion test shall be conducted on the representative DSS specimen, inaccordance with ASTM G-48 method A, using 6% ferric chloride (FeCI3 .6 H20) solutionby weight at 30°C, as well as at 50°C, for duration of 24 hours.

Acceptance criteria: no pitting shall occur on the surface of the test sample at 30°C. Forthe testing at 50°C, the weight loss shall be reported to company for review.

7.4.2 SDSS

The pitting corrosion test shall be conducted on the representative SDSS specimen, inaccordance with ASTM G-48 method A, using 6% ferric chloride (FeCI 3 .6 1420) solutionby weight at 40°C, as well as at 50°C, for duration of 24 hours.

Acceptance criteria: no pitting shall occur on the surface of the test sample at 40°C. Forthe testing at 50°C, the weight loss shall be reported to company for review.

7.5 Crevice Corrosion Test

7.5.1 DSS

The crevice corrosion test shall be performed on the representative DSS specimen, inaccordance with ASTM G-48 method B, using 6% ferric chloride (FeCI3 .6 H20) solutionby weight, at 25°C for duration of 24 hours.

Acceptance criteria: no crevice shall form on the surface of the test sample at 25°C.

7.5.2 SDSS

a) The crevice corrosion test shall be performed on the representative SDSS specimen, inaccordance with ASTM G-48 method B, using 6% ferric chloride (FeCI3 .6 F120) solutionby weight, at 30°C for duration of 24 hours.

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SPECIFICATION FORDUPLEX STAINLESS STEEL AND

SUPER DUPLEX STAINLESSSTEEL

0223E4a ENGINEERSa-9( laras W INDIA LIMITED

(A Govt of India Undetlaxingl

STANDARD SPECIFICATION No.

6-79-0015 Rev. 1Page 11 of 12

b) Acceptance criteria: no crevice shall form on the surface of the test sample at 30°C.

8.0 REQUIREMENTS FOR PRODUCTION TESTING

8.1 Test Samples

Separate test blanks shall be required for each process of manufacture of the finished products.Each test sample shall receive the same working / heat treatment as the finished products itrepresents.

If the test specimen cannot be taken from a finished product, then a representative testspecimen shall be taken from the same heat, heat treated in the same batch, and be subjected tothe same extent of working as the most worked section of the finished product. In case thefinished product is of welded type, then the test piece shall be so chosen as to include theparent metal, the weld metal and the heat affected zone.

8.2 Testing Frequency

The product analysis and the mechanical properties evaluation shall be conducted strictly asper requirements of the relevant material product specifications. Micro-structural examination,ferrite measurement and hardness testing on the finished product, shall be carried out for onesample per heat per method of manufacturer.

The test results shall be submitted to the Company as a part of the product documentation.

8.3 Mandatory Production Tests (First Heat)

On placement of order, a vendor who has met the pre-qualification criteria, shall carry out thefollowing production tests, to meet the acceptance criteria mentioned in the respective clauses.All the following tests shall be witnessed and certified by a reputed the third party InspectionAgency duly approved by the Company, on the first heat:

Chemical composition analysis as per Clause No.5.1Pitting Resistance Equivalent Number as per Clause No.5.2Microstructure examination and ferrite measurement as per Clause No.5.3Mechanical properties evaluation as per Clause No.5.4Visual examination on casting as per Clause No. 6.5.1Radiography examination for casting as per Clause No.6.5.2Wet fluorescent penetrant examination for casting as per Clause No.6.5.3.

8.4 Routine Tests

The routine testing of product of each heat shall be carried out on a regular basis, in house.The chemical composition, the pitting resistance equivalent number, the mechanicalproperties, the micro-structural examination and for casting, the visual examination, theradiography and the wet fluorescent penetrant examinations shall conform to the requirementsspecified in the respective Clauses of this specification.

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Page 139 of 193

SPECIFICATION FORDUPLEX STAINLESS STEEL AND

SUPER DUPLEX STAINLESSSTEEL

StilizaZleTa ENGINEERSstrantEgItaiev INDIA LIMITED

A GA1 of incha Aviel410.01

STANDARD SPECIFICATION No.

6-79-0015 Rev. 1Page 12 of 12

9.0 QUALITY SURVEILLANCE AND INSPECTION

The supplier shall perform all the tests and inspection procedures mentioned above to ensurethat the materials conform to the requirements of this specification. Company, or therepresentative duly approved by the Company, shall have unhindered access to the materialbeing manufactured for inspection and/or witnessing the selection of test samples, thepreparation of test specimens, and the performance of tests. The company or its representativeshall have the right to indicate the pieces from which the specimens are to be drawn forvarious tests. In case of any reasonable doubts regarding the quality of the product, Companyshall have the option to ask for the re-qualification of the mill at the vendor's/contractor's cost.Inspection by the Company or its authorized representative shall not relieve the supplier of hisresponsibility for ensuring the compliance of the materials supplied to this specification.

10.0 DOCUMENTS TO BE SUBMITTED

The vendors/suppliers shall submit the following records of the tests and inspection conductedon the materials, as per the applicable Clauses mentioned in this specification, to the companyin quadruplicate:

Chemical composition analysis reportHeat treatment records and chartsMicro-structure examination and ferrite measurement reportsMechanical properties evaluation reportsCorrosion testing results (Pre-qualification records)Visual examination report for castingsRadiography examination report for castingsPenetrant test report for castings.

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Page 140 of 193

4.5iIlatie4ifft ENGINEERSa' itirds-W7 INDIA UMITED

SPECIFICATION FOR WELDING STANDARD SPECIFICATION No.OF DUPLEX STAINLESS STEEL 6-79-0016 Rev. 1AND SUPER DUPLEX STAINLESS

STEEL Page 1 of 11

TATE chi ck tfil t'1Ic1

.n1W-fi 43141 tril Will V.feTbr

SPECIFICATION FORWELDING OF

DUPLEX STAINLESS STEELAND

SUPER DUPLEX STAINLESS STEEL

3 14.-3G41

1 07.10.11 REVISED & REISSUED AS STANDARDSPECIFICATION PC SG PPL DM

0 28.12.04 ISSUED AS STANDARD SPECIFICATION SG VRK KKM SKG

Rev.No Date Purpose Prepared Checked

by by

Standards StandardsCommittee BureauConvenor Chairman

Approved by

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 141 of 193

SPECIFICATION FOR WELDING STANDARD SPECIFICATION No.aleat ENGINEERS OF DUPLEX STAINLESS STEEL5, gar fa5legilitiO INDIA LIMITED 6 -79 -0016 Rev. 1,..,,wri,..mny ,A Gort of India Undetta NI AND SUPER DUPLEX STAINLESS

STEEL Page 2 of 11

Abbreviations:

ABS : American Bureau of ShippingASME : American Society of Mechanical EngineersASTM : American Society for Testing and MaterialsBV : Bureau VeritasCEIL : Certification Engineers International LimitedCPI : Chemical Process IndustryCSC : Chloride Stress CrackingDNV : Det Norske VeritasDSS : Duplex Stainless SteelHAZ : Heat Affected ZoneISO : International Organization for StandardizationNACE : National Association of Corrosion EngineersPQT : Procedure Qualification TestsPREN : Pitting Resistance Equivalent NumberPWHT : Post Weld Heat TreatmentSDSS : Super Duplex Stainless SteelSSC : Sulphide Stress Cracking

SMMS Standards Committee:

Convener: Mr. PP Lahiri

Members: Mr. A AminMr. GS HegdeMr. R ChaudhuryMr. S GhosalMr. P SahaMr. R Nanda (Piping)Mr. AK Gupta (HMTD)Mr. S Mukherjee (Construction)Mr. R Muthulingam (Inspection)Mr. Raj Kishore (Pipeline)Mr. AR Purushottam (POSD)Mr. MP Jain (Projects)

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SPECIFICATION FOR WELDING STANDARD SPECIFICATION No.OF DUPLEX STAINLESS STEEL 6-79-0016 Rev. 1AND SUPER DUPLEX STAINLESS

STEEL Page 3 of 11

oaraelei oft ENGINEERSslg-ar fameg w INDIA LIMITED

(Inne'airs'-""" ,A GOA of (nth undertaking)

CONTENTS

1.0 SCOPE 4

2.0 CODES AND STANDARDS 4

3.0 WELDING PROCESSES 4

4.0 WELDING CONSUMABLES 5

5.0 APPLICABLE REQUIREMENTS FOR DSS AND SDSS WELDING CONSUMABLES 5

6.0 CLEANING 6

7.0 QUALIFICATION CRITERIA 6

8.0 CORROSION TESTS FOR QUALIFICATION 9

9.0 FABRICATION 11

10.0 QUALITY SURVEILLANCE AND INSPECTION 11

11.0 DOCUMENTS TO BE SUBMITTED 11

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Sti12-a-e75ta■LT

ENGINEERSSPECIFICATION FOR WELDING STANDARD SPECIFICATION No.OF DUPLEX STAINLESS STEEL

AND SUPER DUPLEX STAINLESSSTEEL

INDIA LIMITEDIA Go./ Inda Undertaking'

6-79-0016 Rev. 1Page 4 of 11

1.0 SCOPE

1.1 This specification covers the requirements for the welding processes, the quality of thewelding consumables, the welding consumable qualification, the welding procedurequalification, the welder qualification and the quality assurance testing during fabrication ofDSS and SDSS components. DSS and SDSS welding consumables shall be consideredacceptable when they meet the qualification criteria mentioned in this specification. Thisspecification shall be applicable for both shop fabricated and field/site fabricated components.

1.2 This specification shall be read together with the corresponding product specifications,mentioned in the relevant piping material specifications, and/or the equipment datasheets/design drawings, intended to be used in sour and/or chloride containing environments,as applicable.

1.3 In case of conflict between this specification and the referred material codes/standardspecifications, the requirement of this specification shall govern.

2.0 CODES AND STANDARDS

The manufacture, inspection, testing, marking and supply of the item covered by thisspecification shall follow the latest editions of the following codes and standard specifications:

Standard methods and definitions for mechanical testing of steelStandard test methods for detecting detrimental intermetallic phase inwrought duplex austenitic/ferritic stainless steelsRockwell hardness testing of metallic materialsDetermining volume fraction by systematic manual point countPerforming stress corrosion cracking tests in a boiling magnesiumchlorideStandard test methods for pitting and crevice corrosion resistance ofstainless steels and related alloys by use of ferric chloride solutionMaterial specifications — Welding rods, Electrodes and Filler metals

Non-destructive examinationRules for construction of pressure vessels

Welding and Brazing qualificationsPetroleum and natural gas industries-Materials for use inH2S-containing environments in oil and gas production:General principles for selection of cracking-resistant materialsCracking-resistant CRAs (corrosion-resistant alloys) and other alloysMaterial resistant to Sulfide Stress Cracking in corrosive petroleumrefining environmentsLaboratory testing of metals for resistance to sulfide stress cracking andstress corrosion cracking in H2S environmentsPersonnel qualification and certification of nondestructive testingpersonnel, American Society for Nondestructive Testing (ASNT)

ASTM A 370ASTM A 923

ASTM E 18ASTM E 562ASTM G 36

ASTM G 48

ASME Section II-Part CASME Section VASME Sec.VIII-Division 1ASME Section IXNACE MR0175/ISO 15156-Part 1:Part 3:NACE MR0103

NACE TM0177

SNT-TC-1A

3.0 WELDING PROCESSES

Shielded metal arc welding (SMAW), Gas tungsten arc welding (GTAW), Gas metal arcwelding (GMAW), Submerged arc welding (SAW) and Plasma arc welding (PAW) processesare suitable for duplex and super duplex stainless steel. All necessary operational precautionssuch as cleanliness, protective inert gas shielding applicable for DSS and SDSS shall beadopted while employing these welding processes.

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PRzIe?ifit ENGINEERS5.1g:a telfalesS' INDIA LIMITED

(A Gort cola unactakingi

SPECIFICATION FOR WELDING STANDARD SPECIFICATION No.OF DUPLEX STAINLESS STEEL 6-79-0016 Rev. 1AND SUPER DUPLEX STAINLESS

STEEL Page 5 of 11

4.0 WELDING CONSUMABLES

The welding consumables for welding duplex stainless steels of UNS No.(s) S 31803, S 32205or equivalent and for welding super duplex stainless steel of UNS No.(s) S 32760,S 32750,S39274, S 32550, J 93380 or equivalent shall conform to the recommendations made by theDSS and SDSS base metal manufacturers. The welding consumables shall be used only afterconducting the requisite consumable qualifications tests as given in Clause No. 7.0.

