Escolar Documentos
Profissional Documentos
Cultura Documentos
ghV ,DlpsUtlZ
FOR
HEAT EXCHANGERS
Applicable code & specifications: As per PR SCOPE OF INSPECTION
SL. INSPECTION CHARACTERISTICS QUANTUM REFERENCE ACCEPTANCE FORMAT SUB VENDOR GAIL/TPI
NO. ACTIVITY & OF CHECK DOCUMENT STD. OF REPORT VENDOR
COMPONENT
1.0 PROCEDURES
1.1 Heat treatment ,NDT Documented 100% ASME Sec II ASME Sec II Document - W R
and other procedures Procedures A/IIB /VIII Div 1. A/IIB /VIII Div
including tube to tube / TEMA –R I. / TEMA –R
sheet expansion/ /Spec/Drawings /Spec/Drawings
welding, mockup test
and testing
2.0 MATERIALS
INSPECTION
2.1 Materials At Mills Chemical analysis 100% ASME Sec II ASME Sec II Mill Test W W R
Plates, Pipes, Tubes, Mechanical properties, A/IIB /VIII Div I. / A/IIB /VIII Div Certificates
Tube sheets, Forging, Addl. Tensile on hub, TEMA –R I. / TEMA –R
Fittings Fasteners etc. Bend test, (including /Spec/Drawings /Spec/Drawings
(TO BE PROCURED impact test of
FROM REPUTED plates/forging,
MANUFACTURERS) Hardness check,
simulation Heat
treatment, Non
Destructive
Tests(ECT). Along with
supplementary
properties (if
reqd.).Visual &
dimensional inspection
2.2 Materials After Receipt Review of test 100% ASME Sec II ASME Sec II Material - W R
(for Pressure Parts) certificates markings A/IIB /VIII DivI. / A/IIB /VIII Div Clearance
Plates (Shell (Tube Visual & Dimensional TEMA –R I. / TEMA –R Record
Sheet). inspection /Spec/Drawings /Spec/Drawings
Pipes (shell/Nozzle ), Identification,
Forgings ( nozzle/ tube Correlation & transfer
test ), tubes ,fittings of identity.
,fasteners, Gaskets etc.
2.3 Non Pressure Parts Review of test 100% ASME Sec II ASME Sec II Insp. Report - R R
(including internals, certificates A/IIB /VIII DivI. / A/IIB /VIII Div
supports ,baffles, sliding TEMA –R I. / TEMA –R
plate etc. /Spec/Drawings /Spec/Drawings
STANDARD SPECIFICATION NO. Rev.
GAIL (India) Ltd. INSPECTION AND TEST PLAN FOR HEAT EXCHANGSERS
Pata. 6-81-0009 Rev. 0 0
Page 2 of 7
Applicable code & specifications: As per PR. SCOPE OF INSPECTION
SL. INSPECTION CHARACTERISTICS QUANTUM REFERENCE ACCEPTANCE FORMAT SUB VENDOR GAIL/TPI
NO. ACTIVITY & OF CHECK DOCUMENT STD. OF VENDOR
COMPONENT REPORT
3.0 Inspection of Formed
Components
Visual & dimensional 100% Drawings/Spec Drawing /Spec/ Insp. W R R
Inspection 6-12-0001 ASME Sec.VIII-1 Report
RT of long seam if any. 100% ASME Sec V / ASME Sec/ Spec/ Insp. W R R
Spec/ Drawings Drawings
On knuckle ASME Sec V / ASME VIII-Div1 Report W R R
DP/MPI portion and Spec/ Drawings & Sec V,
welds after Spec/Drawings
forming .
IHT/HT chart review, if 100% ASME Sec VIII - ASME HT Chart - R R
applicable 1/Spec/Drawings Sec VIII-
1/Spec/Drawings
3.1 (Dished end, cone, 100% ASME Sec II ASME Sec II Insp. - W H
bellows, expansion Test Coupon A/Spec/Drawings A/VIII-I/ Report
joints, floating cover Spec/Drawings
etc.)
4.0 WPS and PQR
(Including Weld
Overlay)
4.1 PQR Welding parameters 100% ASME sec IX/ ASME sec IX/ WPS/PQR - W R
Spec. Spec
4.2 WPQ Qualification 100% ASME sec IX/ ASME sec IX/ WPQ - W R
Requirement Spec./Drawings Spec/ Drawings
STANDARD SPECIFICATION NO.
GAIL (India) Ltd. INSPECTION AND TEST PLAN FOR HEAT EXCHANGSERS
Pata. 6-81-0009 Rev. 0
Page 3 of 7
Applicable code & specifications: As per PR SCOPE OF INSPECTION
SL. INSPECTION CHARACTERISTICS QUANTUM REFERENCE ACCEPTANCE FORMAT SUB VENDOR GAIL/TPI
NO. ACTIVITY & OF CHECK DOCUMENT STD. OF VENDOR
COMPONENT REPORT
4.3 Tube to Tube Sheet Chemical & mechanical 100% Spec/Drawings. Spec. DRG. WPS/PQR - W W
Welding properties
4.4 Welding consumable Chemical & mechanical Per Batch & ASME ASME Batch test W R
properties routine Sec II C Sec II C certificates
Spec. Drawings Spec. Drawings
5.0 INSPECTION
DURING
FABRICATION
Visual & Dimensional 100% Spec/Drawings Spec/Drawings Insp. Check - W R
inspection, weld edge, ASME ASME List
5.1 Weld Edge preparation Root gap. Offset, Sec VIII-1 Sec VIII-1
& set up of pressure cleanliness etc.
parts MT/PT of weld edges 100% Spec/Drawings ASME Insp. Check - W R
as applicable Sec V List
5.2 Intermediate Insp. of Visual/interpass temp/ 100% Spec/Drawings Spec/Drawings Insp. Check - W R
welds ISR/PT insp. after List
chipback etc.
5.3 Inspection of Visual inspection for 100% Drawing / Drawing / Insp. Check - W R
Completed welds reinforcement, Spec/ASME Spec/ASME List
Undercuts, surface SecVIII-1. SecVIII-1
defects etc.
STANDARD SPECIFICATION NO.
GAIL (India) Ltd. INSPECTION AND TEST PLAN FOR HEAT EXCHANGSERS
Pata. 6-81-0009 Rev. 0
Page 4 of 7
Applicable code & specifications: As per PR SCOPE OF INSPECTION
SL. INSPECTION CHARACTERISTICS QUANTUM OF REFERENCE ACCEPTANCE FORMAT SUB VENDOR GAIL/TPI
NO. ACTIVITY & CHECK DOCUMENT STD. OF VENDOR
COMPONENT REPORT
Nondestructive Test as 100% Drawings/ Drawings/ NDT Report - W R
applicable Spec/ASME Spec/ASME
Sec VIII-1 Sec VIII-1
PWHT 100% Drawings/ Drawings/ HT Chart - W R
Spec/ASME Spec/ASME
Sec VIII-1 Sec VIII-1
Hardness test Each weld seam & Drawings/ Drawings/ Spec Insp. Report - W W/R
as per Spec.
spec/Drawings
Production test coupon As per ASME ASME Insp. Report - W H
Testing spec/Drawings Spec VIII-1/ Spec VIII-1/
Spec/ Spec/ Drawings
Drawings
6.0 MACHINING
DRILLING
Tube Sheet Hole dia, drift, tube 100% Spec/ Spec/ Drawings Insp. Report - W W
hole surface finish, Drawings TEMA-R
groove depth, spacing, TEMA-R
ligament check and
positional accuracy etc
Baffles Hole dia & finish, 100% Spec/ Spec/ Drawings Insp. Report - W R
ligament check and Drawings TEMA-R
positional accuracy etc. TEMA-R
6.1 Assembly
Tube bundle 100%
Skeletion of tube bundle Completeness of 100% Drawings STANDARD Insp. Report - W W
before tube inspection assembly
STANDARD SPECIFICATION NO.
GAIL (India) Ltd. INSPECTION AND TEST PLAN FOR HEAT EXCHANGSERS
Pata. 6-81-0009 - Rev. 0
Page 5 of 7
Applicable code & specifications: As per PR SCOPE OF INSPECTION
SL. INSPECTION CHARACTERISTICS QUANTUM OF REFERENCE ACCEPTANCE FORMAT SUB VENDOR GAIL/TPI
NO. ACTIVITY & CHECK DOCUMENT STD. OF VENDOR
COMPONENT REPORT
Final assembly after Alignment, 100% Spec/ Spec/ Drawings Insp. Report W W/R
tubes insertion completeness of Drawings
assembly
Shell
Final before release for Completeness, passing 100% Spec/ Spec/ Drawings Insp. Report - W W
PWHT of box template Drawings
Channel /Bonnet Dimensions 100% Spec/ Spec/ Drawings Insp. Report - W W
/Foating Head ,completeness of Drawings
assembly
Tube to Tube Sheet % Thinning, Length of Random Spec/ Spec/ Drawings Insp. Report - W W
Expansion /welding Expansion, finish & Drawings
hardness/Visual,
distortion & DP of
welds
PWHT PWHT chart Review 100% Spec/ Spec/ Drawings Insp. Report - W R
Drawings
Hardness test Each weld seam & Spec/ Spec/ Drawings Insp. Report - W W
as per Drawings
Spec/ Drawings
Production test coupon As per Spec/ Spec/ Drawings Insp. Report - W W/H
Testing Spec/ Drawings Drawings
7.0 FINAL INSPECTION
7.1 Visual and Dimensional Dimensions, 100% Drawings Drawings Insp. Report - W H
Insp. (Internals & completeness of
externals) assembly
7.2 Air test of pads & Tube Leak Check 100% Drawings/ Drawings/ Insp. Report - W R
to Tube Sheet joints Spec. TEMA- Spec. TEMA-R
R
STANDARD SPECIFICATION NO.
GAIL (India) Ltd. INSPECTION AND TEST PLAN FOR HEAT EXCHANGSERS
Pata. 6-81-0009 Rev. 0
Page 6 of 7
Applicable code & specifications: As per PR SCOPE OF INSPECTION
SL. INSPECTION CHARACTERISTICS QUANTUM OF REFERENCE ACCEPTANCE FORMAT SUB VENDOR GAIL/TPI
NO. ACTIVITY & CHECK DOCUMENT STD. OF VENDOR
COMPONENT REPORT
7.3 Hydrostatic Test Leak Check 100% Drawing/Spec/ Test Report Insp. Report - W R
Shell side ASME Sec VIII-
Tube side 1
7.4 Surface preparation Visual insp. for 100% Drawing/Spec Drawing/Spec Insp. Report - W R
/cleaning workmanship
7.5 Painting Visual insp. for 100% Drawing/Spec Drawing/Spec Insp. Report - W R
workmanship
7.6 Final Stamping of Verifying stamping Name plate & Drawing/Spec Drawing/Spec Name plate/ - W H
equipment and marking details Rub off stamping Rub off
etc.
7.7 Drying of equipment Cleanliness Full vessel Drawing/Spec Drawing/Spec Insp. Report - W R
7.8 Nitrogen Filling N2 pressure & non Full vessel Drawing/Spec Drawing/Spec Insp. Report - W R
return valve.
8.0 DOCUMENTATION Verification & 100% Spec (VDR) Spec Q.C. Dossier - W H
Compilation of
inspection & test
records and other
documents for
submission to customer,
certificate of
completeness with
index.
Legends: H-Hold (Offer for Witness obtain clearance) ,W-Witness ,R-Review ,A-Approval ,I- Information ,X-submit, PO – Purchase Order ,PR – Purchase Requisition ,.VDR-
Vendor Data Requirements.
All the NDT /Leak testing /Heat treatment /Special manufacturing procedures have to be specially approved or only previously approved procedures have to be used. In case of
conflict between purchase specification, contract documents and ITP more stringent conditions shall be applicable. This document describes generally the requirements pertaining
to all types of Heat Exchangers, Requirements specific to the item are only applicable.
STANDARD SPECIFICATION NO.
GAIL (India) Ltd. INSPECTION AND TEST PLAN FOR HEAT EXCHANGSERS
Pata. 6-81-0009 Rev. 0
Page 7 of 7
~--~~O~·~i --~~--~~~~L-~~
DATA SHE~T- SHELl ANC TU!E HEAT t:XCH~'iGER (MkSi I of 7
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"''"", I
26 FOUI.INO RESIST. IMIN.I ..,1,oc.n/k;:al c. c. c.c '-1 I ~ C::.t. 2
27 HEAT EXCHA.NGEO tea•if\ 5 y ('~ P'-+c 'It I' :_ M:OCOAAEC1f:>.oc I
28 TRANSFER A .ATE laAIJm:ZPc;." 51!RIIIC: £ CLEAN
19 CONSTRUCTIO N OF ONE SHELL SICETCI1 1 8V~ t..._E NC?21.E OAI!"'hTIOIIol
30 S"' Ell SIC(. TUB!: :S•Of
31 OfSIGNtTUT PRt:S~ -alc... ~I~~&UII'tl 7. S' J f>l/ H •~v/
32 DESIGN l EM, ERA TUFIE, OC"" '"'J • ~ 1 71.. / ,) ,{)
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-
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34 CORROSION Al l OWANCE
''"" ,·.s 3.0
35 CONN~CTIONS IN l.i'c u ~ r:: f.~ 2~ j
36 SIZE & OUT I r:-r tt Rf _!,.;...,"~~ nr: '-
37 A.IITII~G INHAMtOI ATE {.. ,~ 8 ) ~
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42 TU BE!HE ET·STATIONARY c. ~ . S/1 . &'It, G~ h.., TVIES11 EET· F LO-'T fNG C. S .5.J 51(: ~L ..,.::
43 fl.O A.TI NQ 11 EAO COVER ( ~ 5t. ;-, (., GR '~- IMPINGEMENT PROT~CTION Y&S pv1
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-
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•
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48 EXPANSION JO INT TT'E.
~9 CODE REQuiRE MENTS ( ASME lllltr>11 I"):OOE $UMJt~E$NO LUMMUS SPEC TE~IA Cl>15S · &·
50
51
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GENERAL NOTES
t3} PRESSURE DROP AT FULl VAPOR ROW THROUGri TUBES (LOSS OF COOLANl) • 0.04
(5) OAILL A HIGH POINT VENT THROUGH THE TOP TuBE SHEET FROM WATER SlOE
(ldiJ DEG FROM CW INLE: I) 3'4 '
(7) TWO IDENTICAL ~iEAT EXCHANGERS ARE REQUIRED AND -.AE INSTALLED IN PARALLEL
- :r.
- .. •r.
-
-.. ....-··_ .. ..
360
60
130
370
140
N6 (0.5”)
410
N8 (0.5”)
370
6600
350
295
40
N2(16”)
N7 (0.5”)
380
S2
100
143
130 210
643
290
113
300
S3
N1 (12”)
50
400 N8
N1, N5
N2, N3, N4 N6, N7
1917
1. OPERATING PARAMETERS:
SHELL SIDE : COOLING WATER
INLET PRESSURE : 4.5 kg/cm2
INLET TEMPERATURE : 33®C
OUTLET TEMPERATURE: 45C
TUBE SIDE : HYDROCARBON
INLET PRESSURE : 0.45 kg/cm2
INLET TEMPERATURE : 227®C
OUTLET TEMPERATURE: 50C
2. TUBE DETAILS:
NO OF TUBES : 2262
TUBE ID : 19 mm
TUBE OD : 25 mm
LENGTH : 7000 mm
TUBE MATERIAL: SA 179.
TUBE ORIENTATION AS PER THE ATTACHMENT (FIG-2).
3. STUD DETAILS:
S1: 93 NOS OF STUD (3/4” * 19”)
S2: 36 NOS OF STUD (3/4” *10”)
S3: 71 NOS OF STUD (1” * 15”)
K5 [O . .S.j
S'U PPORT PA D
[4 OS. AT 9D,
[o ..s.j
8
-t- - ~
~~~IITTTT-=====*~ ~
t ~
I<
I<
1. OPERATING PARAMETERS:
SHELL SIDE : COOLING WATER
INLET PRESSURE : 4.5 kg/cm2
INLET TEMPERATURE : 33®C
OUTLET TEMPERATURE: 45C
TUBE SIDE : HYDROCARBON
INLET PRESSURE : 0.45 kg/cm2
INLET TEMPERATURE : 227®C
OUTLET TEMPERATURE: 50C
2. TUBE DETAILS:
NO OF TUBES : 2262
TUBE ID : 19 mm
TUBE OD : 25 mm
LENGTH : 7000 mm
TUBE ORIENTATION AS PER THE ATTACHMENT (FIG-2).
3. STUD DETAILS:
S1: 93 NOS OF STUD (3/4” * 19”)
S2: 36 NOS OF STUD (3/4” *10”)
S3: 71 NOS OF STUD (1” * 15”)
VAPORMWT
83.17
83.17
f C'f 7
•
6 708.62 0.0886 0.3481 0.5105 16.81 42.01
7 709.01 0.08872 0.3504 0.5099 16.86 41 .71
8 709.57 0 .08893 0.3539 0.509 16.94 41 .23
9 710.64 0.08933 0.361 0.507 17.11 40.24
10 713.48 0.09051 0.3825 0.5016 17.57 37.35
11 714.44 0.09092 0.3902 0.4997 17.72 36.33
12 744.4 0.09757 0.5855 0.4677 21.06 22.18
VAPOR DATA
POINT DENSITY THCOND VIS C. Cp COMPRESS ENTHALPY
KG/M3 KCAL/HR.M .C. Cp KCAL/KG.C Z(DRY) KCAL!KG
1 3.0833 0.02686 0.01137 0.5216 0.981 177.4
2 3.3242 0.02316 0.01057 0.4842 0.977 160.2
3 3.6396 0.0194 0.009705 0.4421 0.97 142.9
4 4.0797 0.01557 0.008738 0.3941 0.959 125.7
5 4.1027 0.01536 0.008679 0.3912 0.958 124.7
6 4.088 0.01535 0.008678 0.391 0.958 124.6
7 4.061 0.01534 0.008674 0.3907 0.959 124.4
8 4.024 0.01532 0.008671 0.3902 0.959 124.1
9 3.962 0 .0153 0.008667 0.3894 0.96 123.4
10 3.813 0.01523
•
0.00865 0.3873 0.962 121 .3
)j(. 'D VT'-1" S' \~ -:;uJ 1) f.... ': 6< C. 0- \ / 'r '(')
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• • •
EA-201 CASE I ·
FIRST STAGE CONDENSER
220 l
2oo 'f . - ! ____ I__ I I I I 1 1 I
- j
~ ~--
180 ] '
!
160 - -- -
~ ___ [
a:
~
<( 140 ---- I· +·--·-· •
~
w
f-
100 ---- .
I --
""'h -
1••~-;-. i p I [=1 -- I -. ~~ -
E
- -
.4 0I.!U [
80- ··- t--
·- -
604- - - +-
"'
":t:.