5.0 APPLICABLE REQUIREMENTS FOR DSS AND SDSS WELDING CONSUMABLES

5.1 Chemical Composition

The chemical composition of the DSS and SDSS welding consumables shall be adjusted withrespect to austenite formers such as nickel and ferrite formers such as molybdenum, in orderto obtain the requisite ferrite-austenite balance and the corrosion resistance properties in theas-welded condition of the weldment. The specific chemical composition of as-welded depositshall be as recommended by the DSS and SDSS base metal manufacturers.

5.2 Pitting Resistance Equivalent Number (PREN)

5.2.1 PREN shall be calculated by the following formula:

PREN = % Cr + 3.3 x (%Mo) + 16x (% N)

5.2.2 PREN for DSS

The pitting resistance equivalent number of the DSS welding consumables shall be greaterthan 35, when calculated as mentioned in Clause No.5.2.1.

5.2.3 PREN for SDSS

The pitting resistance equivalent number of the SDSS welding consumables shall be greaterthan 40, when calculated as mentioned in Clause No. 5.2.1.

5.3 Microstructure

The ferrite content of the weld metal estimated through metallography examination should bebetween 30 to 55% to obtain weld joints with the best ductility and corrosion resistanceproperties. The welding consumables composition and the welding heat input should be soselected as to give the ferrite content of the weld metal between 30 and 55%. Ferrite contentmeasurement shall be carried out by the metallography method in accordance with ASTM E562.

5.4 Mechanical Properties

5.4.1 DSSTensile Strength 680-880 N/mm2Yield Strength (0.2% Offset) 450 N/mm2 (Min.)Elongation 25% (Min)

Impact Energy (Charpy V-notch)

at 20° C 100 J Average/ 75 J Minimumat -30° C 60 J Average/ 40 J Minimum

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SPECIFICATION FOR WELDING STANDARD SPECIFICATION No.OF DUPLEX STAINLESS STEEL 6-79-0016 Rev. 1AND SUPER DUPLEX STAINLESS

STEEL Page 6 of 11

15rairege ENGINEERS511g-ien titgleg IS INDIA UMITED

Goa of Irdia Underlalong)

5.4.2 SDSSTensile Strength 800-1050 N/mm2Yield Strength (0.2% Offset) 550 N/mm2Yield Strength (1% Offset) 650 N/mm2Elongation 25% minimum

Impact Energy (Charpy V-notch)

at 20° C 100 J Average/ 75 J Minimumat -30° C 60 J Average/ 40 J Minimum

6.0 CLEANING

6.1 Cleaning of weld joints before and after the welding shall follow the good engineeringpractices applicable for stainless steels. All accessible weld surfaces shall be cleaned afterwelding by using pickling paste or pickling agent recommended by the welding consumablesuppliers, for a minimum period of 20 minutes, followed by water washing. This process shallremove all oxide, tarnish, heat tint and surface contamination.

In the case of tube-to-tube sheet joints of the exchanger, extra care shall be taken tocompletely remove the traces of the pickling paste or agent to maintain weld quality.Wherever completely removal of pickling paste or agent cannot be ensured, such as air coolerwith plug type headers, pickling shall not be carried out.

Where access for cleanings not practicable, such as pipe butt welds, reliance must be placedon good purging practice to minimize contamination of the backing gas by air. The purge gasmust contain below 10-ppm oxygen or moisture to achieve maximum corrosion resistance ofwelds.

6.2 The area where DSS and SDSS fabrications are carried out shall be separated from carbon andlow-alloy steel fabrication area.

7.0 QUALIFICATION CRITERIA

7.1 Welding Consumable Qualification (One-Time Qualification)

Each classification of the DSS and SDSS welding consumables, used for welding procedurequalification, welder qualification as well as for production welds, shall be procured fromqualified welding consumable manufacturers.

7.1.1 Qualification Criteria for Vendors/Manufacturers with Prior Experience Track Record

Vendors/manufacturers who have proven track record of supplying DSS and SDSS weldingconsumables for sour service and chloride containing environments in chemical processindustries (CPI) to any of the reputed operating companies/Engineering Consultants orProcess Licensors such as UOP, IFP, EXXON, BP, CHEVRON, IOCL, HPCL, BPCL, andEIL shall be considered as qualified vendors/manufacturers', on production of the relevantpurchase orders and test certificates, certified by a witnessing third party inspection agencysuch as DNV, Lloyds, BV, ABS, TUV, SGS, CELL, and EIL for the conformance of thematerials to the respective materials specification of the mentioned operators/engineeringconsultants. For qualified vendors / manufacturers, Clause No.7.1.2 is not applicable.

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SPECIFICATION FOR WELDING STANDARD SPECIFICATION No.OF DUPLEX STAINLESS STEEL 6-79-0016 Rev. 1AND SUPER DUPLEX STAINLESS

STEEL Page 7 of 11

ISIIRZRY:flat ENGINEF_RS2-ar EVeg W INDIA UMITED

Gorl of India undensiong)

7.1.2 Qualification Criteria for New Vendors/Manufacturers without Track Record

A vendor/manufacturer who has no track record of supplying DSS and SDSS weldingconsumables for sour service and chloride containing environments in chemical processindustries (CPI) to any of the reputed engineering consultants/operators, as mentioned abovein Clause No.7.1.1, shall be considered as a new vendor/manufacturer. The chemical, themechanical and all the corrosion tests shall be carried out as mentioned in Clause Nos. 5.0, 8.0for qualification by any one of the reputed third party inspection agencies like Lloyds, BV,CEIL, DNV, TUV, and EIL.

Sulphide Stress Cracking (SSC) test as per Clause No. 8.1, Chloride Stress Cracking (CSC)test as per Clause No. 8.2, Pitting Corrosion test as per Clause No. 8.3 and Crevice Corrosiontest as per Clause No.8.4, are mandatory for DSS and SDSS welding consumables.

In case the vendors/manufacture(s) had already conducted all the corrosion tests in the past,and has an approved quality assurance system in place, and the test results are certified by awitnessing a third party inspection agency such as DNV, Lloyds, BV, ABS, TUV, SGS, CEIL,and EIL, the test results shall be furnished by the bidder, along with his bid, for Company'sreview.

The vendors/manufacturers shall be qualified based on the satisfactory review of the submittedtest results. The Company's decision in this regard shall be final and binding on the bidder.

7.2 Welding Procedure Qualification

7.2.1 General

7.2.1.1 Each particular welding procedure shall be specially qualified. Previous test reports shall notbe recognized as a qualification record for the work to be performed on a new job.

7.2.1.2 Welding consumable qualification tests and welding procedure qualification tests shall beconducted before the start of fabrication, by employing an approved welding procedure inpresence of the Company third party inspection agency such as DNV, Lloyds, BV, ABS,TUV, SGS, CEIL, and EIL.

7.2.1.3 All the mills supplying the raw material/pipes etc. shall be required to pass the tests requiredfor the procedure qualification testing. Approved procedure shall be common to all the mills.

7.2.1.4 In case a combination of different UNS No. has to be used, due to unavoidable reasons, eachcombination shall be specifically subjected to welding procedure qualification testingincluding all the corrosion tests.

7.2.1.5 Laboratory tests shall be performed at an acceptable reputed laboratory.

7.2.2 Test Samples

Procedure qualification tests shall be performed on welded test pieces that include the parentmetal, heat affected zone and the weld metal.

7.2.3 Procedure Qualification Tests (PQT)

PQT shall be carried out as given below:

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SPECIFICATION FOR WELDINGOF DUPLEX STAINLESS STEEL

AND SUPER DUPLEX STAINLESSSTEEL

46111Retit et ENGINEERS51g9- Ralegre INDIA UMITED

eli-i-n-11 a coN al Oda unaciaingl

STANDARD SPECIFICATION No.

6-79-0016 Rev. 1Page 8 of 11

7.2.3.1 Chemical Composition and Microstructure Examination

The chemical composition analyzed shall conform to the claimed composition mentioned inthe technical brochures of the welding consumable manufacturers approved by the Companyprior to qualification.

The ferrite content measurement of test pieces shall be carried out by both of the followingmethod:

Metallography examinationMagna-gage method/Ferrite Scope

The procedure of ferrite measurement and the calibration of measuring instruments shall bearthe approval of the Company before being employed. Ferrite content measurement shall becarried out by the metallography method in accordance with ASTM E 562. Acceptance levelshall be as per Clause No.5.3.

The weld metal of DSS and SDSS shall be checked by the method in accordance with ASTMA 923, for the presence of intermetallic phases that are detrimental to the weld metal. Theintermetallic phases shall not be more than 1%.

7.2.3.2 Mechanical Properties

These tests shall include tensile testing, impact testing and bend testing, in accordance withASTM A 370. Bend tests shall be performed with a plunger diameter equal to 4 times thethickness. The acceptance values for tensile and impact testing shall be as per Clause Nos.5.4.1 and 5.4.2. In case of bend testing, the specimen shall not reveal any crack or fissure.

7.2.3.3 Hardness Tests

Each qualification test shall include a cross-sectional hardness survey. The test method shallbe in accordance with ASTM E 18. The distance between indentations shall be a maximum of1.0 mm. The hardness values shall not exceed RC 28 for DSS and RC 32 for SDSS.

If any other methods including portable hardness tester are to be deployed for checkingproduction welds, then the correlation between the qualification method and the productionmethod shall be established and the calibration graph shall be generated for use at thefield/shop. The acceptance criteria shall be as per Rockwell 'C' scale.

7.2.3.4 Corrosion Tests for weldments

Sulphide Stress Cracking (SSC) test as per Clause No. 8.1, Chloride Stress Cracking (CSC)test as per Clause No. 8.2, Pitting Corrosion test as per Clause No. 8.3, Crevice Corrosion testas per Clause No.8.4, are mandatory when DSS and SDSS weldments are intended to be usedfor sour service and chloride containing environments.

If DSS and SDSS weldments are intended to be used only for chloride containingenvironments, the SSC test as per Clause No.8.1 shall be waived off. The remaining corrosiontests specified in this section shall be carried out for DSS and SDSS weldments meant for usein the chloride containing environments.

7.2.3.5 Radiography

All welds shall be 100% radiographed. The radiography procedure shall be followed as perASME Section V. Acceptance standard shall be as per ASME. Section-VIII, Division-1, UW-51. The operator's certification to SNT-TC-1A or equivalent is required.

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SPECIFICATION FOR WELDING STANDARD SPECIFICATION No.OF DUPLEX STAINLESS STEEL 6-79-0016 Rev. 1AND SUPER DUPLEX STAINLESS

STEEL Page 9 of 11

IsirEzrda ENGINEERS5@zir lalaregWINDIA LIMITED

IA Govt of India Undertaking)

7.2.3.6 Penetrant Test (PT) And Magnetic Particle Test (MPT)

All fillet and groove welds other than those to be examined by radiography shall be tested byfluorescent penetrant test or by fluorescent magnetic particle test. No defect indication shallbe accepted. The procedures for penetrant tests and magnetic particle tests shall be followed asper ASME Section V. The operator's certification to SNT-TC-IA or equivalent shall beensured.

7.2.3.7 Post Weld Heat Treatment (If Required)

For DSS and SDSS, no post weld heat treatment is envisaged or recommended. In case,autogenous welding is adopted or if the process licensor or the client recommends a PWHT,then the only PWHT shall be solution annealing. The solution annealing heat treatmentprocedures shall be established for ensuring retention of the properties of the welded joints forDSS and SDSS materials. The heat treatment procedures shall be approved by the Company'srepresentative before their implementation.

7.3 Welder Qualification

Welders shall be qualified at the fabrication yard/barge employing the qualified weldingprocedure. The qualification test pieces of each welder shall be subjected to microstructureexamination, mechanical tests, cross sectional hardness survey, radiography examination,fluorescent penetrant and fluorescent magnetic particle tests, and with the same test procedureand acceptance criteria as mentioned above in Clause Nos. 7.2.3.1, 7.2.3.2, 7.2.3.3, 7.2.3.5,7.2.3.6 respectively.