~
"\
90 100 ~
10 20 30 40 50 60 (l
%DUTY ""
~
~HEET b :;J: 7
• POINT
1
2
3
GENERAL DATA-- EA-201 CASE VI
DUTY*
0
-0.857
-1 .714
DUTY%
0.0
11.1
22.2
TEMPC
227.81
193
155.62
WT%VAP
100
100
100
VAPORMWT
90.77
90.77
90.77
4 ·2.5709 33.3 114.84 100 90.77
5 -2.6895 34.9 108.86 100 90.77
6 -3.428 44.4 106.33 80.71 89.57
7 -4.285 55.6 103.69 58.54 88.43
8 -5.682 73.7 101.55 36.43 87.57
9 ·5.9989 77 .8 99.87 14.29 86.95
10 ·6.5507 84.9 99.02 0
11 -6.856 88.9 86.45 0
12 -7.713 100.0 50.01 0
• 8
9
7
10
11
671.07
676.7
681.29
683.73
696.58
0.08717
0.08746
0.08767
0.08778
0.09074
0.2698
0 .2807
0.2898
0.2947
0.3414
0.5419
0.5379
0.5345
0.5326
0.523
14.88
15.19
15.44
15.57
16.9
50.94
49.45
48.28
47 .68
41 .05
22.45
12 731.77 0.09913 0 .5424 0.4968 20.87
VAPOR DATA
POINT DENSITY TH COND VIS C. Cp COMPRESS ENTHALPY
KG/M3 KCAL/HR.M. Cp KCAL!KG.C Z(DRY) KCAL/KG
1 3.2262 0.02837 0.01126 0.5524 0.981 189.9
2 3.4714 0.02468 0.0105 0.5176 0.976 171.3
3 3.7871 0.02093 0.009676 0.4788 0.969 152.7
4 4.2164 0.01711 0.008772 0.4347 0 .958 134.1
5 4.2827 0.01657 0.00864 0.4282 0.956 131 .5
6 4.244 0.01639 0.008654 0.4224 0.956 130.5
7 4.201 0.01619 0.008662 0.4164 0.957 129.4
8 4.1 66 0.01603 0.008666 0.4117 0.957 128.5
9 4.138 0.0159 0.008666 0.4081 0.958 127.9
' -- -··
0 180_1 " '
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0
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20 30 40 50 60 70 80 90 100 ""''
0 10
%DUTY """'
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H GENERAL SPECIFICATION
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REVISED & OfiSSUEO MJ SPECIFIC:A rtOH
1-SSU(O A$ sPECif'ICA 1lON
REVISION
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BY
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GENERAL SPECIFICATION SPECIFICATION REV
! IN:liA LIMITEO! FOR
1
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6.0 HEAT TREAT'MENT
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t5 7.0 INSPECfiON AND TESTING
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j~ 8.0 STAMPING, NAME PLATES AND WAR.NING PLATES
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PROTECf!ON AN'D DESPATCH
VENDOR'S GUARANTEES
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I~! tlus Sf"'CU•catton eo~cn !hi! •(l"!l~rU rec;um~mt:"l': fer resid!W ~~n d-:1 1illQS. t ""'-ttu.b
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tabroatioo, wO<tDWISbop, impcalon and teruns of ohell alld !Ube h03! oxclnr>~~ers :tnd is
uXe&.-.lc:d tu suppler:tl«:fft the: minin1u,1 teqlllrement'J of the 2pplic:lblc codes EJL simcWds
wherever lndicol.o4 in 1bG roqu;.izion wU be followed unleA tndi<oted ccllenrl5C.
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!~ This 'fCCinco.tion sh•ll not be eoosickred limilioa and it sluU be Vend«'a "'!"'ftlibiliry «>
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"""'1)1y with :oil rcquirtmCiliS of MJI.enol or Putcllase Rllqulsiuon or Bid documcnu 10 wblch
this apeciflc:uion is annexed.
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•"' 12.1 CODES AND R£G\JLATIOHS
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The followi,g coda in l!lttr edition ~lmor:ed In t!rawlnp or data shec!s or cloaign basis
shall form the buis for desl8n. materials, fnbricalion, lni!POC!Ion, lesling and acc<plaOOO of
!be equipmefll :
( (a) ASMB Boiler and Pressure Vm<l Code Section VUI Division I (Code), ASI-IE
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.. Section U Port A, 8 , C and 0, A$1-1£ Section V. ASME Soction IX .
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TEMA (Cbss U lij)eCi(l<d on !be dnw\oa> or dau sbcus or desill' basis).
Indian Boiler RcguiJitlon (IBR). If applicable (latest edition witb amendn>cl¥s UIXO
date).
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(d) Natlooai and loco! laws or regulooons, as oppiiCAbk.
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1.2.2 POR HEA'f EXCHANOE'RS UNDER THE PURVIEW OF IBR.
h (a) VePdor •11311 cany "'" d.,isn calcuhuioos as per IBR and only in cue <>f any doubt,
~~
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refer the ..,... 10 Pun:l>asu and ElL for clarilicauons.
~~ In case lbc equipmcN is nwruftctuttd in India. the design calall&ll<lCIS and
~!
(b)
fabrication dnwmgs al\er preliminary review of Purcllascr and lliL lhllll be go1
!J •pprovcd by Vendor from Chief lllspector or Boilers (CIB) of the scate wbcre
•• VendQr's shop Is loaued, bet- sun of fabrlearion. Vendor sboll .also provide
\ ..
H ~ necessary as&iitance to Puroh.aser for obtaining approval from CJa. of S£a(c of
!i ~&
ins:t:aJJ.ation such. as providina addicionaJ copies of calcul•dons tnd dnwinp as
R>qllired by CIB, otc.
·~
p (t) In case tbc equi~ is ~ OUISidc India, the design ealell!slion• and
~1! robricatlon drawings after prellmln•ry review by Purchaser and ElL Jball be p
l! approved by Vendor fr<>m the agency JUtllorbed by tBR in tbc coonuy oflabncauon
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and CJB of che J.tare where th:e equrpment is r.o be i~lalled, berore the start of
rabric:ulon.
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(dl It shall be !lie rcopon~lbility of me Vendor to incorporolc rnodlfoc•dOI\$ "' oddilions
if required by CJB Of i!S au&horisod ...,.:Y in (b) and (c) above and oboaOI the fino!
approval .
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~· (c) l'll.rcba.erlnd ElL 5ball be kep< infonncd of all ehanget or mQdificatioM desired by
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CIS. All cosiS toward$ approval from CIB wll be borne by Vendor.
AJI materials, ftbri~don, wcldins, testin&etc. shall mte1rhe requlremervs of rnR.
H
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GENERAL SPECIRCATION SPECIFICATION REV
A EHGINElRS INOlA LIMITED FOR
,. NEWO£Lt-tf HEAT EXCHANGEJIS 2
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n 'li lh~ 't.;ntlc.>r bXic:..J. un ,J'i:uhbl<! f.il!llj'Jt$ Such t.i.("'f!~U,n'IS muM~ C~'lrht P~.Wr-'1:'... ,,: ;..--. •
" dlt" funl\:llt "SCHEDULE OF DEViA l iONS " tn the Vt&vJv~'•s 'f.hiUllon, 5Y :a'"J to 1v,)~ .UYy !
CX)QIIJSiufl 'I'" ambti'Ul}' m:! f.t) l3ClJIIJ.IC atnf)S.U of~ m ~~~ ~i~e tJ11! ([ I
shaiJ be: r~k.tu for !fMled thlf except foe the dcv~.o~t.vns p.A;IUd out ul"ttkr IJIC ..SCHf.rt.iLE
OF OEVIA'IlONS" in me Vc.udot'!i off~r. all Other teehntcal Tt'qUh'!IT\CI"W'i llhall hr. ll.IJ(feQ
10 by !he Vendor
I
Ot-nc:ralJy nn de..,.i.aclons sh.;ill be cntcrta;iru.-d after the order tl:l:s beto :\iXel)ted by 1he ~or
un.J,cs$11 lt to c.o~Jy wjth st:llutocy or code requueOlCru. Aii w".ivers and dwi:l:iOD after
Ot<ler slull be "'""" clu"ou&b llw: R<g;ioml Procur<mffll Of l"'l!eC'oon Office Loduts•m <he
prescn"bcd ful11lllt. Delay in supply or llw: cqulpm<nt h<cauoe or IIJCb ck•~arioos beOS not
emertaiotd or approved by PurcllJscr or Bit or any delay in r1roe«sln' the sane by
Putctw<r or Ell s!WI be ro Veodor's lllXOUn< Any additiooal design wolk in supfKl of
such a dcviarioo sholl be pcrfonnallly llw: Vendor and submlll<d along wrlll the 4e.,.;on
I4 c..otradlctory nqull'ftllftlll
In case or ~&ny comndiction between the requimnenu of the requJsatioo, drawings ani oth¢r
documenu rormlna pan of the requisition. the mancr shall be resolved by Vc!Por in
consu!Wioo wirh Purd"..ser 0< ElL. Decision of Purcil»er or Ell. shall be bindJ>i and
without sny implic:ttion of cos' and time, il not resolved ac biddtng suge
20 1\tftTERIAL SPECIFICATION
2. I Gener:ll
2. Ll All mmnals and accessories required ror llw: f'abricatoon, inspecuon, leSlil\l CIC. ofihe heat
e.ct.an;er shall 1>< supplied by !he Vend<>r unloss olhtllllis< IIUIIJ!. Wh<ntVer SOOlt ll'leriaJ
Is to be supplied by the Puttha!;f!-r. thlt sl\all bt so indic;u~ as Free Issue Ma.tenalllnd the
supplcmenlary spcoirlcarl""' in lllis rcgard shall be oortlpl1ed wirh.
2. l .3 All miucr~als for prusure pans andl part& welded 10 pressure pans Including ro&teriJIS in tl:te
~of oubYmlon, sball be "''"''''P•nied willl mill ,... ceniliwcs duly cenlfiod by a
r<putcd rhud party l!'l>pcclion ogcncy. In rhe abccncc of mill test etttifiulellle lll$l(rill aball
be gor lcslod from a rcpured third parry inspecrion agency like Ell, Lloyd$, BV, DNV «c.
and tesa: results WII be submlt&ed in lieu of mill Cdl cenifieate. All cou 1owarcb such leaing
and i)lSpe<Uon shall be borne by the Vendor. All nurerialuhall be Inspected 11 Vendor'• and
:Rib-vendor's shop for verification prior to use on the job. The deciston of AUlhariso:l
l~pectoc 10 aocq>t or reject mas.eriah on the basis of such testin., ~haU be final.
'2. 1.4 When:v¢r Simulated heal ue::Ume[lt or te3t specimens IS rtquired u per Code or speclftatiorl,
the simulatiOII cycle $hall include one e.ltlra cycle of strcll$ relieving Jor mny eventu:.lily of
repau JJ site by Putthase:r dUnJ18 the lire of !be equipment.
2. t .S The exchnnger minimum design rneu1l 1emperature (MOMT) shall be taken as 0 'Cor !.'he
desigp Ll:n~rarure $pcc:ifiet1 in drawing or dacasheet whicbe\'ct l' lower. unle~ .spetifled
Otherwise rn dC$i&n basi$ or dllasflc<ts «drawings.
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• h •ll ~;- ·::-~ :::::.: !' ...... ..,__ ·~..ui ... ~ ~ ~ cf MOMT, .;:-f.. . . :- 1"-:.•
~~ ,.tt: J:S spectf.ed te ~!.~k ~~WJ1 ~:Lf'kJ!J06 or ;t; ;:i v~n w ,,m
1~1n. ;r.. 'ft i·"'!
·~-t.:.:-.-...4 ... ~" · V uio:.~tt.eoncaetWt.'\1" ~'t'!i.aes ..,.=l be -.- n:-' ,er ci t:w:
•ll""' .. prt 00 ... or awbcoble -....-...~
..U. .,.,. '""*'
.t the vendor"> shop with tho<""' """"'OIIUtt
In >4dil""' 10 ""' ..... done l l dle
tet ( ttute opecimens) I"' beat shall be rcpe3led ofier receiPt of lll"t<rl31
S>m< as Civcn obo"" U tho..., I'<SUlls clt-oes
""' m«t d-.c """""' """'IY rcquo ,..,...,.. SJ""" ....... the =<cml siWI be: rqcctllll
2I6 PLATES
2 I 6 1 Prmure 1"-<t: h:lvin& :1\idmw 16 01111 w 50 nun (bout meluslve) shall be ultr3S011io:ally
.......S (UST) .. per SA-435
2. 1.6.2 """"""pans ha•in& tlucblcss areatcr tlll1! 50 mm sboU be UST &I per SA-578 Level 8
2.1.7 TUBES
2.1.7.$ u is preknblo w~Ue ordefina rubes dle ma.<imwn Yield srrenglb and lwdne.uof rubes are
Jii<CIIicd II.ICb os 10 be low« tbao . - of tubcsh<d. in O«<er 10 ~·• • 50Wld expanded
lUbe to tube shea joint. C01t1J1Yina wrlh Code r<qwr-
Pipes lhall be .....mess and •= ob<>vc IW NB Wll be hot finis~ . Dimensions and
tol<niiCOS slull be 1ft xcordancc "ith ANSI36 10 or ANSI 36.19opplicablc u pu nwcrial
speeifiCOIIOfl.
2.l Spocillc: -.ia1 requirfmeDIS (l'rtss~ portS and parts weld<d to .,.......,. p:uu)
I
GENERAL SPECIACATIOH SPECIACATION REV
~ENGINEERS
w INDIA LIMITED
NEWOfl.Ht
FOR
HEAT EXCHANGERS ,._,..,.,, -
6 -16-0001 2
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(li) 0\arpy V-notch test as per supplemervary requirement SS. Test cempera.ture
wll be Miro5 29•c for MDMT s=oer th:rn 0< equal 10 o•c. For MOMT
IdS lhan o· c
rdcr dau.u 2. 1.5 *\IC. ln~aa energy values shall be as per
pua U0-34 of Code. or u per opphcablc: material spoc:ifteation, whiche><r
is IUab<r OnettDUoo of lest bu sb.all be tronsverse 10 rollinJ drr«tlon
(<) Unl«s sp«ified o1herwioe in requlsilion or bid doeunlent, all CS ma1uials speelrtc:d
aJ HJC ICStc:ll1lull meet the following requlrancnts.
IV) P1.ues shall he IO SA SJ6 Or 60 only (Hisl>et gr:ldeslik SA Sl6 Gt.6S and
10 are 110( "tepta.blc). The plata a.haU contain calcium or other rare cllnh
clcrncms to create spherical inclu3iont instead of :strin.gen. 'The pliUtl sholH
be tC$1ed in l)CCOtdance with NACB TM..Q2-84 U.'iiog the:: tc~U SOIUiion or
NACE TM.-OJ-77. The a«:ep<ance criteria ahall be Gtock length ntio 10 ')\
maximum.
(i) All LTCS l.nd CS c:barpy plate: matcditl shall bt co fill.: grain pract:JCCI and the
:tustcnlllc anin site shall be measured and reported lt'l the mill test ee-rllf.clte.
(g) CS pipes shill be SA-106 Gr. B. LTCS pipeo shall be SA 333 Gr. 1 or6.
(b) Non-- forcings (SA 266, s.... 3SO ecc.) $b.all be in IIOnllillised and l~ml
conchtion.
2.2-2 LAS MATERIALS
(a) All t..AS pl.,cs. pipes, forging• and fittings shall be in norm.1lised and 1c01pered
CQndilionll. lise or C-1h Mo materiaJs arc prohlbitc:d
{b) For t WCr-M. Mo materials the max.imurn room u::mptrature te.nsile SUC:r\8th of :all
pressure cO,.Ilinlng components, rruucrial¥ and welds shall be 100000 psi.
(c) For LAS tubes (SA·I99. 209 and 213) hard""'',.., shill be perf()nned on ouulde
of lhe tubes u pc:r SA-4SO.
__
ENGINEERS INDIA LIMITED FOR
NEW O!LHI HEAT ~XCHANGERS 6-15-0001 +2 .
..___ ~·~-·-
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Pa.o• 6 ol 20 ,
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(a) All SS lllilerial 000 sffies) sb.all b< In lhe sol~ beal<reottod (tully anocalcd) and
pictlod condilloo. All Slabll.t.od grades of SS( SS 321, SS 347 eu:.) lllall be Jl•co
ttabillsarion beA<<reulmcOI, in additioa to ..rorion -lin&.
(b) All SS (300 series) pwca sii&U be boc rollod and shall have No.1 finish on boch
oidea.
(c) SS 000 ..riel) m.arerials l<lr all componcul.s u1cluding ...,..p.....,.. pons likt
baffica, licrodl, at. &hall be procured wilh lhe IOC test as per AST'M A·262 (les<
lball be clltricd out, after the rpeelfled beAr <re.ttmenr and se,.ltisarloo per
opeclfrcarion) wilh ......,.,..ble
conosloo rm and practices u under •
ii) Nitric acid service: Practice C wnb corrosion mte nol arcatcr th!f.n 25 aills
per yt>t.
(d) For srraijh<chrome (13!11 Cr.) INUrial , mulmum cvtoon eonten<shall nor exceed
0.08!'. Hardll<$S of UNS no. 541000 and S4100R •hall nor exceed 75 RB and !hat
of 540500 shall 001 w:ecd 80 RB
I
2.2.4 NON-FERROUS MATERIALS
(a) All copper based non-ferrous pious shall ~ pnx:urcd in ani'IC31ed condition. \
(b) l'l>l<l for preaaur< pans ahall be IOOll ulltUOftieolly examined. Vendor shall submit
lhe procedure for UST tO Aulhorised lospector for approval,
(c) In acldirion ro hydrolest,:lll rubes .tha.U be tddy c:un~ cesced in their (lOll lnne:tled
condittoo. I
(d) All pipe bcMs shall be 11rcss ~ief IIJl!lealcd afler bendmg. I
(e) The paragr>plu NF7 o.ad NFI4 in Pat! UNI' of Code are mand<l<ory.,Tblo applies
co non..ferrOU5 ctaddihg and wdd ovcrtay.
I
A
w ENOIN~ERS !NotA UMITEO
NEWDELHI
GENERAl SPECIRCATION
FOR
H~AT EXCHANGERS
SPECIRCATION
8·15.()()01
PotG*7 el 20
REV
2
II
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p l~<oc::; sh..lll be (Cikd..or. or :::.mfo:aon bc>nde<J tJtc.
lO} Cl;Ki plates :'-hall oc uh:rl."St~o.icJJiy examined it·um the eLo.ddmg. $ U.rf :tt.-,: tn J;;~·vnl:m1_-.:
with S,'\ -57:!. Se:t:miog s.tu.ll te 100~ oft.~~ plate surfuc.e Acceptar:ce st:md:ud Sl-,;t!l
be level B. Cl.aJ plait:<; &hall meet the mtpplementary t'equirementll of S1 ot St\.·578.
All ultraJ~c>nic testing shall be undertaken after specified beat tt~t l)r clad plate:•.
(C) Both base nwerial and cl:.d rn:LC.erial shall meet the specification of the r~ve
materials M stfpula~ in this speeificaliM.
(d) Alloy clad Sleel plates shall be as per SA 263 or SA 264 or SA 265 . ll<lnd berween
dadding and the base mec.tl shall be checked for a minimlnn strtngth of l4 kg/nunl
in !!hear for alloy clad steel plates, by oonductio.g shear tesl as per applicable material
5petiftcatiou.
(e) for copper- aUoy clad plates, the bond between cla.ddin~~: and base: metal s.haJJ be
checked ror a minhnum strength of 10 kg/mml in shear by conductiiug shear test.
(f) During tension test of clad plau:s the cl~ldi.ng shall be removed and the tensile
propenics of the ~se matc.rial shall meet the Code material requiremems. ·
(g) For austenitic SS clad plates the SS surface shall be acid picklc:d as per ASTM A~
380. .For cbromium steel cl~ .surfaces the pickling sh:lll be ;~s per Vendor's
established procedyre. 'J1)c S3.!Tll:· shaJI be submitted to Pureb:tSer or f.IL fo r
apProvaJ.