8.0 CORROSION TESTS FOR QUALIFICATION

8.1 Sulphide Stress Cracking (SSC) Test

DSS

SSC test on duplex stainless steel shall be carried out by using the following test solutions andtest conditions:

i) a) Test solutionTest temperatureStress value

d) Acceptance criteria

ii) a) Test solutionTest temperatureStress valuePartial pressure of H2SAcceptance criteria

SDSS

: NACE TM0177: 24°C: 350 N/mm2: test sample failure at or after 720 hours.

: NACE TM0177: 90° C: 325 N/mm2: 16 bars: test sample failure at or after 720 hours.

The Sulphide Stress Corrosion Cracking tests on super duplex stainless steel shall be carriedout by using the following solutions and test conditions:

i) a) Test solutionTest temperatureStress value

d) Acceptance criteria

: NACE TM0177: 24° C: 425 N/mm2: test sample failure at or after 720 hours.

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SPECIFICATION FOR WELDING STANDARD SPECIFICATION No.OF DUPLEX STAINLESS STEEL 6-79-0016 Rev. 1AND SUPER DUPLEX STAINLESS

STEEL

ISIMZIel ENGINEERS5fg:ar INDIA LIMITED

Go. aI kid. Und.na.nalPage 10 of 11

ii) a) Test solution : NACE TM0177Test temperature : 90° CStress value : 390 N/mm2Partial pressure of H 2 S : 16 barsAcceptance criteria : test sample failure at or after 720 hours.

8.2 Chloride Stress Cracking (CSC) Test

DSS and SDSS

The CSC tests shall be conducted on representative specimens of DSS and SDSS, inaccordance with the testing procedure mentioned in ASTM G-36, in aerated, boiling 40%calcium chloride (CaCl 2) solution at 100° C with the pH of the solution maintainedaround 6.5.

Acceptance criteria: Stress to cause rupture in 500 hours shall exceed 0.85 times theactual ultimate tensile strength values of duplex stainless steel and super duplex stainlesssteel material individually.

8.3 Pitting Corrosion Test

DSS

The pitting corrosion test shall be conducted on the representative DSS specimen, inaccordance with ASTM G-48 method A, using 6% ferric chloride (FeCI3 .6 H20) solutionby weight at 30°C, as well as at 50°C, for duration of 24 hours.

Acceptance criteria: No pitting shall occur on the surface of the test sample at 30°C. Forthe testing at 50°C, the weight loss shall be reported to company for review.

SDSS

The pitting corrosion test shall be conducted on the representative SDSS specimen, inaccordance with ASTM G-48 method A, using 6% ferric chloride (FeCI 3 .6 I-120) solutionby weight at 40°C, as well as at 50°C, for duration of 24 hours.

Acceptance criteria: No pitting shall occur on the surface of the test sample at 40°C. Forthe testing at 50°C, the weight loss shall be reported to company for review.

8.4 Crevice Corrosion Test

DSS

The crevice corrosion test shall be performed on the representative DSS specimen, inaccordance with ASTM G-48 method B, using 6% ferric chloride (FeCI 3 .6 H20) solutionby weight, at 25°C for duration of 24 hours.

Acceptance criteria: No crevice shall form on the surface of the test sample at 25°C.

SDSS

The crevice corrosion test shall be performed on the representative SDSS specimen, inaccordance with ASTM G-48 method B, using 6% ferric chloride (FeCI 3 .6 H20) solutionby weight, at 30°C for duration of 24 hours.

Acceptance criteria: No crevice shall form on the surface of the test sample at 30°C.

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5'1411E1.151:e7ENGINEERSINDIA LIMITEDIA Gov? of Inch, Undertaking)

SPECIFICATION FOR WELDING STANDARD SPECIFICATION No.OF DUPLEX STAINLESS STEEL 6-79-0016 Rev. 1

AND SUPER DUPLEX STAINLESSSTEEL Page 11 of 11

9.0 FABRICATION

9.1 No fabrication shall start until the Company approves the results of the welding consumablequalification, the welding procedure qualification tests and the welder qualification tests as perthe approved procedure.

9.2 Quality Assurance Tests on Production Welds

As a part of quality assurance, field/shop fabricated weldments shall be subjected to thefollowing tests, as per the applicable Clauses mentioned in this specification:

Hardness test as per Clause No. 7.2.3.3Radiography as per Clause No. 7.2.3.5PT /MPT tests as per Clause no. 7.2.3.6Ferrite Measurement as per Clause No. 7.2.3.1.

9.3 The weld joints not conforming to the specification requirements with respect to the results ofabove tests, shall be cut out to make fresh joints. The reasons for such a breakdown in qualityassurance system shall be investigated and the report shall be submitted to the Company forreview.

10.0 QUALITY SURVEILLANCE AND INSPECTION

The vendors/suppliers shall perform all the tests and inspection procedures mentioned aboveto ensure that the welding consumables, the procedure and the fabrication conform to therequirements of this specification. Company, or the representative duly approved by theCompany, shall have unhindered access for inspection and/or witnessing the selection of testsamples, the preparation of test specimens, and the performance of tests. The company or itsrepresentative shall have the right to indicate the pieces from which the specimens are to bedrawn for various tests. In case of any reasonable doubts regarding the quality of the product,Company shall have the option to ask for a re-qualification, at the vendor's/contractor's cost.Inspection by the Company or its authorized representative shall not relieve the supplier of hisresponsibility for ensuring the compliance of the materials supplied to this specification.

11.0 DOCUMENTS TO BE SUBMITTED

The vendors/suppliers shall submit the following records of the tests and inspection conductedon the materials, as per the applicable Clauses mentioned in this specification, to the companyin quadruplicate:

Chemical composition analysis report- Heat treatment records and charts

Micro-structure examination and ferrite measurement reportsMechanical properties evaluation reportsCorrosion testing results (qualification records)Radiography examination reportPenetrant test reportMagnetic Particle test report.

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151fRiseAstigat efaleg

ENGINEERSINI NA LIMITED/A “nul Ina. Lnden.,),

STANDARD SPECIFICATIONFOR POSITIVE MATERIALIDENTIFICATION (PMI) AT

SUPPLIER'S WORKS

STANDARD SPECIFICATION No.

6 -81 -0001 Rev. 2Page I of 8

c 1T covingii 4,flcomoict) TIPTth LI 111

f'6g itta-vr

STANDARD SPECIFICATION

FORPOSITIVE MATERIAL

IDENTIFICATION(PMI)

AT SUPPLIER'S WORKS

40D., 15,

2 20.10.11 REVISED AND RE-ISSUED AKC DM

1 15.07.08 REVISED AND RE-ISSUED NKR SSL SKP VC

0 07.12.00 ISSUED AS STANDARD SPECIFICATION AKC AKB AKB MI

Standards StandardsRev.No Date Purpose Prepared

byChecked

byCommitteeConvenor

BureauChairman

Approved by

Formal No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 152 of 193

151M-ae? le. ' ENGINEERSimegver INDIA LIMITEDyin eRaWanJelwill Govl of India Undertakno

STANDARD SPECIFICATIONFOR POSITIVE MATERIALIDENTIFICATION (PM I) AT

SUPPLIER'S WORKS

STANDARD SPECIFICATION No.6-81-0001 Rev. 2

Page 2 of 8

Abbreviations:

API American Petroleum InstituteAS Alloy SteelLSTK Lump Sum Turn KeyPMI Positive Material IdentificationSch ScheduleSS Stainless SteelTPI or TPIA Third Party Inspection Agency

Inspection Standards Committee

Convenor: Mr.AK Chaudhary

Members: Mr. SS LotayMr. SC GuptaMr. RK SinghMr. Rajeev KumarMr. Anoop GoelMr. G SureshMr. G Poornachandra RaoMr. MP Jain (Projects)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 153 of 193

STANDARD SPECIFICATIONFOR POSITIVE MATERIALIDENTIFICATION (PMI) AT

SUPPLIER'S WORKS

151M4-e?fte ENGINEERSOgrir tfigtegW INDIA LIMITED

Gorl of India undertaking}

STANDARD SPECIFICATION No.

6-81-0001 Rev. 2Page 3 of 8

CONTENTS

1.0 SCOPE 4

2.0 REFERENCE DOCUMENTS 4

3.0 DEFINITIONS 4

4.0 PMI EXAMINATION 5

5.0 ACCEPTABLE METHODS FOR PMI 5

6.0 EXTENT OF PMI EXAMINATION 6

7.0 RECORDING AND DOCUMENTATION 7

8.0 MARKING 7

Copyright EIL —All rights reservedFormat No. 8-00-0001-F1 Rev. 0Page 154 of 193

STANDARD SPECIFICATIONFOR POSITIVE MATERIALIDENTIFICATION (PMT) AT

SUPPLIER'S WORKS

/ft ENCJNEERSbeire,altateg '-‘60- 1 INDIA LIMITED

STANDARD SPECIFICATION No.

6-81-0001 Rev. 2Page 4 of 8

1.0 SCOPE

1.1 This specification applies to the requirements for Positive Material Identification (PMI) to beperformed at the Supplier's works on Metallic Materials procured either directly by theOwner/EIL/ LSTK contractor or indirectly through the sub-Suppliers.

1.2 Any post order deviation from this specification must be approved by Owner/EIL in theDeviation/ Waiver Permit format (No. 5-0000-0180-F1) enclosed with Material Requisition.

1.3 This specification covers the procedures and methodology to be adopted to assure that thechemical composition of the material is consistent with the material specifications as specifiedin purchase documents using 'Alloy Analyzer' at the time of final inspection before dispatch.

1.4 The scope of this specification shall include but shall not be limited to Positive MaterialIdentification (PMI) to be performed on Materials listed below:

1.4.1 For alloy Steel materials as below:Alloy Steel Pipes including Clad PipesAlloy Steel Flanges & ForgingsAlloy Steel Fittings including Clad FittingsAlloy Steel FastenersAlloy Cast & Forged steel valvesAlloy Steel Instrumentation Items (Control Valves, Safety Valves etc.)Longitudinal Pipe & Fittings Welds.Gaskets (for Ring Type Joints)

1.4.2 For Carbon Steel materials as below:All Carbon Steel Piping items under NACE or HIC or H2Carbon Steel flanges and valves (Rating 900# and above)Carbon Steel Pipes & fittings for following thicknesses:Size 1"- 2" NB : Sch 160 & aboveSize 3" NB : Sch XS & aboveSize 4" - 12" NB : Sch 120 & above

Following items shall be excluded from scope of PMI examination.

Gaskets other than for Ring Type JointsInternal Components of Valves

1.5 All grades of material supplies including Stainless Steels shall be liable for PMI test at site. Incase of any defective materials being found at site, the Supplier shall be responsible to effectreplacement of such defective materials at project site without any delays to the satisfaction ofEIL site RCM (Resident Construction Manager).

2.0 REFERENCE DOCUMENTS

2.1 API Recommended Practice 578 (First Edition, May 1999) - Material Verification Program forNew and Existing Alloy Piping Systems.

3.0 DEFINITIONS

3.1 Supplier: Any Supplier or Manufacturer on whom an order is placed for the supply of referreditems. This definition shall also include any sub-Supplier or manufacturer on whom a sub-orderis placed by the Supplier.

Copyright EIL — All rights reservedFormat No. 8-00-0001-F1 Rev. 0

Page 155 of 193

STANDARD SPECIFICATIONFOR POSITIVE MATERIALIDENTIFICATION (PM I) AT

SUPPLIER'S WORKS

SaIRCIELM—; ENGINEERSPar taiReZ VW INDIA LIMITED

STANDARD SPECIFICATION No.

6-81-0001 Rev. 2Page 5 of 8

3.2 Inspection Lot: A group of items offered for inspection covered under same size, Heat andHeat treatment lot.

3.3 Alloy Material: Any metallic material (including welding filler materials) that containsalloying elements such as chromium, nickel, molybdenum or vanadium, which are intentionallyadded to enhance mechanical or physical properties and/or corrosion resistance.

4.0 PMI EXAMINATION

4.1 The Supplier shall submit a procedure of PMI to comply with the requirements of thisSpecification Approval of PMI Procedure shall be obtained from Owner/EIL/TPIA prior tocommencing manufacture/ inspection of product.

4.2 PMI examination of materials is independent of any certification, markings or colour codingthat may exist and is aimed at verifying that the alloy used are as per specified grades.