(h) For all clad plates used in Hydrogen or IUS service with design tem;peramre greater
tbsn 3SO'C, Hydrogen disbonding teSl shall be carried out. The: tes~ cQndition shall
b\l reprt:~<:nl31ive oflhe ICIUIAl dc:~ign conditions a~ lh<: proc;~urc ~ball be ~l•bro.incd
to Aulhorised lnspec•or for approval.
1.3 Non pre.ssurt. paru
2.3.1 CS plates ~hall be minimum IS-2062 or SA 283 Gr. Cor equivalent. Pipes $hall be to IS
1239 or SA 53 or cquiv!l.lcnt.
2,3.2 Saddle material shall be same :.J.S th:-&t of shell rQr shell deSign r;:mperaturc greater than
350'C.
2.4
The materials for various components in a heal excb.anger shall be as per Purcbaser or EJL•s
rcquiromenr. This does 001preclu.-de use of equivalem or bener ma1erials. However, lhest
deviations should be d early jndie::Ued i.O the prescribed ronnat. If an equivalent OO.li!Cfinl
sought by the Vendor is 10 a specification. other dun IS or ASTM or ASME, it is necessary
for the Vendor to $Ubmit the sped lications or the equivalent awe-rial with .complete details
in English for approval.
3.0 SUPPLY
Supply shaJI be in accordance with requisition or bid document'i to which this specification
Is au.ached. It shall. hi)Wever. include lbe following:
All ""C"'IfY acc:eJIOfies such u $14)p0ftl. b.lind flanges, lest aukcf$, bolts, nucs etc:. shall
be provided atld $Upplied by lbo Vendor for turin& Of beat <J<dl!n&ets, in hb IMp and for
" 'bo"l'Jtft u:sting hy Pllr<huer 11 oi~e, whenever rcqyir<d.
3.3
3 3.1 Vendor WJI obo $Upllly ue bole., ltvcUinJ shims or intmnediJu: sui)llOn.' lor !lacked unlla.
Gasket$, nllls and boles rclatin& 10 Jnre.reonneainJ 00%1les (rube and shell slde) ineludJng
ljlVOS Wll bo $Upllli<d hy Vendor. All m..e nomponerws shall be desparclled separately
wilh due care having been taken rcprding identirtcl!ion of tbese for ease of iasl.altation,
3.3.2 Earthing Jugs shall be provided on c.acb heat exchanger and •IWI be located in such a way
u 10 mrid any louting witlt the exebanaer fow>d>rion bolts a1 si<c.
3.33 Vendor 10 tupply one 11t1 o( 1orque wrend!e5 for bois size M4S (I !I ") 10 MS6 (2 \j ") and
a scr of boh censioner for boll s izes greater tb:m M56 (lW.•) in cue tbese bolt •l= m
beinJ used in excltan&e<1 eovored In !he requl$ition.
33S Addit'tOOS like ctau for piping. ladder. platform, ioaularion cleats de. wt!Jch may be
tCC(IJired II a Inter .1111ge 8haJJ be provided.
3.4 Calbodic proccrtion
Wb<nevor oalbodio protec<ioo is specified both sacrificial anodes 'IIIII bxcmal painlins shall
be proYided as per ElL Speeif>eation ~201 unless specified odlcrwise.
3.S Spans 10 be suwiJ<d by veodor
3.S I BOLTING : 20" $1uds and nucs bul DOl less rllan 4 studs wilh 8 nucs for eaehjol nt.
3 S.2 GASKETS : 400" &»k<U O<her man 1hoso used fo r bydroleMing >nd despa<cb for ea<:h
joint.
3.S,3 Spare bullings and g.,kets wll be provided for all joiJU of ginll ~. ftOatlllS head,
ctwmel QOVer, tubclbect, intcrconnocd.na notzles. noxrJcs with blind Oangc etc.
6·15.0001
" - 9 •HO
REV
2
. --- ------- ., .
• .- ··-. ..............
. ..
.' .' r. ~1 ' ' ' , ...... ,. .... · - • • ... "'" _.,. . . . ,.,..,,. ..'<'Hf"""' <'h , ,, ,._. ~ ,,.,. n.n m1ri'lmu\A" rn-;'"'
.J\.lU be (i)lll)W(d by grm.Jing tQ J. ~"lUOOth and regular !WffJCe. Qxy-acetyl ~rte fl.unc: t."Uflln.io:
shlll be followed by machining QC gooding m dimin.rte any di~>IOJ:.Iliot) ot mattrial
affected.
4. 1.2 For L.A.~. the <dge.• for welding. shall b< mode by oxy-w:~ylenc tlltlitc culling or by
machinirt¥. Cold shearing may be used for cuning lhlck:ness upro 10 mm. Oxy-:leety len~
flame c:uuins llhall be used with pccheat snd •hall be fol lowed bv maclnning or grindhlJI to
ehmin:uc any discoloration or materW affetecd.
4. l.4 All weldln& odacs after cutting slWI b< Dye l'<n<tr>nl(DP) or m>gnctic partki<(MP)
examined ror laminadons. eratki or stgree:uion. Add1tlonaUy UST shall be c:uried ou1
within twice the nwueriaJ 1hickness of edge (or LAS materials or when rl'le serv1ce is low
remperawre or hydrogen or HIC.
4.1 .5 The parasraphs NP7 and NF J4 iD Jl'll' lJNF of Code are rnondotory This sppli<s to non-
ftrrous tbddina and weld overlay.
RerOIIing after weldmg is not norma.lly recommended. However. if for lurge diameter
sheila, rerolliJl&of welded shell course i.s ineviuable, procedure for rerollin.g along with
extenl or I)On de11tructive tests (NOT) shall be subrnined for appn:waJ of the Authorbcd
Jnspeaor. All weldJ on the section to be rerollcd must be ground flush. Al:\er rnollin,a all
the welds on the rc·rolled $Ct.1ion must be DP ctM:dtotJ. su~h weiUs sbaU then be suhjoc:ted
to radiography ., required by drawi~s am Code.
4 .2 .2 DISHING
All dt5bed hc>ds shsll ptofcrably be or tingle picc>c c:cl01SINCiioo. Howt'er dished eDia with
one chonbl team are acc:epgbk: for $hells with di.Jmetcr grute:r dun I m. In such cues.
Ill< dlordal scam tflall p<ermbty b< in die middle ooe-lhlrd or tile blank. Dished <nels slull
1>< torisphericsl (knu<klc radiu• ISlt of outside diam<ter aoo crown radius 80!1 or outSi<le
di1flll<er) or 1:1 ellipsowl. Dish.cd heads shall!>< wbjcctcd 10 DP test on ((nuclde ponloO$
(bach in.<tlde tLnd outskJc) and weJd edges aficr hen& 1reatrne1U. Vendor (() ensure ad~llUa.cy
or indicated thinning allowance for dished head It nominal thic.kne:ss. indic.,led Is I\Ol
acle_qunlc then the nomin.1J d1ickness should be incrells.ed accordingly, keeping minimum
thklmcss n.s per hem dr.~.wing . A strnight race or 38 rnm or 3 times the. nom.innl thlck.J.ess
of dished ht.lld, whichever is less, shall be provided.
4.3 Wddin&
4 .3. 1 All ~Jdtna .00 weld overlays shall!>< done w1t11 decuodes. fillen and Ouxcs of reputed
.-.ate with pro..., reprodutibiluy of roults. Bt>nd..,.,. wll he speeif.ea!ly appro•<d by
Autl'loris<d l"'!'CCtO<. FO< CS prossurc poru, tl>< electrodes >ball he of low hydroc<n type
·-i ;. I
I •
•• ct:IMID.. t:\;U<:OJ.tJ ;~._lJ ~ ,~t.;kk:J •ttl\ el.-~,:trt.JU= d1r!t pnxiUCC:: lJl UU$.'f4tic dit•·t~UIJiil
·J tuc;fccj WckJ d.ei)l"-ii HI ~ 1.. \oi I~'F ,...~.:::; :;i.:!.;!".. .,;..u_o,•ur-IIOU WCiu oiCfJ'>Slf
' 4.J.2 All weldma proe«!ures llu!l be ocllnuaal for appmval by Aw!>Qri<O<J lwpoaor giviJ1811ll
-~
1."
•,; reJeva01 der•ils. Welding qua!lfu::t~IOI\ recorils sl~:~ll lndicale hardness vlfuao oi wcld mersl,
-·li
~;; RAZ ;and pueo~ mcu1 and ~fO n::m1ta or in~ te11u when dada.n ll:rl~"'rurc are beft)w
o•c or wbc:o II'C<iriQ!Iy in.!icakd roc ......w. beina ,.tided. No ....tdmM •Mil be
undemken unul me welding procedure an" ""'lder's qtuliftc:llion h3ve btm approved by
tbc Authori.ted INj>Cdor. All wddin& procedures and welders shall be ~•a!ifkd for the
particular type of welding and Dlllteri>l in aecnrdm:e with lbe ASMP. Surio.~ IX. Vendor
;; sllall be responsible for me qualitY of me wclds perfonned.
!::;
..
H
" 4.) .3 Pmsurc boldma?.•w shall be filii penerndon welds. Roo< pus ohingluW. welded joints
shall be done wtlh GTAW process. Backing $!:rip tor sinJie side "'elded joinrs is no•
permined. For LTCS moterials, b<>th h~Jide m1 outside of w~ldt shall be pound ftuoh or
li• dtes!A!d ~. All imemll welds in me lhell shall be 8f0Und ftush In order IO inserr and
r.movetube buodlo, AltO alll)1lt1'n:ll welds shall be p>und 01JOb 10 me Well ortocihtating
u dnioins of complete equipment, All other weld ""'Y be leA in tile desealed «>ndltion only.
·~
(
H
.~
4.3.4 Longirudinal seams shall be •••ggered willllbe circumferential dlSIIUI<C bet-.. me cenues
of weld.< beb,g at least $ rimeo the thickness of me lhieker-plate, Weld S<:arns shall be
loeored so as to avoid ioterfcrenco with weld...., of noules and utcma1 llladlme11cs.
lA
;~ 4.3.5 AUachment 10 pressure pan sbaJl be of same qU3lity as the presow. pan . All LAS weld
~~ au.acluntru co pressure retaining eomponenl shall be full penetration weJd and ground to
a "mooth coocavc concour. ~f.Uial anxbmeDu like tup. suppons etc. orCS 5tu.JJ not be
d~1 ~lded dln:c!ly oo high alloy or au.,enh lc SS hear e.•cllJlnier c:ompo!lf<IIS. Tbd< arladunern
"*•s should be of me same m>ICrial as me hea1 excllan.ger oocnponeOI. U lh~ bi 001 SO,
'u.t intermediate pad plates or !be samoo mau:rialcype u the heat •"ban&« compooiCO! may be
wed. Tbes.: podt sball be a1 I<Ut I OOmm wider and loJ18er rhan Ibe llltlCitmtnr and sboll
be •• l=t 5 mm thick. Wdding of CS or LAS 10 austenitic: SS sball be clone ,.;,h austennic
111 • SS dearodes or filter w•rc (AWS-ASTM·F. 309L or E-309 MoL only).
II11i Wrapper plares, reinforcing podt or sdiTen<rl ofhi&h« thickness than II'C<lncd eao be used
provided the~ is no cbange lD basic dunens"K)ns and wtth the approval frBm Aurhorised
lnspeccor. No sepatate deviation pennit iJ rtquired for the same
(
ii
•11 4.3.6 P:tnitlon pta<e of CS and 300 series SS CXC<I'I for low l"'11tf11Ul'C sel'!lce, shall be welded
~~ 10 ch3nn<ls ere. by continuous fille< weld.< whh minimum size or 6 mm on bo<h sides. For
• E Ill ~r material$ and tor llydtogen and low ,_.lure servl.,.., all weJds involving
a panioloo plates shall be full penctrari<>n weld. Parti<ion plates dliclter than 10 mm ohlll be
F
-ll
IIJlCrcd ro 10 II'Cil a1 panirion groove end eJ<eepl wh<n mentioned o<hcrwlse on dnWil\ll.
One weep hole of~ nun diamtltr tbtll M provided at rile ecn!er of eacli honzor•lll pass
:li
&1
partilion plate and • S mm radius norch on rop and bonom polnr of each vtrtictl pass
p:anltion plate ror all multipus. e~ ror dfeedve veming and dnining.
l~ 4,). 7 Weldin& of shell 10 Wllolhbcd ....,..._ st:Wt meet me requlrem<nl$ of COde eonsklering
H
t! 4.3,8
that the tubeshee[ is unsupported
When impact ICSIS ore required on material as per Code or specificat;o, the ~·elds shall •IJo
be qualified for impoa IC:SI. In such ~... following speci•l requiremtnt sh>U 'I'PIY 10 me
·~
welding procedure qualifiCalroo:
.H.
i) Qu>lifocat;o, tesU shall be mode on plarcs of the ASMB specif~e01ion ss specined for
!he cxch:Ulger us1Jl8 weldlJ18 dectrod.. of AWS or SFA speelfrcauon aed wire &.
DUll or rh< speelf~at;on and brand •• are 10 be U.led on Ulc job,
!"
.••
I'
-
-•·~ I ..... ' "'• !! !~.! !:-.: ;.' .r••• l!!"'.!!.,... ~~!n;'"':t...., ... ' .. ti ,,...1'!'~1 ,~.-1.. . ,.,.-,_;..IY'-' ~;.-..
(;.~ut:al ~i1<l.:u.c::;t .
Spect!ia.:J:,·, te!( :::IJ' ·· ,r:all l':c i>..:i-.! :u t:lt~d~·1 1.. ~ !i~J
,, ..., ,.,..
-~
sttess rt hcf tc:mpc:ratures f\J r appr.lximltt:ly the ~arne le-ngth ot umc a:s Lht hn,.Jl.W
--
~:s
~ c-:.•
n .:hnoger Ftn.tl cooling rate shall bt' appruxlmJte lo lb011 etpectetl fu r the ftnt$hcd
exch:lfl8C r,
li...
H
iv) Charpy Y·noldl impact rem sb:lll be made on the weld and HAZ uf the t"'t piOie
for <Och weklln& pn>«<iure w be qualified. TCSl proo:tdurc sb:lll be .. p.r UG 34
or CC>de Teot t<mp<rorur<: shall not be hish<r than MDMT. lmpac:l energy
requonomc:,...$ball be as pee Table 1.15 of SA 20 of ASME Sectioo U Pan A"' UG
·-
jl 43 .9 WELDOVERLAY
3-1 ol Codo "'lud>ever is higber
il
u
4.3 .9. 1 Weld deposit overlay wll be clone by t qu3lofied weldtng pr«edure and Sllrfu:e shill be
properly mtthincd or around tlwb after overlay. Minimum thklcness of linished weld
u depa~ i t shall be as indicated in the drawings or .speclficatioos. In c:ue a h.igher deposition
p t.hie-kntss 11\d multiple wekllaye£8 Me rtquired to o.chieve the minimum specified und1luccd
deposit mc1al, the same shall be done only after Utkina prior approval from Ell. Minimum
thic.kne:ss of undilutod finished weld overlay from top shaJI be 2 nun or as specHied in the
fi
•I:
dr:t•Ni.ngs. For non-ferrous weld deposit, the Iron dilution should be restricted 10 2.$1
(maximum) in the finished undiluted layer (thkkness defined above).
•, 4.1.9.2 Tht weld overlay proc::cdu~ $hall beq.Wified on base rMtal oftbe same ccmposi•~n u the
!J-, exclwlger eocnpooc01 >nd m<e<ing lbe req.ouemerou of ASME Seetioo IX .
!: 4.3.9.3 lbt wdd _.-lay wll be relative.ty smoo<h "'"' 110 nocchc$ and undcraou tlul ..ould oa
as :stress nlstn AU enacts, fiS.!Utes and cireu.lar dtfccu JfQICt th;m 1/16 inch dbmdtr
H $ball be remo•ed. Repurcd areas >ltall be DP clle<kcd Weld overlay sb:lll be applied w
u~~ base m«al w~uch hu been gric bla:s.ted 1tJ"ld i:~ .smood1and dean so a.~ ro ensuR fu ll hoondtOS
Welding overlay cladding shall be applied after any notma.H.sing bot befnre the po1U wtld
heat treaunc:nt (PWHT). The weld overlay shall consist of at le-ast 2 layers.
4 ,3 ,9.4 The alloy clndding 1hall be C-Ut ~kat all seamll to pennit back·welding o.t the base mcrul.
Wdd metal sllllll be ground nus~ ••Ill fu lly ou•ered wiOt the applicable weld deposit. The
li
ll
weJd joil'll 1n bMc plate shall be L OO~ DP cestcd for detection of cracks and Oaws before
wdding from clad side. Tht: we-ld deposit shall be at lease as thick .as tbr: cladding.
H 4.3.9.5 Sheik. coneo and di1hed helds formed from cbod platc:s shall be UST mer lorml111 for a
minimum ol lOll or lbe cbod surr.et, intludi!ll 110 Ieos tban one "''''fC feet in d<h 10
If square fecc or frxuon tbtrcof. Unbondtd areas dw canooc be C:'I'ICOml'lSScd by a 3 1nth
diamet<r c~l< •hall be repaired by weld OYetlay WhM repairs in exreos or 5 ll or lbe
H
il
toni examined Ilea an requjred., the compltt.t exe-hanacf 1hall be 100,.; UST. Repaired
areas and wck1 deposit overlay at weld seams sh1lt be OP examined. UST shaH be repeated
lor di<hed he:tds after heat trearmem. All UST shnll be In accordance with SA 518 S6 lor
l·· spot exa.mimuion aOO SA 578 S7 for 100% e~~:eminJu i on.
if
i ~ 4.3.9.5 All wdd overlays shall be 100% DP examined In ncc:orda.nce witb the mc:•bod described in
ASTM·8· 165. 11te butier layer shall be IOOll examlrtod. Wben !he OYerlay Involves
II multiple pu.ses (layers) and the procedure usa an lntcnncdillte heat treatment with cool ill&
H to room temperature prior 10 applying the subsequent Layer. each layer shaH be eumioed.
Where ovrrlay is to be machined such as for ftance laei111, madtined sur lace shall be 100
S eumined al\er (111&1 PWHT. II 100$ ol overlay IS <Ulllloed prior tO tit< final PWHT.
I'zf
• v
o,·erla) lllall be '90' eumioed (noc less th>n lOll of lbe surlatt) after heat trearmeno
H
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hll ca. I! r"fP"" N we~ ng RX;.:j,J,
,11..~"t!:C!'1~ !.-.sy..t.l.vl (ut avpcuvai
~It •}( nt; d~emJCl! .!JUJYSil uh.1?l ~...1 ill!'.muu'"' on
--
~
~~
4.).9. 7 For all wdd ovetlilYS ll!ed in hydrogen or H2S ll:I'Vi(:C wirb design ~r.uure g~ tban
35Q•c. H)<borcn dlmndlfl& tesc :hall be c.arrled •>~Jt . Tbe test cc.~OtJn)()n sball be
~;; repreo;c:nuuive. of the at:tual dc•ign coudicioot and dx procedure "Sb.tJI be s:ublniuod (()
i~ Audlonled Inspector for "'''lrovo!.
·-
£ •
i!