4.3 The Supplier shall identify all incoming alloy materials and maintain full traceability of all alloymaterials, including all off-cuts. Transfer of identification marks shall be undertaken prior tocutting to ensure maintenance of identification on off-cuts.

4.4 The Supplier shall ensure that all alloy materials are segregated and stored in separatelyidentified locations to prevent the mix up of materials of different alloy specifications or alloymaterial with carbon steel. Non ferro-magnetic materials shall be segregated at all times fromferro-magnetic materials.

4.5 PMI examination is subject to surveillance inspection by Owner/EIL/TPIA.

5.0 ACCEPTABLE METHODS FOR PMI

5.1 The method used for PMI examination shall provide a quantitative determination of the alloyingelements like chromium, nickel, molybdenum or vanadium in Alloy Steel items.

5.2 Instruments or methods used for PMI examination shall be able to provide quantitative,recordable, elemental composition results for positive identification of alloying elementspresent.

5.3 The acceptable instruments for alloy analyzer shall be either "Portable X-Ray fluorescence" or"Optical Emission" type each capable of verifying the percentage of alloy elements withinspecified range.

5.4 Chemical spot testing, magnets, alloy sorters and other methods using eddy current ortriboelectric testing methods are not acceptable for PMI examination.

5.5 The PMI instrument used shall have the sensitivity to detect the alloying elements in thespecified range.

5.6 All PMI instruments shall have been serviced within a 6 month period of the time of use toverify the suitability of batteries, sources etc., and the data of the last service shall be stated onthe PMI Report Form (Sample enclosed).

5.7 Each analyzer must be calibrated according to the manufacturer's specification at the beginningand end of each shift. Instrument must be checked against known standard for each alloy typeto be inspected during the shift.

Copyright EIL — All rights reservedFormat No. 8-00-0001-F1 Rev. 0

Page 156 of 193

STANDARD SPECIFICATIONFOR POSITIVE MATERIALIDENTIFICATION (PMI) AT

SUPPLIER'S WORKS

ISillaZreqe ENGINEERSs'Ig7e2eg W INDIA UMITED

Govt a Inaa Undenakingi

STANDARD SPECIFICATION No.

6-81-0001 Rev. 2Page 6 of 8

5.8 Certified samples, with full traceability, of a known alloy materials shall be available for use asa random spot check on the instrument calibration.

5.9 The surfaces to be examined shall be prepared by light grinding or abrasive paper and solventcleaner. Evidence of Arc burn resulting from examination shall be removed by light grinding orabrasive paper. No permanent marks, which are injurious to the usage of product in service, areacceptable.

5.10 Alloy Steel ring type joint Gaskets shall be inspected by using portable X-Ray fluorescenceinstrument.

5.11 Testing shall be done as per the procedures outlined by the manufactures of alloy analyzerbeing used. Modification of these procedures if any must be approved by Owner/EIL.

5.12 The persons performing PMI shall demonstrate their capabilities to the satisfaction ofOwner/EIL/TPIA visiting engineer. If the Supplier has qualified operator on their rolls, he mayperform the examination. Otherwise PMI examination shall be sub-contracted to an independenttesting agency approved by EIL.

5.13 Whenever material is identified as not meeting requirements by the visiting engineer a rejectionnote shall be issued.

6.0 EXTENT OF PMI EXAMINATION

Following sampling plans shall be applicable for PMI examination of various items.

Flanges, Fittings 100%Valves, RTJ Gaskets

Pipes 100% (for pipes procured from traders).

2 random samples drawn from eachSize/Heat/Lot (for pipes procured directly from mills)

C. Fasteners

Lot Size Sample Size

Upto 100 2% (Min 2)101 to 500 1% (Min 3)501 and above 0.5% (Min 5)

Note:

For Welded Pipes and Fittings, PMI shall be performed on Base Metal as well asweldments.

Whenever any sample drawn to PMI test on the basis of percentage selection in B & Cabove, fails to meet specification requirements, 100% of items of lot shall be tested forPMI.

Copyright EIL — All rights reservedFormat No. 8-00-0001-F1 Rev. 0Page 157 of 193

STANDARD SPECIFICATIONFOR POSITIVE MATERIALIDENTIFICATION (PMI) AT

SUPPLIER'S WORKS

i.311-aelti. ENGINEERS

ogrir EiRtegi INDIA LIMITEDIA Go' at India Undertaking)

STANDARD SPECIFICATION No.6-81-0001 Rev. 2

Page 7 of 8

7.0 RECORDING AND DOCUMENTATION

The results of PMI examination shall be recorded in a Report Format as enclosed with thisspecification.

8.0 MARKING

8.1 All alloy materials tested by PMI shall be identified using either of the following methods byindicating "PMI OK"

Bar Code/Hologram StickerA low stress stamp marking

Copyright EIL — All rights reservedFormat No. 8-00-0001-F1 Rev. 0Page 158 of 193

STANDARD SPECIFICATIONFOR POSITIVE MATERIALIDENTIFICATION (PMI) AT

SUPPLIER'S WORKS

012-ael ie ENGINEERSst",ar &Reg W INDIALIMTED

GOA Of India undertakng)

STANDARD SPECIFICATION No.6-81-0001 Rev. 2

Page 8 of 8

POSITIVE MATERIAL IDENTIFICATION REPORTBULK MATERIALS

Page of

Project: Client Job No.

PMI Report No. Supplier/Sub-Supplier

Purchase Order No. Testing Agency

PurchaseRequisition No:

PMI Location

Bulk Item Type (as per Requisition)

Material Specification/Grade

Number of items in Lot

Requisition Item No./ Description Major content, Weight Percent RemarksAccept/Reject

Element Cr Mo Ni V

Specified Range

Actual observations

Instrument Type / ID

Last Service Date Inspection Agency Witnessed By

Copyright EIL — All rights reservedFormat No. 8-00-0001-F1 Rev. 0Page 159 of 193

ENGINEERS INSPECTION AND TEST PLAN

STANDARD SPECIFICATION No.

$1=g-ZIE fa5le'S.

INDIA LIMITED

FOR

6-81-0009 Rev. 3 IA Govt of India Undertaking)

HEAT EXCHANGERS Page 1 of 7

c 1-1

fiteTur trtuur EW-9-r

INSPECTION AND TEST PLAN FOR

HEAT EXCHANGERS

Cbt -Y-L-

3 09.09.2013 REVISED AND RE-ISSUED TKK G DM

2 15.07.2011 REVISED AND RE-ISSUED HP SCG AKC DM

1 25.10.2005 GENERAL REVISION TSSR PRV SY VC

0 01.11.02 ISSUED FOR IMPLEMENTATION NKN SPS AKB GRR

Rev. No. Date Purpose Prepared

by Checked

by

Standards Committee Convenor

Standards Bureau Chairman

Approved by

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved

Page 160 of 193

$1g-ez 051-eg ,4-17R rieoxecrINCI5.0

ENGINEERS INDIA LIMITED IA Goof of India Undertaking)

INSPECTION AND TEST PLAN FOR

HEAT EXCHANGERS

STANDARD SPECIFICATION No.

6-81-0009 Rev. 3

Page 2 of 7

Abbreviations:

CEIL Certification Engineers International Limited MRT Mechanical Run Test CIMFR Central Institute of Mining & Fuel Research NDT Non Destructive Testing CE Carbon Equivalent NPSH Net Positive Suction Head DFT Dry Film Thickness PO Purchase Order DPT Dye Penetrant Testing PESO Petroleum Explosive Safety Organization DHT De-hydrogen Heat Treatment PQR Procedure Qualification Record ERTL Electronics Regional Test Laboratory PR Purchase Requisition FCRI Fluid Control Research Institute PMI Positive Material Identification HT Heat Treatment RT Radiography Testing HIC Hydrogen Induced Cracking SSCC Sulphide Stress Corrosion Cracking ITP Inspection and Test Plan TC Test Certificate IP Ingress Protection TPI or TPIA Third Party Inspection Agency IHT Intermediate Heat Treatment UT Ultrasonic Testing IC Inspection Certificate VDR Vendor Data Requirement IGC Inter Granular Corrosion WPS Welding Procedure Specification MPT/MT Magnetic Particle Testing WPQ Welders Performance Qualification MTC Material Test Certificate

Inspection Standards Committee

Convenor : Mr. S C Gupta

Members:

Mr. R.K. Singh

Mr. Rajeev Kumar Mr. Himangshu Pal Mr.Neeraj Mathur

Mr. T Kamalakannan Mr. Deepak Gupta (Project) Mr. Mayank Jain

Format No. 8-00-0001-F7 Rev. 0

Copyright EIL — All rights reserved

Page 161 of 193

k_71 ENGINEERS INSPECTION AND TEST PLAN

STANDARD SPECIFICATION No.

tiff INDIA LIMITED

FOR

6-81-0009 Rev. 3 IA Govt of India Undertaking)

HEAT EXCHANGERS

Page 3 of 7

1.0 SCOPE

This Inspection and test plan covers the minimum testing requirements of Heat exchanger

2.0 REFERENCE DOCUMENTS

PO/PR/ Standards referred there in/ Job specifications /approved documents.

3.0 INSPECTION AND TEST REQUIREMENTS

SL NO.

STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK

RECORD SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER EIL/TPIA

1.0 Procedures

1.1 Hydro test ,heat treatment, NDT, hot forming and other Procedures Documented procedures. 100%

Procedure documents

- H R

1.2 WPS/ PQR /WPQ/Mock up Documented procedures. 100% Procedure documents

- H R-Existing

W-New

2.0 Materials inspection

2.1

Plates, pipes, Forgings, Expansion Bellows, Anodes, Fittings, Fasteners,

Gaskets, etc (As applicable) As per PR/Purchase

Specification 100% Mill TC H H R

2.2

Tube sheets, Tubes & Non standard flanges

(Supplier / sub supplier to arrange TPIA Certification)

As per PR/Purchase Specification

100% Mill TC / TPIA'S

IRN H H R

3.0 In process inspection

Format No. 8-00-0001-F7 Rev. 0

Copyright EIL — All rights reserved

Page 162 of 193

ei ENGINEERS INDIA LIMITED

• I el eage Z1,1 IA Govt of India Undertaking)

STANDARD SPECIFICATION No.

6-81-0009 Rev. 3

Page 4 of 7

INSPECTION AND TEST PLAN FOR

HEAT EXCHANGERS

SL NO.

STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK

RECORD SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER EIL/TPIA

3.1 Materials identification of pressure parts

Review of test certificates, markings visual & dimensional inspection, identity correlation & transfer of

identity

100% Material clearance

record - H H

3.2 Non Pressure Parts

Review of test certificates 100% Material

test certificate

W R R

3.3 Inspection of formed components

NDT of weld seam as applicable 100% NDT

Reports / RT Films

H H R

DPT on knuckle portion (both inside and out side) and weld overlay as

applicable

100% Inspection report

H H R

HT chart review as applicable 100% HT Chart W W R

Test coupon as applicable 100% Inspection

report W W W

Visual & dimensional (min. thickness, profile, ovality etc )

inspection

100% report

Inspection H H W

UT for lack of bond (after final heat treatment if any) formed from clad

plates as applicable 100%

report

Inspection H H R

3.4 Welding consumable Chemical , mechanical properties &

IGC as applicable 100% Batch test

certificates H H R

Format No. 8-00-0001-F7 Rev. 0

Copyright EIL —All rights reserved

Page 163 of 193

rwart ..3mcn.o

STANDARD SPECIFICATION No.

6-81-0009 Rev. 3

Page 5 of 7

4oi ENGINEERS 51gar 25:leg INDIA LIMITED

IA Govt of India Undertaking)

INSPECTION AND TEST PLAN FOR

HEAT EXCHANGERS

SL NO.

STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK

RECORD SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER EIL/TPIA

3.5 Weld edge preparation & Set up of

pressure Parts

Visual & dimensional inspection, weld edge, root gap, offset, alignment, cleanliness etc.

100% Insp Inspection check list

- W

NDT of weld edges as applicable 100% Inspection Insp check list

- W -

3.6 Intermediate Inspection of Welding Visual / inter pass temperature /DPT

as applicable 100 % Inspection

report - W -

Heat treatment as applicable 100% HT chart H R

3.7 Inspection of tube sheet Hole diameter, drift, layout, groove depth, ligament, tube hole surface

finish etc 100%

report

Inspection H H H

3.8 Inspection of Baffles Hole diameter, drift, layout, etc 100% Inspection Insp

report W W -

3.9 Skeleton of tube bundle before tube

insertion Visual / Completeness of assembly 100% Insp Report - H -

3.10 Tube bundle assembly Visual / Completeness of assembly 100% Insp Report - H H

3.11 Floating head assembly (As applicable) Visual / Dimension 100% Insp Report - H R

3.12 Pull through test of shell Passing of Gauge 100% Insp Report - H R

3.13 Tube to tube sheet joint ( welding/expansion)

% thining, Length of expansion, weld visual and DP as applicable

100% Insp. report

- H RW

3.14 Pneumatic Test of RF Pads & Tube to Tube sheet joints Leak Test 100%

Inspection Report

H H R

4.0 Final inspection

Format No. 8-00-0001-F7 Rev. 0

Copyright EIL — All rights reserved

Page 164 of 193

ENGINEERS INSPECTION AND TEST PLAN

STANDARD SPECIFICATION No.

ligaroot,cg w INDIA LIMITED

FOR

6-81-0009 Rev. 3 1.11VM el,M1.1151,PRISTI1

IA Govt 01 Ind. Undertaking)

HEAT EXCHANGERS Page 6 of 7

SL NO.

STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK

RECORD SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER EIL/TPIA

4.1

Visual and dimensional inspection (internals & externals) including welds of shell, channel shell, shell cover shell

etc. (before PWHT as applicable)

Visual/ dimensions, completeness of assembly and weld visual for

reinforcement, undercuts, Surface defects, etc.

100% Inspection

report - H H

4.2 PMI as applicable Chemical check Each

component and weld

Inspection report

- H R

4.3 Inspection of completed welds

PWHT as applicable 100% HT chart H R

NDT as applicable Spot/100% NDT report / RT films

- H R

Production test coupon testing as applicable

as per specification /

drawing

Inspection report

- H H

Weld chemical for undiluted chemistry as applicable

Each component

for each welding process.

Inspection report

- H R

Hardness for weld /HAZ as applicable

As per spec. Inspection

report H RW

4.4 Hydrostatic test (As applicable) Leak check 100% Inspection

report - H H

4.5 Drying and nitrogen filling Visual/ gas pressure 100% Inspection

report - W -

Format No. 8-00-0001-F7 Rev. 0

Copyright EIL — All rights reserved

Page 165 of 193

ENGINEERS INSPECTION AND TEST PLAN

STANDARD SPECIFICATION No.

$1g-af faiteg INDIA LIMITED

FOR

6-81-0009 Rev. 3 erterr,

IA Gcnit of India Undertaking)

HEAT EXCHANGERS

Page 7 of 7

SL NO. STAGE/ ACTIVITY CHARACTERISTICS

QUANTUM OF CHECK

RECORD SCOPE OF INSPECTION

SUB SUPPLIER SUPPLIER EIL/TPIA

5.0 Painting

5.1 Final painting (As applicable)

Visual inspection (after surface preparation and final painting for workmanship, uniformity) DFT

check

100% Inspection

report - H

6.0 Documentation and IC

6.1 Final stamping, review of inspection documents and issue of IC

Verifying stamping details and review of inspection documents

100% IC /

Inspection reports

- H H

6.2 Final documents as per PR Verification & compilation of inspection & test records for

submission to customer 100%

Final dossier

- H H

Legend: H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or 10% ( min.1 no. of each size and type of Bulk item)), R-Review, W-Witness (Give due notice, work may proceed after scheduled date).

NOTES (As applicable► :

1. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be applicable. (Unless otherwise agreed upon)

2. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred there in /Job Specification /Approved Documents.

Format No. 8-00-0001-F7 Rev. 0

Copyright EIL — All rights reserved

Page 166 of 193

Olgz=ENGINEERS NDIA LIMITED (A Govt. of Indle Undortoking)

PART DETAILS

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0001 Rev. 4

Page 1 of 2

+2 -0 T

+1.5 -o.o 6 T1

CX45• 1.,) +

N + 0 *** 0

0 m

— — —

< (...) CD

+ 0 Z.-5

0 1--

„,

±1

DETAIL-2

BC

D

r.r) 1:trl o

+0.8 -0.0 TO SUIT toc/

+ ?? ,IG! no . —o +1.< 6X45' --\ T (21 o 7

m

r, ci, nj ?cl'' '?

7 ** ..,

0+ m

>2 ‹ z ' 5 0 > < (,)

11111 11 ■ 21 :. < o

m o

DETAIL-3 DETAIL-1

T2

•X4 • T 6X45• T G1 T 6X45• T1 r•-, + o

--------\ ** ,o + o

** •,) + o + o

I m m m m

- — - .

< a (.) m : AP.... . < c, o -- ci < (..., ***

m m co 0)

m

CD r> 0 MIIIIIIMIII

m

DETAIL- 6

+ o * ---

DETAIL-4 o

H m

...

DETAIL-

H

5

m

DETAIL- 7 r.,) + 1---- --1

** y) + C)

F ** ** r --1

** r- \

1>-- 411

/-1)

L4 TUBE

03 x :,* -:, i- _i w _ m SIDE SIDE *** ***

o a

o com

***

- ■■ R2 r)

l

<-) m r) i m 0

T3 tn i m T3

T3 T3 m

DETAIL-11 DETAIL-1Q DETAIL-9 DETAIL- 8

---1

REQD A1/A2

alb kiA> 4

"1,111/

ill». ___ _ 11:1111111111111111 „1,01

lirily 111311) ■

DETAIL-13

SUPPORT PL REF. T/SHT OR CH. COVER

— J 20 25

ii 3

1 L

0 r..) m

I

**1

T3

r"

1.) mI

1 ii E. • ,

1-1 C--- DEFLECTOR T

L ,:f 1 STRIPS

.511121LIQL.I2EELFSIQE STRIPS END DETAII,

PGARRZIPDFEUTLC T2 =Ti +3

DETAIL- 15 DETAIL-1 2 DETAIL-14

KT

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM VC

4 06.05.14 REVISED AND REISSUED AS STANDARD k"Ni"---GCP

Rev. No. Date Purpose

Prepared Checked

by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Format No. 8-00-0001-F4 Rev.O

Copyright EIL - All rights reserved

Page 167 of 193

mi

-r T3

**

ci—zsi/ SC 4 06.05.14 REVISED AND REISSUED AS STANDARD GCP

Iffiteid ENSNEERS Ogat18 INDI 11ffieu A LIMIT1ED

Govt. of Inctla Undortoking) (SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0001 Rev. 4

Page 2 of 2

PART DETAILS

DETAIL-21

DETAIL-1 9 ED

X4

5

DETAIL-23 DETAIL-22

DETAIL-24

DEPOSIT

DETAIL-28 DETAIL-29

T3 ro

DETAIL-25

DETAIL-30

DETAIL– 27

***

CHANNEL SIDE

mI

DETAIL-31

NOTES: –

1. FOR CHANNEL COVER & TUBE SHEET A, BCD & D ETC. SHALL BE SAME AS FOR MATING FLANGES.

2. IF SPIRAL WOUND GASKET IS USED FOR A JOINT:– a) DIAMETER OF TUBE SHEET & CHANNEL COVER

'D' SHALL BE GASKET OD + 8 mm. b) DIAMETER OF FLANGE RECESS FOR GASKET SHALL BE

GASKET OD + 11 mm. 3. (9 WELD DEPOSIT OR CLADDING SHALL BE AS SPECIFIED ON

EQUIPMENT DRAWING. 4. FOR ASTERISK MARKS REF R TABLE-1. 5. WHERE EVER 'R' IS SPECIFI D, IT INDICATES TO BE RADIUSED.

6. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

TABLE NO.– 1

DIMENSIONS * ** *** FOR IJA & NON ASBESTOS 5 6 5 / EIASTOMER GASKET. FOR 4.5 mm SPWD GASKET 6 7 6

FOR 6.35 mm SPWD GASKET 8 9 7

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM VC

Prepared Checked by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Copyright EIL - All rights reserved

Purpose Rev.

No. Date

Format No. 8-00-0001-F4 Rev.O

Page 168 of 193

STANDARD No.

7-15-0002 Rev. 4

Page 1 of 3

TYPES OF NON STANDARD

GASKETS

(SHELL & TUBE EXCHANGERS) $14= IENG~S

INDIA UMITED 14111,1111•111M~ (A Govt. of India Undortoking)

TYPE-1

TYP E— 4

TYPE-7

TYPE-1 0

TYP E— 2

TYPE-5

TYPE— 8

TYPE-11 06.05.14 REVISED AND REISSUED AS STANDARD

RKG AKM VC

Checked Stds. Committee Stds. Bureau

b Convenor Chairman

y Approved by

Copyright EIL - All rights reserved

27.01.09 REAFFIRMED AND REISSUED AS STANDARD 3

Rev.

No. Date

Purpose

TYPE— 3

TYPE— 6

TYPE— 9

on

TYPE-12 SC

Format No. 8-00-0001-F4 Rev.O

VPR

Prepared

by

Page 169 of 193

TYPE-1 3 TYPE-1 4

Ognr ENGINEERS egOINDIA LIMITED

4~1111•111~111110 (A Govt. of Indlo Undortoking)

TYPES OF NON STANDARD

GASKETS

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0002 Rev. 4

Page 2 of 3

TYPE-1 5

TYPE-1 6

TYPE-1 7 TYP E-1 8

TYPE-1 9 TYPE-20

TYP E- 21

4 06.05.14 REVISED AND REISSUED AS STANDARD S&CP 3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR

Xet

VC

T

RKG AKM

Rev.

No. Date Purpose Prepared Checked

by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Format No. 8-00-0001-F4 Rev.O

Copyright EIL - All rights reserved

Page 170 of 193

ENGNEIERS INDIA LIMITED (A Govt. of Indlo Undortoking)

TYPES OF NON STANDARD GASKETS

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0002 Rev. 4

Page 3 of 3

PERMISSIBLE TOLERANCES PASS PARTITION PLATE THIS SIDE

FILLER TYPICAL SECTION OF METAL

JACKETTED GASKETS

D + 8

4 WIDE NOSE

GASKFT WIDTH

METAL WINDINGS METAL WINDINGS WITH FILLER

TYPICAL DETAIL OF SPIRAL WOUND GASKET

GENERAL NOTES: —

1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

2. THE HARDNESS OF THE METAL FOR SOLID OR CLAD GASKETS SHALL BE MINIMUM 15 BHN LOWER THAN

THAT OF THE MATERIAL OF THE FLANGE GASKET SEATING SURFACE AND IN ANY CASE NOT TO EXCEED

THE FOLLOWING.

(a) LOW CARBON STEEL / LAS — 110 BHN

(b) 5 Cr. 1/2 Mo. — 130 BHN

(c) STAINLESS STEEL — 160 BHN

(d) 11 — 13 Cr. — 170 BHN

(e) MONEL — 130 BHN

(f) SOFT IRON 90 BHN

(g) COPPER, BRASS 50 BHN

(h) ALUMINIUM 30 BHN

3. FILLER IN METAL JACKETTED GASKETS SHALL NOT BE OF COMPRESSED TYPE. 4. ALL GASKETS SHALL BE MADE IN ONE CONTINUOUS PIECE ALL AROUND INCLUDING THE PASS PARTITION

RIBS AND THEREFORE MUST BE CUT FROM ONE SHEET. 5. THE CORNER RADII OF ALL GASKETS TO BE 10 mm. 6. SOLID FLAT METAL GASKET SHALL BE 2 mm. THK. 7. FOR SPIRAL WOUND GASKETS:—

a) THE PASS PARTITION RIB SHALL BE OF METAL JACKETTED WELDED TO CENTRING RING. b) CENTRING RING THK. SHALL BE SAME AS NOSE THK. c) GASKET THK. SHALL BE AS SPECIFIED IN EQUIPMENT DRAWINGS. IT SHALL BE MIN. 4.5 FOR

SHALL DIA UP TO 1000 & MIN. 6.35 FOR SHALL DIA MORE THEN 1000, IF NOT SPECIFIED. 8. 'm' AND 'y' VALUES SHALL BE AS PER ASME SEC. Vlll DIV. I. 9. GASKET PLAN IS VIEWED FROM DIRECTION 'X' .