=~
4.J. IO PToducuon '""coupons (P'TQ ore required for CS welds above SO nlltl lhi<*nes$. for LAS
weld.• above 25 mm or when l'l:qUired by th: Code. The iollowma $ball •pply:-
~- a) Two PTC. reprcstOI:atiYC: ot one lon,&iwdinal and another c1rtumfercnuaJ seam shall
H~
be provldcd for each proetdure. po&ilion and lhick:nes.s.
•i;
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H
H
b) PTC shall he from maltrial of the wne heat •nd thickneso u o1 par<n< mcul.
Durin& ond lftcr Mldln& PTC shall be subjecced co •am• he3t ,,..1men1 u and
together wilh lhc oourse lhey n:present, excn PTC shall be praervol 10 calte care
of evClliUality of tt1o:su.
c) The ICSU mendonccl below sllall be carried om u per metllods of ~ing in Co)de:
H
~t
• J
I)
li)
One transverse tcn.non lest
Two side bend lCiit.S wich weld located in lbe ccmer of bend-
!t
~:
uij One ban:lllt:!S C«t on PTC weld and HAZ. The acctplahlo: llmiiS "'" 200
BHN for CS, 225 BHN foe P3 and P4 materialS and 235 B HN for PS as
per 6-15-0091.
~~
H IV) Micro and macro examirwlon of welds.
u v) For CS, <harpy V ootc~ ccsu on weld and HAZ slull be canied ouc. For
MOMT below O' C. impacc 1e11 c~racure shall be MDMT. For MOMT
greater lb4D or equal 10 o·c. th: .... ,_....,. ohall b< o•c. The
H
ii vi)
ac:eepco.nce criteria for i.,..,.ct enersy shall be II$ per table a 2 .15 of SA 20
of ASME Section II part A or UG-84 of C>de whichever i11\iJj>c:r.
For LAS, clttrpy V DOitb...,.. on weld ond HAZ IJtall be carried our for 25
\.
H
•i 4 .4 Tube ro tubesbeo< jolms
mm lbiekness and abave or when speeificd in requl.sition. Ta r tempctanlTc
and a<:cql(ance criteria shall be u per <louse 2 2.2 (d) (II) above
~~
~J Requiremonrs of 6-15-0003 shall be C<lm!)lied wilh for •-elded rube 10 IUbcJI>e<r join«s and
mac of 6-15-0004 shall be eomplied wich for expanded cube 10 IUbcshecc joinu.
ii!
c -
1,• 4.S Hardnw Umitadons
d
••
••
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1-brd.ntss limitation for maic:ri.:ll.s wherever spcti(ltd on drawrngs or duasheeft an! LAS
materiW shall be as per Spce. 6-1~1 . Hardness lim!cariQn for tube to tubeshcec weld in&
h shall be -.tablished on a mock-up with JimulW<>n heal trea<m<nr. Hud..,s of suslgllt
I
f. a dtrome malcrials in rho eold formed mre, H"Z and welds ah•ll not exceec:J 88 RB.
"l
!i
••
a GENERAL S PECIFICATION
•
\
A SPECIACATION REV
w ENGINEERS INDIA UMITED
NEWOEUtl HEAT EXCHANGERS
FOR
6·1 6-0001
Ptffl 1 ~ol 20
2. ' I
L;
Of.:c."'f.i •~t :-ortrw -:>e ;.;.;:~...;. di••ko:.Ji,}n.;. JriUin,ti. (Jdmt Jn..-1 tol-;:;:.n·.c~ (¢•· ::.:;;::~!.: lla!l~e:;
Ffnrl blir.d "'"~ts if ti'qnir-rl\ sh:i:U be a:;. per ;-\SME B 16 5 (foe $i'u uptc 24" :-rm ~c
ASME B 16.4'1 Serle$ B (for SIZr".S. ;~bove 2.4" NB) far d'e respecuve d:•ss ~ Weld overlays,
wherever specified oc required, st\::1:11 be in addiuoo to the duckne:s~ J:i pet" thc::se stantlard$.
Bolt holes on these nozzle tlsoge\: snnn $traddle ptiac.ipal venical and borizomat cc:nu:r lines
of equipment. Jf !he co~t to whicb noz:zJes are atti!Ched i$ sub&equently stress
relieved, il shall be: Vendor's tesponsibilicy to maintain true gasket faces by m:JChinln.g or
otherwise. If distOrtion expected is coosidcrnblc. final machining operation shollld be done
after stress relieving; sufficient m:acbiuing allowance for this purpose should be available.
G>Skoc•, lor flanges 10 ASME B l6.5 ml 816.47. shall be as per ANSI 8!6.20.
4 .6.2 NOZZLES
4.6.2.1 Nozzle pipes shall be attaclled to the heat exchanger component." hy full penetration welds.
A!W:Iunc!\1 welds ming n•~Y inner and outer fill<1 w<l<l:l arc IIQI pcnniutd. Unless
otherwise indicated on the da.tii.Sht:et..'i or drawing,!, 1leclcs of all nozzles sh.:all be flush with
chc if)Side of the heal exchanger component. ln.'lide comers of nonle pipes ar shell and
channel inside diameter shall be radtused. All nozzles 2" NB and b<:low, except long weld
neck, shaJl have two stitTencr11 (30 mm x 6 mm) at right angles,
4.6.2.2 Whenever noztle i11.$idb is required lObe overlayed, these slt:IH be done by weld ove-rlay or
cladding. Minimum nozzle ID before weld depositing to be SO nun in such cases. Liners
an: not acceptable.
4.63 REINFORCING PADS AND TESTING
Reinforting p3ds whe:ncveT required as per drawings or Code shall be Qf tbe $3ffiC material
or equivalent as the beat exch1tngcr component to which it is welded. AU reinforcing pads
; hall 1>< ptovided wirh two 1/8. (3 m.m) NPT tallPed hole:!! loe:ued 180" aparr ror air ~oap
solution test with a pressure or 1.25 kg/cnY!g). This test shall 01Jso be requ:ir¢1.1 to bt: carried
out for slip Oil flanges. Higher test pressures are no« recommended because or
accompanying cisks and also because tbe sonp bubbles have a chance to biow off. Tell-tale
boles in d1e rein!orting ~s shall be plugged with bard grease uoii!".')S otherwise indicated
after the hydrotest of the e.x_ch.anger.
4.7 6olt"i, studs ttt. and tapped boles
4.7.1 All inch bolting and threading slull conform 10 ANSI B 1. 1 excepl (or $i-Ze l" and above
wh.t.re h shall be 8 threads per iach. Metric bolting and threading shall confonn to ISO-
R26J e.xcepr for size M24 and above. where it stull have 3 nun pitch.
4.7.2 Sruds shall extend beyond !he 1\U! by aboo1 I0 mm and shall lx: threaded full leog1b excep1
when square ends are required (or use with bolt t¢1\Slooer. In which case the extension shall
be as per bolt tcnsioner manufaciUret's reconunendarion. The studs for ~xteoded tubesheers
and the u uds for use with connecting piece shall aLiio have square ends.
4. 7.3 All nuts sh.all be of heavy series only a!ld nut searing face.s sbaJI be madlinod or spot f~M::ed.
4.7.4 Threads on e.xrenud bOldng, plugs e(C. shall be lubricated with graphiu: grease. for working
temperan.re upc_o 200•c ;~nc:l with Molybdenum Disulphide for higber cemper.JtureJ.
4. 7.5 Tapped holes drilled on '"' channet side face of cllld lube sbce" for rtmov•ble bundles sh.oll
be fitted wi(h plugs of a rruuerial similar to channel side material in cont!l<:t wi(h tubeside
nuid, For CX(ended rubesh«ts, r~ppod holes shall be provided for ginh bolting.
Ia
l,. ENGI,..EERS INDIA LIMITED
NEW 0£1.!11
GENERAL SPECIFICATION
FOR
HEAT EXCHANGERS
SPECIFICATI ON
6·15..()001
2
P-ag" 14 of 20
•• • :· r::: tr'J..... ... ... ~· ~ ...£ ...
..! ' .. --
"
~8
t.S.l V~ r .).i._aU bt ft'.Jpoll.liibte Cot uk:mg 001.:Quat~ prc'lm£1\lc Jl.lt.::.l.SW'CS w tefli&Ure the qualily
tOO finiih of mareru!s ~ to 3.votd. any N:ling
4.S .2 S..it;al>le onetbod o( lll&lunent l!ko dowell«<. •11>11 be provided for prq>er asaembly of
ch2rmel, chaMe1 covers. suuionary tubeshcet ecc.
4.8. 3 Sucked c<&:h:lllgers shall be assembled in die worbbop for a trial fit. Speci>l <>re >ball be
eu:rrisl:d il'! maina up cor;ocetina noz:zJe flangei.
4.8.4 ·r· .merever 1ndi<11ed on drowins;s. d<ntXes m.1ld1 nwt for wanl>ly and Wil be: puncbed
on all maling pam
4 .8.5 Lifting 1111' shall be provided u per SWitl.'lTd for limns of clulnne.ts, <lultmet covers, shell
covers, teat rinas. ttsc flanges etc.
4.8.6 In case or removable bundles t1v: f<~llowing are noquired:·
(a) Slalionary lube sbecu lball be drilled and lapped •• venical (0') poririon for
auaching eye bolls: or a lifting Jua or lde<jlllle lhid<ncss ohall be waded Wldl 2,
mm (minimum) diamc<et bole.
(b) Orillinc ond tapping as above ohall be carried oul on Ooollng IUbeshcc<.
(c) LMI suppon plate shall be drilled (lS mm diAmelcr hole) for lifllng. LO<l\l suff<rung
may be neces.nl}' 10 adequately suppon !he bundl<.
4.8.7 Pulllng eye boles INde rrem fMpl CS shall be fi!O'Iided for All removable bundles. The••
shall be provided loose.
4.8.8 SuliOnal}' rubes'- shall be drilled and lapped for de rods. C... sbould be talten 10 enoure
lhot holes .,. 001 drilled tl!rouih.