10. FILLER SHALL BE ARAMIDE FIBRE UNLESS SPECIFIED OTHERWISE IN DRAWINGS & ASBESTOS NOT TO BE USED.

4 06.05.14 REVISED AND REISSUED AS STANDARD

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD

VPR

RKG

Rev.

No. Date

Format No. 8-00-0001-F4 Rev.O

Purpose Prepared Checked

by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Copyright EIL - All rights reserved

NO

SE

THK

. mm1le111111111111111111111111111111

CENTRING RING

GASKET O.D. (D)

CENTRING RING THK

AKM

SC

VC

Page 171 of 193

2-22 16 HOLES FOR M-16 BOLTS (FOR 6" & 8" SHELL SIZES)

2-30 16 HOLES FOR M-24 BOLTS (FOR ALL OTHER SHELL SIZES)

A

VIEW AT 'A—A'

10 I> A

A

SHELL

1-10 0

VENT HOLE

10

25 (TYP.)

ENG1NERS INDIA LIMMED

11011.1 (A Govt. of Indlo Undertoking)

SUPPORT FOR HORIZONTAL EXCHANGERS

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0004 Rev. 4

Page 1 of 2

rtl 2-22 X 57 SLOTTED X 65 SLOTTED HOLES FOR M-16 [3.2.1 HOLES FOR M-24 BOLTS (FOR 6" & 8" BOLTS (FOR ALL OTHER SHELL SIZES) SHELL SIZES)

SADDLE NO.

UNIT SIZE O.D. mm

A B C D NO. OF RIBS

TOTAL WT. OF 2 SADDLES (kg.)

REMARKS

i 168.3 160 200 50 — 1 17

2 219.1 160 230 50 — 1 18

3 273 220 260 70 — 1 21

4 323.8 230 270 75 — 1 22

5 355.6 260 280 90 — 1 26

6 406.4 300 310 110 — 1 30

7 457.2 350 330 135 80 2 36

8 500 400 350 160 105 3 44

9 550 400 380 160 105 3 44

10 600 430 400 175 120 3 46

11 650 460 430 190 135 3 50

12 700 510 450 215 160 3 56

13 750 530 480 225 165 3 60

14 800 590 500 240 180 3 82

15 850 610 530 255 195 3 84

16 900 660 550 280 220 3 92

17 950 690 580 295 235 3 98

NOTES: — 1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

2. INTERMEDIATE SADDLES TO BE TAKEN TO THE NEAREST SIZE.

* 3. FOR S.S. 10 mm THK. FOR SADDLE NOS. 1 TO 17 & 14 mm THK. FOR SADDLE NOS. 18 TO 37.

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD GCP KA RK

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM

NoZ4

VC

Rev. No. Date Purpose

Prepared Checked by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Förmat Nn R-nn-nnn1-F4 RPV 0

ennvrinht Fil - All rinhts rpsprvpr1 Page 172 of 193

2-10 0

VENT HOLES

Prepared Checked

by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Copyright EIL - All rights reserved

Rev. No. Date Purpose

Format No. 8-00-0001-F4 Rev.O

ENGNEERS INDIA UMETE) (A Covl. of lndle UndArtoking)

SUPPORT FOR HORIZONTAL EXCHANGERS

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0004 Rev. 4

Page 2 of 2

4-33 0 HOLES FOR m-27 BourT-'-e.

4-33 X 68 SLOTTED 1 I I■

HOLES FOR M-27 BOLTS 35

VIEW AT 'A—A'

SADDLE NO.

UNIT SIZE O.D. mm

A B C D NO. OF RIBS

TOTAL WT. OF TWO

SADDLES (kg; REMARKS

18 1000 900 650 370 180 8 258

19 1050 950 675 390 200 278

20 1100 1000 700 420 220 290

21 1150 1050 725 440 230 302

22 1200 1100 750 470 250 320

23 1250 1150 775 490 270 336

24 1300 1200 800 520 280 348

25 1350 1200 825 520 280 356

26 1400 1250 850 540 300 368

27 1450 1300 875 570 320 380

28 1500 1350 900 590 340 398

29 1600 1400 950 620 350 406

30 1700 1500 1000 670 380 440

31 1800 1600 1050 720 420 472

32 1900 1700 1100 770 450 516

33 2000 1800 1150 820 480 546

34 2100 1850 1200 840 500 568

35 2200 1950 1250 890 530 602

36 2300 2000 1300 920 550 606

37 2400 2100 1350 970 580 640

194 4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD CP ; SC

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR R G AKM VC

Page 173 of 193

1-10 0 VENT HOLE

o_ >-

10

2 10 0 VENT HOLES

IN WRAPPER PLATE

10(r(P.)

2-10 0 VENT HOLES

013:MENGINEERS

ONDIA UMITED 11~1~11113•••0 (A Govt. of Indlo Und«toking)

SUPPORTS FOR HORIZONTAL STACK UNITS

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0005 Rev. 4

Page 1 of 2

2 10 0 VENT HOLES

* >

o_ } 15(TYP.)

IN WRAPPER PLATE

*14 FOR S.S

m

O(TYP.) .L 20(TYP.) 1

2-30 0 HOLES

4-33 0 HOLES

FOR M-24 BOLTS

2-30 X 65 SLOTTED HOLES FOR M-24 BOLTS 1351

FOR M-27 BOLTS

/<

t \

4-33 X 68 SLOTTED 1 HOLES FOR M-27 BOLTS

1351

**

FOR TYPE I AND II SADDLES FOR TYPE III AND IV SADDLES

REFER SETTING PLAN.

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD CP

AKM vc 3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG

Rev.

No. Date Purpose

Prepared

by

Checked

by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by

Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

Page 174 of 193

RKG

AKM

VC

Prepared Checked

by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Copyright EIL - All rights reserved

Rev. No. Date Purpose

Format No. 8-00-0001-F4 Rev.O

51XOENGNEERS NDIA UMITED (A Govt. of Indla Undortokh,g)

SUPPORT FOR HORIZONTAL STACK UNITS

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0005 Rev. 4

Page 2 of 2

SL. NO. UNIT SIZE O.D. mm.

A B C D NO. OF RIBS

TYPE—I TYPE—Il

1 219.1 400 230 130 — 1 3

2 273 460 260 160 — 1 3

3 323.8 510 270 190 — 1 3

4 355.6 540 280 200 — 1 3

5 406.4 590 310 220 — 1 3

6 457.2 640 330 250 80 2 4

7 500 680 350 270 103 3 5

8 550 730 380 290 105 3 5

9 600 780 400 320 120 3 5

10 650 830 430 340 135 3 5

11 700 880 450 370 160 3 5

12 750 930 480 390 165 3 5

13 800 980 500 410 180 3 5

14 850 1030 530 430 195 3 5

15 900 1080 550 460 220 3 5

16 950 1130 580 480 235 3 5

TYPE—III / IV

17 1000 1190 650 510 180 AS SHOWN

18 1050 1240 675 530 200

19 1100 1290 700 560 220

20 1150 1340 725 580 230

21 1200 1390 750 610 250

22 1250 1440 775 630 270

23 1300 1490 800 660 280

24 1350 1540 825 680 280

25 1400 1590 850 710 300

26 1450 1640 875 730 320

27 1500 1690 900 760 340

28 1600 1790 950 810 350

29 1700 1890 1000 860 380

30 1800 1990 1050 910 420

31 1900 2090 1100 960 450

32 2000 2190 1150 1010 480

33 2100 2290 1200 1060 500

34 2200 2390 1250 1110 530

35 2300 2490 1300 1160 550

36 2400 2590 1350 1210 580

NOTES: — 1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD iSkCP

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR

Page 175 of 193

3 (NOTE-2) 6 3 3 3 3 3+CORROSION ALLOWANCE

(NOTE-4)

TU

BE

SH

EET

TU

BE

SH

EET

TU

BE

SH

EE

T

TU

BE

SH

EE

T

0.4

DE

PT

H O

F G

RO

OV

E

0.4

DE

PTH

OF

GR

OO

VE

u_ O

c.) 07

0 O

c.)

CLADDING

EXPANDED LE

FIG.-2

4 06.05.14 REVISED AND REISSUED AS STANDARD CP

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD

VPR

SC

VC RKG AKM

TUBE HOLE PREPARATION BVGNEQZS

OfazIM INDIA LIMITED AND ROLLER EXPANDING

(A Govt. of Indla Undortoking) (SHELL & TUBE EXCHANGERS & AIR COOLED HEAT EXCHANGERS)

STANDARD No.

7-15-0006 Rev. 4

Page 1 of 1

EXPANDED LENGTH

FIG.-1

NOTES : - 1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

2. FOR TUBESHEET THICKNESS WHERE THE GAP BETWEEN 2ND GROOVE & BACK OF TUBE SHEET IS LOWER THAN 6 mm DELETE 2ND GROOVE.

3. FOLLOW SPECIAL CLOSE FIT AS PER TEMA / API 661 UNLESS SPECIFIED OTHERWISE.

4. FOR CORROSION ALLOWANCE LESS THAN 4 mm., INCREASE THIS DIMENSION TO TUBE SHEET THICKNESS

MINUS 18 mm. BUT NOT TO EXCEED 7 mm.

*5. CHAMFER (1X45') OR RADIUS (R=1).

Rev. No.

Date

Format No. 8-00-0001-F4 Rev.O

Purpose Prepared Checked

by by

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Page 176 of 193

SLIDING STRIP STATIONARY TUBE SHEET

SECTION—AA

TYPE - 1

STATIONARY TUBE SHEET

SLIDING STRIP

M-12 STUD 22 LG. THREADED

SECTION—BB

TYPE - 2

TYPE - 3

M-12 STUD 22 LG. THREADED

STATIONARY TUBE SHEET

SLIDING STRIP

AKM VC 3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG

Rev. No. Date Purpose

Prepared Checked by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD GCP KA SC

0148MENGINMS

ONDIALIMITED (A Govt. of Indlo Undortoking)

SLIDING & DEFLECTOR STRIPS TO TUBE SHEET

WELDING DETAILS

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0007 Rev. 4

Page 1 of 1

NOTES: —

1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

2. USE TYPE-1 WHEN SLIDING STRIP & TUBE SHEET MATERIAL IS DIFFERENT & W ?, 25

3. USE TYPE-2 WHEN SLIDING STRIP & TUBE SHEET MATERIAL IS DIFFERENT & W < 25

4. USE TYPE-3 WHEN SLIDING STRIP & TUBE SHEET MATERIAL IS SAME

5. FOR DIMENSIONS 'T' AND W' REFER GUIDE LINES FOR TUBE LAYOUT.

6. FOR DEFLECTOR STRIPS UNLESS SPECIFIED OTHERWISE USE DETAILS AS ABOVE.

Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved Page 177 of 193

Rev. No. Date Purpose

Prepared Checked by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Copyright EIL - All rights reserved Format No. 8-00-0001-F4 Rev.O

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD %,\CP KA

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM

SC

VC

0048~ENGMBZS NDLek UMITID (A Govt. of Indlo Undortokklg)

EYE BOLT DETAIL

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0008 Rev. 4

Page 1 of 1

NOM. BOLT DIA A

THREAD LENGTH L

STOCK B

I. DIA. C

0. DIA. D

SAFE LOAD IN kg

mi 0 20 32 26 42 600

M12 24 38 30 52 1000

M16 32 45 35 64 1800

M20 40 50 38 72 2700

M22 44 58 44 84 3000

M24 48 64 46 92 3300

M27 54 70 50 102 4200

M33 66 76 56 114 6800

M39 78 90 64 132 8100

M45 90 96 74 154 9900

M48 96 102 84 162 11400

M56 112 127 102 168 14200

NOTES: —

1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

2. EYE BOLT SHALL BE MADE OF FORGING.

3. MATERIAL OF CONSTRUCTION CARBON STEEL HAVING U.T.S OF 42 kg/mm2 MIN.

4. UPTO M22 COARSE THREAD SERIES, M24 & ABOVE SHALL HAVE 3 mm PITCH.

Page 178 of 193

CHISEL TIE—ROD SPACER

13■IGNEERS INDIA UMIT133 (A Govt. of lodla Undortoking)

METHOD OF FASTENING NUTS TO THE TIE RODS

STANDARD No.

7-15-0009 Rev. 4

(SHELL & TUBE EXCHANGERS) Page 1 of 1

STEEL TIE—ROD

TIE—ROD SPACER

NOTES: —

1. ALL DIMENSIONS ARE IN mm. UNLESS STATED OTHERWISE.

2. WELD 1st NUT TO SUPPORT PLATE

3. WELD 2nd NUT TO TIE—ROD

4. WELD BOTH NUTS TOGETHER

5. ALL WELDS TO EXTEND THE LENGTH OF ONE FLAT OF NUT.

LAST SUPPORT PLATE OR BAFFLE

NON FERROUS TIE—ROD

LAST SUPPORT PLATE OR BAFFLE NOTE: —

*BREAK THREAD OF TIE—ROD IN TWO PLACES NEAR LAST NUT

WITH BLUNT CHISEL TO LOCK TIE—ROD NUTS IN PLACE.

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD ')'‘CP KA

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG

AKM

VC

Rev.

No. Date Purpose Prepared Checked

by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

Page 179 of 193

GASKET SIDE EXPOSED SIDE

Fl ANGF OR CHANNFI COVFR

NCOUNTER BORE d + 2

THREAD=2d

BO

LT C

IRC

LE

DIA

ME

TE

R

d = DIAMETER OF JACK SCREW

ENGNIEIRS NDIA LIMMED (A Govi of Indki Undertaking)

JACK SCREW TAPPING AND ARRANGEMENT

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0010 Rev. 4

Page 1 of 1

/ I

"91't

2—HOLES

/ I

3:5:(

3—HOLES 4—HOLES

NO. REQD. 'd' SHELL I.D.

2 14 UPTO & INCL. 300

3 16 301 TO & INCL. 580

4 20 581 & LARGER

LOCATION OF JACK SCREW TAPPING HOLES 1. HOLES ARE TO BE LOCATED ON THE BOLT CIRCLE DIAMETER

OF FLANGE AND HALF WAY BETWEEN ADJACENT HOLES.

2. FIRST HOLE SHALL BE LOCATED BETWEEN FIRST AND

SECOND BOLT HOLE COUNTING CLOCKWISE FROM MARK 'T'.

3. HOLES SHALL BE SPACED AS FOLLOWS 2—HOLES LAYOUT 180' APART

3—HOLES LAYOUT APPROX 120' APART

4—HOLES LAYOUT 90' APART.

NOTES: — 1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE. 2. JACK SCREW SHALL BE OF STAINLESS STEEL MATERIAL.

4 06.05.14 REVISED AND REISSUED AS STANDARD IS‘')/CCP KA

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD

Rev.

No. Date

Purpose

VPR RKG AKM VC

Prepared by

Checked by

Stds. Committee Convenor

Stds. Bureau Chairman

Approved by Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

Page 180 of 193

G 0

SC

AKM VC

Rev.

No. Date Purpose

Prepared Checked

by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by

034~INDIA LINITED FIXING DETAIL OF DOWEL PINS

(A Govt. of Inao UndertakIng)

STANDARD No.

7-15-0011 Rev. 4

Page 1 of 1 (SHELL & TUBE EXCHANGERS)

FIXING DETAIL OF DOWEL PINS (AT STATIONARY TUBE SHEET)

FIXING DETAIL OF DOWEL PINS ( AT CHANNEL COVER )

SEE NOTE-9

20 20 SEE NOTE-3

(sr

NOTES: —

1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

2. DOWEL PINS TO BE PROVIDED ONLY WHEN CHANNEL CONSISTS OF PASS—PARTITION PLATE/S.

3. DOWEL PIN SHALL BE OF CARBON STEEL UNLESS SPECIFIED OTHERWISE.

4. MIN. 2 DOWEL PINS SHALL BE PROVIDED FOR EACH FLANGE & SHALL NOT BE LOCATED AT 180' APART.

5. ALL SHARP EDGES OF DOWEL PINS SHALL BE ROUNDED OFF.

6. SHALL END OF DOWEL PIN SHALL BE HELD IN POSITION BY TIGHT FIT.

7. LUG TO BE WELDED TO TUBESHEET. HOWEVER LUG FOR DOWEL PIN MAY BE THREADED AND SCREWED IN TUBE SHEET TO AVOID PWHT IN SPECIFIC CASES. MATERIAL OF LUG SHALL BE COMPATIBLE WITH TUBE SHEET MATERIAL.

8. WHEN GAP BETWEEN SHELL & CHANNEL FLANGES IS 25 MM. OR LESS, DOWEL PINS SHALL BE PROVIDED IN CHANNEL FLANGE ONLY.

9. AT THE LARGER END OF DOWEL PIN THE LENGTH CAN BE REDUCED IN CASE OF A SMALLER GAP BETWEEN SHELL AND CHANNEL FLANGES.

4 06.05.14 REVISED AND REISSUED AS STANDARD ‘CP KA

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG

Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

Page 181 of 193

Oli4=ENGINEERS NDIA LIMETED

INUI.11111111~0 (A Govt. of Indla Undortoking)

LIFTING LUG DETAIL

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0013 Rev. 4

Page 1 of 1

10 FULL FILLET WELD ALL AROUND

LIFTING LUG FOR SHELL COVER.

LIFTING LUG FOR

CHANNEL AND CHANNEL COVER

FLOATING HEAD COVER

SHELL I. D. A D R THK.

UPTO 450 65 25 28 12

451 — 1000 75 30 35 16

1001 — 1200 100 30 35 20

1201 & ABOVE CUSTOM DESIGN

NOTES: — 1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

2. MATERIAL SHALL BE COMPATIBLE WITH PART IT IS WELDED TO. (USE BOILER QUALITY FOR CARBON STEEL)

3. USE TWO LIFTING LUGS EACH FOR CHANNEL AND SHELL COVER AND ONE FOR CHANNEL COVER AND

)(4."/

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD iSkP KA RKkLi-I SC

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM VC

Rev. Prepared Checked Stds. Committee Stds. Bureau

No. Date Purpose by by

Convenor Chairman Approved by

FLOATING HEAD COVER.

Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

Page 182 of 193

CHANNEL SHELL COVER

SHELL

SHELL FLANGE

SHELL COVER FLANGE

LIFTING LUG

TOP AND BOTTOM PLATE

CHANNEL FLANGE

CHANNEL COVER

LIFTING LUG 25

25 SLIDING LINK SEE DETAIL

PLAN OF DAVIT SUPPORT ASSEMBLY OF DAVIT ON EXCHANGER

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD (')66P KA RKT

DETAIL—'A'

BOTTOM PLATE 10 o WEEP HOLE

STOPPER PLATE/

d0

5R 3

DETAIL OF SLIDING LINK 6 0 FLAT

DETAIL OF DAVIT DETAIL OF DAVIT SUP ORT

II II

SHELL/CHANNEL

FLANGE

TOP PLATE

16 THK. RIB PLATE

'A'

II

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM VC

Prepared Checked by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Copyright EIL - All rights reserved

Purpose Rev.

No. Date

Format No. 8-00-0001-F4 Rev.O

ENGINEERS INDIA UMITED (A Govi of Indlo Undortoking)

DAVIT FOR SHELL & CHANNEL COVER

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0014 Rev. 4

Page 1 of 3

Page 183 of 193

STANDARD No.

7-15-0014 Rev. 4

Page 2 of 3

lgelEr4GMERS

4fazi INDIALJMITED

NIRVI (A Govt. of Inctio UndortokIng)

DAVIT FOR

SHELL & CHANNEL COVER

(SHELL & TUBE EXCHANGERS)

DIM

EN

SIO

N-A

0 0 0 -4- i- rl, rd N N r.r) (C11

-° .0°00 oo CO f' )̀ co dr r')

0 0 o cy rr, N N

.-- r'' .-

-° Ln °00 o CO .4- 0 CO .nd- tv)

0 up°

0 c‘i N 1.r) N N (1) (£7, (0

dr- CO 1.1"

00 0 0 ..4- r.r)

0 0 0 c \I ,- F- N 1..-) N c‘l ,,,.— s'-' ,--

CD vd- 1.0 ro ,j- r. 0 "

.- ,r) 0 0 0 csj 0 I- - ro N N

up in o Lo dr

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o st. 0

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o o o c■j a) t- o iv.) CV

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r-- 0, K)

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.- 0 ° 0 O -i- ,— Lo - --

8 N

11•3 O)

5?) o r.,)

0 r.r) r̀ )

Lr) c\J

- °

1') 1- 1̀" 0 0

o N

Lo 00

o cr) r.,-)

o co Nom) N,

co N

° ° 0 ° c\I - ''') .... ,._

0 In Cd

0 0 c0

0 0 r.,)

0 rO r.,)

0 r,"

0 N

° 0 ° 1- "

l'' 0)

N '-- ° 000

lt, r--

0 1.,)

0 ro

re9 c\IC)

- ° 0 o ° ° 1- -

o o N

tn N co

o r-- C•1

o co N

00 ro N

° 6". ° O I— 0

0 0 c.,

rr) C•J cc)

o CO N

o ro N

° °

0 ° 8 co ,— . c9r ii.ri (5) cs4

2 c.r

o 1.'"

o "

5 ,..0 8 1". - CO

0° CsI

c.,") Lr) c., L?) (., N ° N

r: o 52 -I3) 1- r‘-j

0 {.:3

0 L.)-

o R,

o ,__°.

Lo -J

o "

: : : o 9, V) I- (‘1:5

03 c°

C D ?

o C-d-

o_ u j.-

o "

co .-

0_ 0 co

00 -

(3I- 00001D LI F') , •-

N N •"'"

0 c.,, co ‘_

I- 5 < o 75

03 0 o -.1 Z -f)

_J 021

0

_J

U)

0 LL

wI

0 C.)

LIJ zz

tY0 IJ-

o

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD )6;)

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG

Rev. Prepared Checked Date Purpose

No. by by

RKT(J21..,-Av:, SC ,(04

KA

AKM

VC Stds. Committee Stds. Bureau

Convenor Chairman Approved by

Copyright EIL - All rights reserved Format No. 8-00-0001-F4 Rev.O Page 184 of 193

BNIGNEERS INDIA UMETED (A GovL of Indlo UndeflokIng)

DAVIT FOR SHELL & CHANNEL COVER

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0014 Rev. 4

Page 3 of 3

TABLE — 3

WT. X C.

(ToN) (mTR)

DIMENSIONS/SIZE OF DAVITS

N....E SCH bic F

NB SCH T R S NB SCH

UPTO 0.1 2"-160 1-1/2"-160 3 32 3"-1 60

0.11-0.3 3"-160 2"-160 3 47 4"-80

0.31-0.6 4"-160 2"-160 13 59 6"-80

0.61-1.25 6"-80 3"-160 10 86 8"-80

1.26-2.5 8"-80 3"-160 11 112 10"-60

2.6-4.0 10"-60 4"-120 8 139 12"-60

4.1-6.3 10"-120 4"-120 8 139 12"-60

6.4-7.8 10"-160 4"-120 8 139 12"-60

NOTES: —

1. ALL DIMENSIONS ARE IN mm. UNLESS OTHERWISE INDICATED.

2. WHEN DAVITS ARE REQUIRED, USE THE FOLLOWING PROCEDURE TO FIND OUT THE DIMENSIONS 2.1 IDENTIFY THE DIMENSION A, i.e. THE MAXIMUM DIAMETER OF THE COMPONENT TO BE HANDLED.

2.2 REFER TABLE-1 OR TABLE-2 (AS THE CASE MAY BE ) FOR THE DIMENSIONS AND SIZES B,C,D,L,N & d INDICATED IN THE COLUMN CORRESPONDING TO DIMENSION A.

2.3 DETERMINE WEIGHT OF THE PART TO BE HANDLED (i.e. WT. OF SHELL COVER ASSEMBLY OR CHANNEL COVER)

2.4 CALCULATE THE PRODUCT OF WEIGHT (IN TONNES) X DIMENSION C (IN METRES)

2.5 REFER TABLE-3 & OBTAIN DIMENSION AND SIZES E,F,T,S & R INDICATED IN THE ROW AGAINST THE PRODUCT CALCULATED AT 2.4 ABOVE.

3. MATERIALS OF CONSTRUCTION—a. TOP/BOTTOM/RIB PLATE— COMPATIBLE WITH PART IT IS WELDED TO (USE BOILER QUALITY FOR CARBON STEEL)

b. OTHERS IS 1239 OR EQUIV

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD CP KA

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG

Rev. Prepared Checked Date Purpose

No. by by

RKT

AKM Stds. Committee Stds. Bureau

Convenor Chairman Approved by

Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

Page 185 of 193

antnedirkEts/GINEERSligar EIRegle INDIA LIMITED

lawaleizowisagos0 (A Go* of India Undorteing)

EARTHING LUG STANDARD No.

7-15-0016 Rev. 4

Page 1 of 1(SHELL & TUBE EXCHANGERS)

10 THK. CARBON STEEL PLATE

\ 14 0 HOLE (FOR M12 BOLT)

NOTES: —ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.DO NOT WELD EARTHING LUGS TO PRESSURE PARTS. IF REQUIRED,TAKE PRIOR APPROVAL OF COMPANY.EARTHING LUG TO PROTRUDE OUT OF INSULATION, WHEREVER REQUIRED.ALL EXCHANGERS TO BE FITTED WITH 2 EARTHING LUGS.

5. LOCATION OF EARTHING LUGS :—FOR VERTICAL EXCHANGER WITH 2 LUG SUPPORTS :— ON BOTH LUG SUPPORTS AT VERTICAL WEB.FOR VERTICAL EXCHANGER WITH 3 LUG SUPPORTS :— ON ANY TWO AT VERTICAL WEB.FOR VERTICAL EXCHANGER WITH 4 LUG SUPPORTS :— ON ANY TWO DIAMETRICALLY OPPOSITE ATVERTICAL WEB.

(iii) FOR HORIZONTAL EXCHANGER ON TWO SADDLE SUPPORTS ONE ON CENTRAL WEB.

./48 VPR

Preparedby

4 30.09.2011 REVISED AND REISSUED AS STANDARD

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARDRev.

No. Date Purpose

RKT AKM / SC DMRKG AKM VC

Checked Stds. Committee Stds. BureauConvenor Chairman by Approved by

Format No. 8-00-0001-F4 Rev.0 Copyright EL - All rights reservedPage 186 of 193

YEAR BUILT

kcal /hr

OlgziTX ENGINEMS NDIA LIMITED (A Govt. of Indlo UnclortokIng)

NAME PLATE

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0017 Rev. 4

Page 1 of

6R

4 — 5.5 0 HOLES

NAME OF MANUFACTURER

ENGINEERS INDIA LIMITED DESIGNED BY

MANUFACTURED FOR

ITEM NO.

MANUFACTURER'S SERIAL NO.

CODES

=INSPECTED BY

DESIGN PRESSURE

DESIGN TEMPERATURE

TEST PRESSURE (HYD)

DATE OF TEST

OPERATING FLUID

CORROSSION ALLOWANCE

RADIOGRAPHY

HEAT TREATMENT

DUTY / SURFACE

1WEIGHT FULL OF WATER

TOTAL WEIGHT EMPTY

BUNDLE WEIGHT

SHELL TUBES

m2

'c kg/cm2 g

mm

kg/cm2 g

kg

kg

kg

15 20 52 78

1 5n

CFW

SIDE SHELL

3 THK. FOR SS (MIN.) 6 THK. FOR CS & LAS (MIN.)

MATERIAL : — NAME PLATE STAINLESS STEEL 18 : 8 NAME PLATE BRACKET :— SAME AS EXCHANGER SHELL

170 x 130 NNAME PLATE BRACKET

NOT S: —

1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

2. ALL LETTERS AND LETTER BLOCKS SHALL BE ENGRAVED IN BLACK.

* 3. H = 75 OR 'INSULATION THK. + 10 WHICHEVER IS GREATER.

4. NAME PLATE SHALL BE RIVETED WITH 5 0 ALUMINIUM RIVETS AND SHALL BE TACK WELDED TO BRACKET ON ALL FOUR SIDES.

:(?5. BRACKET WITH NAME PLATE TO BE LOCATED AS MARKED ON DRAWING.

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD t•>6CIp KA RKT SC

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM

Rev. Prepared Checked Stds. Committee

No. Date Purpose by by Convenor

Format No. 8-00-0001-F4 Rev.O

VC Stds. Bureau

Chairman Approved by

Copyright EIL - All rights reserved Page 187 of 193

Prepared by

Checked by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Copyright EIL - All rights reserved

Rev. No. Date Purpose

Format No. 8-00-0001-F4 Rev.O

AMONasEERS INDIALIMM) (A Govi of lndla UndiertakIng)

WARNING PLATE

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0018 Rev. 4

Page 1 of 2

6R 4 — 5.5 0 HOLES ryp\ Ty6pi

3 THK. STAINLESS STEEL PLATE

AR

DO \OT RL\ THIS EXCHA\GER WITHOUT FLUID 0\ SHELL SID

160

DETAIL — 1

OUT SIDE SHELL

* 6R 3 THK. FOR SS (MIN.) 6 THK. FOR CS & LAS (MIN.)

185 x 130

NOTES: —

WARNING PLATE BRACKET DETAIL

MATL. SPEC.:— SAME AS EXCHANGER SHELL H = 75 OR 'INSULATION THK. + 10 WHICHEVER IS GREATER.

1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

2. MATERIAL TO BE 18:8 STAINLESS STEEL FOR WARNING PLATE.

3. ALL LETTERING WITH THE EXCEPTION OF WORD 'WARNING' TO BE ENGRAVED 2 mm. WIDE x 2 mm. DEEP AND FILLED WITH BLACK PAINT AFTER ENGRAVING.

4. THE WORD "WARNING" IS TO BE ENGRAVED 2.5 mm. WIDE x 2 mm. DEEP AND FILLED WITH RED PAINT AFTER ENGRAVING.

5. WARNING PLATE TO BE HELD WITH 5 0 ALUMINIUM RIVETS ON WARNING PLATE BRACKET AND SHALL BE TACK WELDED TO BRACKET ON ALL FOUR SIDES.

6. BRACKET WITH WARNING PLATE TO BE LOCATED AS MARKED ON DRAWING.

Q A 4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD CP KA RKT1l

4

— SC

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM VC

Page 188 of 193

OgrXeINGINEERS N31A UMITIED (A Govt. of Indio UndertokIng)

WARNING PLATE STANDARD No.

7-15-0018 Rev. 4

Page 2 of 2 (SHELL & TUBE EXCHANGERS)

6R 4 — 5.5 0 HOLES 3 THK. STAINLESS STEEL PLATE -1-si \ 6

TYP

AR\

DO NOT EUX THIS EXCHAXGER WITHOUT FLUID OX TUBE SIDE

160

DETAIL — 2

FOR NOTES REFER SHEET 1 OF 2.

4t/hs 4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD i>lP KA RKT SC

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM VC

Rev.

No. Date Purpose

Prepared

by

Checked

by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

Page 189 of 193

+0.0

REFER PARA 3.121 dc 3.122 OF TEMA

±3 ADDITION NO LONGITUDIANAL ELEMENT OF THE INSIDE SURFACE SHALL HAVE A BOW OF MORE THAN 1mm. PER METRE OF LENGTH UP TO MAX. OF 3mm.

Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

1 _

Mo

±3

ENCNEERS UMITFD

11111.11.1•1111~10 (A Govt. of India Undertoking)

±16

TOLERANCES

(SHELL & TUBE EXCHANGERS)

±6

STANDARD No.

7-15-0019 Rev. 4

Page 1 of 3

±3

±3

fn0 + I

LIGAMENT BETWEEN HOLES WILL BE SAME AS LIGAMENT BETWEEN HOLES IN TUBE SHEET ( AS PER TEMA )

±6

±1.5 FOR EXPANDED I

+1

FOR WELDED

3

+0.8 —0.

to

-H

-...JMPINGEMENT PIATE

E—A

+0.8 —0.0

±0.8

±6(MAX.) (NOTE-4)

iqg +l

SECTION—AA

U—TUBE BUNDLE OVERALL LENGTH ±12

+0.8 —0.0

±3

BAFFLE

TAKE (-1 TOLERANCE WHEN TAKE (+) TOLERANCE WHEN CUT IS ON THE ( OF TUBES re=5_11U2EMEEILT±LE=

DETAIL—B TUBE SHEET / (TYPICAL) .Q1:16fflELSME13

Rev.

No. Date Purpose

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD 661D KA RKT

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM

Prepared Checked

by by

VC

Stds. Committee Stds. Bureau Convenor Chairman

Approved by

Page 190 of 193

TOLERANCES

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0019 Rev. 4

Page 2 of 3

Rev. No. Date Purpose

Prepared Checked

by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by

RKT

AKM VC

±3 ±3

±3 ±3

00

—+ I

+2.0 —0.0

+8:8

rAri

±0.8 +0.0 +0.0

—0.8 r---1 -0 •8

le I

1n1 .c:D

ii-1 c0 + I co

d 0

-H -H

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD 4P6CP KA

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG

vt.

fI L

+3.0 —0.0

+0.8 —0.0

+0.0 —0.8

cc! 0 -H

L

+

+I-H

. —0+2

+0.8

3 MAX. I

I

TRUE VERTICAL C.

Format No. 8-00-0001-F4 Rev.0 Copyright EIL - AII rights reserved

ENGNEERS 11431A UMITED

somnewormowe (A Govt. ot Indlo UndortokIng)

Page 191 of 193

NENGNIA IRS ID UMITED

1:1111.1~1V111~0 (A Govl. of Indlo Undertoking)

TOLERANCES

(SHELL & TUBE EXCHANGER)

STANDARD No.

7-15-0019 Rev. 4

Page 3 of 3

1.0 FOR NOZZLE 4- dc UNDER

2.0 FOR NOZZLE 6" TO 10" INCL 2.5 FOR NOZZLE 12" TO 16" INCL 3.0 FOR NOZZLE 18" dc ABOVE

1.

11' ! ACTUAL NOZZLE Q

TRUE HORIZ Q

TRUE VERT q_

+1.0 —0.0

00

GENERAL NOTES: —

CUMULATIVE TOLERANCES ON CONSECUTIVE DIMENSIONS SHALL BE LIMITED BY OVERALL DIMENSION TOLERANCE.

2. SPECIFIC TOLERANCES DESIRED FOR ANY PART SHALL BE SHOWN ON THE DRAWING AND SHALL BE GIVEN PREFRENCE TO THOSE GIVEN IN THIS STANDARD.

3. TUBE HOLE TOLERANCES SHALL BE AS PER TEMA.

4. ONLY WHEN NUMBER OF BAFFLE PITCHES EXCEED EIGHT.

L3'

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD ;1--"G(6P KA RKT 'N3s/ Ofr

.-SC

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM VC

Rev. Prepared Checked Stds. Committee Stds. Bureau

No. Date Purpose by by

Convenor Chairman Approved by

Fnrrnat Nn R-nn-nnni-F4 RAV n Cnnvrinht Fll - All rinhts rpsnrvnri Page 192 of 193

ROUND OFF SHARP EDGE

LONG BAFFLE

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD SZGCP KA

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG

Rev.

No. Date Purpose Prepared

by

Checked

by

RK 4)2

AKM

VC Stds. Committee Stds. Bureau

Convenor Chairman Approved by

ENGINIEERS INDIA UMITED (A Govt. of Indlo UndortokIng)

DETAIL OF SEALING STRIP ASSL'Y FOR TWO PASS SHELL

(SHELL & TUBE EXCHANGER)

STANDARD No.

7-15-0021 Rev. 4

Page 1 of 1

TUBE OR SPACER L.LJ _J

0

SPACE TO REMOVE BOLTS

FULL LENGTH BACKING 7.5

STRIP 15 WIDE x 6

kkk\ M-6 HEXAGONAL HEAD BOLTS & NUTS @ 100 PITCH (MAX.)

z

_J

80 HOLE 97 45

8 STRIPS 0.1 THK. STAINLESS STEEL FOR EACH

—SIDE TYPE A-177-3/4 HARD OR FULL HARD TEMPER

NOTE:

TO FACILITATE ASSEMBLY AND MAINTENANCE HOLES DRILLED IN LONG BAFFLE TO BE SLOTTED AS SHOWN

DETAIL SHOWING BOLT HOLES IN LONGITUDINAL BAFFLE

1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

Förmat Nn a-nn-non1-F4 RPV 0 ennvrinht Fll - All rinhts rPsPrvr4r1 Page 193 of 193