4.8 9 l~eabl• and 180' rorauble bundles •hall have conlmon p...,_p4.Udon aroove
amngcmel\l in lbc reopective WbeS~ For uchangcn wbere bundles are •pocifted 10 be
lmttthanaeable, !he same shAll be ensured •• the Vendor's shop by OCtUlUy ins<nin& !he
bundles or U5lng a 1empla<e c:onsWlna 4 IWI d"-er baffles. eadl spaced " a di!Unce
equol "' the blme pitch.
4.8.10 Jack sorews ohall be provided on •U ,ginh flanaes.
4 ,9 Dl:scalina. pick! ina and ~·lvadon ohall be done [or all ss pam or heal -..hangers in
occordonce with ASTM A·380. The Vendor shall >11pply d<l<lils of the J><OCc:dure for
approval co the Aulhoriscd lnspec:wr.
4. 10 No disconion wb:ll.soever sJ:u.Jl be pcrm.;ned on tbc gask-er. ~ina surfaces due ro rube ro
\
rubcoheet woldmg, sbell to tube•h<:et weldmg. PWHT <1<. If distoned, !he s:uae >bAll be
1110<hlned subeequ<t'dy
4.11 I The climeosional IOierlllCCI shall be within Lbe limits indlwc:d on ElL drawinSJo and
standard$. }Vhere rolc:ranec.s are noc specifted, these shall be in accordllncc w1th the
rcquir<men~s or TEMA and Code.
'
A
w EN GIN EERS IN DIA LIMITED
NEWDCI.Jfl
GENERAL SPeCIFICATION
FOR
HEAT EXCHANGE.RS
SP€CIACATION
6·U.0001
P~• 161'1• ?n
REV
2
I
'"• • ' I j ,.,
7. I l hupcaoon shall be arncd ""' botb ~ r.btictlion and before dclivay and also for
sutordered maten:lls, 1! :t.ny. In addition to fina.lmspe~;tion aAJ cert1ticadon by Aulhorised
lmpcctor dutina tile <GW$0 Of manufotturo, Au<honsed Inspector'& wriuen opproval sb:IJI
be oblain«l by 1he V.OOor •t vorlollS Sl>ges or f•briauion. For this purpn<O, Vendor shall
prepare his Quality Assurance Plan. defining the $tages or fabricatiOil, hold pohus for his
o-n inspcc:r1on .00. lhaE by the Ao:tborized fNpeetioo or Code or starut:ory Authorities
lnspcaion c«: The Quali<y Assurance Plan sbalJ be dlscussed wilb .~ud!onsod <nsp«~ or
befon: Sian or job and lllUIU>IIy agreed The variooH sages of fabricalion 10 be onspcacd
(by Vcn<br or 1be AUihori'"'d lmpc«or) •hall include bul not limited 10 <he following:
(b) edt< prq>anlioo for ,.ddq. inolud1111 visual tbccll for l:uniJI>Iions.
(g) pronlc and lhiMing of dlall<'l ends Jnd wrkonical pioccs after fonning.
(b) chcckrna of lllbc:sl>oOI >1\<r drillins indudiJla .,.w tbccll for lamo..,..,.
(i) rubesbcct (0 shell $C1 up ror ftxed rubeshee( exchangcn, prior ro welding opera(ion.
(j) tube to tubcsheet joint expansion or welding.
7. 1 l The preornce of <be AUihonscd lllspca.>r ohall no< modi f)' or ""'""' dlc oblia>~- o( dlc
Vendor to carry Of.ll hjs own CQU and conuol. Shc>ufd any maccnaJ :and/or equipment bt
round n01 in co•u.pliance with lhe requirements specified. the AUihori3ed ln:lpector or his
delegate stl.a.ll be emilled 10 Irrevocably reject them, even lr suck non COR'()Iian<:e has not
bcco evidmee<l in the course or i~pections and/or tests.
7. 1 4 1bt Aulhonscd lnspec10f .,.,11, a.t 1be time of hiS initial vtsu, a.et up \With che Vendo«' I(NIJ
dccails of irup¢~ion stages to be:: wirnessed or c:aTTied out; the schedule of tuUJrc visits :~nd
2
'-a• 11 of 20
•
=1/Vi·- ·- .
• '"" ::t, .• :•• ~ iJ
I
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..·-,;
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••
" •5 Tbe Vendor Sholll T\llflty tJl.! 1\uthor\s.:d Jo\-:wt•)( StJt'tltlt:t.!!.h 1:134-::;••·· ... "•! flO. .. .. .. .._
~r..=..-::1:-~ :U V"--'lu~~ U,Ud W .atnve at tne Vc=ndM'S &hop 1n tim e (0 Wi(I)C:Sl lhl~ t\f.,_, 'ltiort<
'"
••
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7.1 6 The Vmlof !!WI pt<Mdc to !he Amllcris<d ln!it>«•or, free aeo:esa 10 hi$ shops 01 olltinlol.
He •boll aJ:;n illlpply all r.»!Jllld bel<lcs 10 !he ~ lnspcaor ro. csrrymg out che
i;; itrfptatOD. 1be Vender ~hall also arrange for sunililt flttiU!es !11 his sub-cootrxwr·s s.OOpa
~~s 1 I 7 The Vendor m"'' satisfy the Autflorio<d ln.pec:tor that U>e W<kting proco31ra, wel<lers,
e:Jectrodc:s. ftua,~ ~wires etc. &re in accordmce Wilh the tequiremCIUS Of tbe Codt
and specificatio~ . Funher the weiJea •• qual ifu::.Woo test ft1U5.l be carried oul i_n the prcsmce
·=
~~
of !he Authoru<d lnopc:ctor.
.. 7.1.8 Pnor 10 fin.tl inspection. all Sl"8, weld spat..,looseS<ate, dirt, &rit. poiot,arease. oil and
H
Clhfr forei&n maa<r <hall he """'ved In onlcr 10 f.acoli!Jlle inopection. All reinforcing pads
and sl1p on type flange wckb shall be pressure u.l<d ...W. air and ""'P solUiion before and
aft<r boar ..........,. (if ony) and befo"' final hydroo!Jltic lese.
~~
1£ 7. 1.9 A dimensional cheekcng of equipmenoubnll be carric<l ooctaldng inco ucoun~lhe colmnces
( p
~!
•hown on jol:> drawings and mndards, design opec:irtcatlons or Cede. tho mo"' '"'"ll'"'
values •hall govern. t>imcnsiorull ~heek.s are 10 be tak.m of !he ku<rnal meuu..,.,.. or
equ;pm.ru •.,..met with otern.tl ones and che,. nre 10 be rec<lrded on a c:opy of the
p drawinas as being the •As Sui.lt" dirnensiolll.
••
,£ 7.2 Hyctr..cadc ,..,.
fi
': i 7.2. 1 Hyd-...,. shall he wilnes!<d by the AU!ltorised IMp«(Or, When ilydJ·c.ta&ic teiiLS Ire
e- pcrfQmled tho rndicatlna sauae sbnll be connected 10 the upper 111011 pen of !be equopmffl.
~.;~ Tts•in&"""" shall be clean po!Oble water. Sea water shall not be 111ed. For SS cquipmenl,
w11er used for che8e tests slull IICM tonlaln more INn 1S ppm chloricles. Minimum mccal
H
.,.
temperature during hydroouuic ,..,. shoJI be 20'C. T.,c pr,.SUTc:$ $ball he maincaulcd foe
;u least ono hour. Shell lU'd Q.lbt Ji.de4 sh:dl be teSted separately. anlc::ss orherwisc men1ioncd
on the drJwing. For tuhe$hec:t.s d"'lgn<:d for diffcrelllial pressure, special care shall he oaken
i!
,~
duriJll cesllng. Equipmonl dtlwinss •hall clearly indicate by a nolO, if ruhe$htell h•ve bc<n
designed [Or diff.,ntial pte$!Ure. Drying OUl U per clause 9.1 -<hall he ClUried 001
imrnedoately atltr h)'dJOICSl.
(
ii
! i
7.2.2 All vmic:aJ exchangers sball be lt!led In vcnical po; ition, Altecn.11ivety. e)l-tban&ef 0\ay bt:
tested in horizontal position with rest pressure modified with prior approv:tl Designer. or
:=
s! 7 2.3 SliCked c.u~w>&m wilb nou:les interconnected shall be hydro<esled In sut<k<d condicion
except when the h.ydrote.~' pressure or the lndivkluaJ w:hanJcr i1 dlffcrenc
If
Ji 8.0 STAMPING, NAME PUTilS A-~ WARNING PLATES
H
~ - 8. 1 Each excNl!8er shell shall he fined with an SS name pt•••·
t~ 8.2 Warning plates, if required. shall be provided.
H
H
8l The following ex<:h>nger pa"" sh•ll have ohe hero nurubef stamped for heat
cxchangen in low tc:mpcnrure service in wbk:h cascl:be uem oornber shall be marked with
•=pc
u nOtt·nmovable ink:
Sholl Sirlh flanges, shell cover flange, channel Jinh llanJes, flat channel cover. n•uonary \
H
al1d n-in& rubeshe<u, flootmg head cover flange, floating head backing ring, COilllCCtiAg
pieces. te.llc rinas, test Oanges and ~r main rtnlCWlble parts.
J4
t- B \
w A eNGINEERS IN DIA LIMITED
N£'W ~-.Uti
GENERAL SP'ECIACATION
FOR
HEAT EX CHANG ~RS
SPECIFICATION
6 ·15.0001
hoe ,. of :10
REV
2 I
-..·1 ,... ,t.,.-. - • ·'i . ll.ii':~l~u ..;_,
tJi :1;.;,,,1.{ .,\111 <l~~-~ \..OI..'•i, ;..;Jt J:~i>k \~\ ,,~:\"!!)~,:~ ·~!·o~.~hl." \1~ ,,,; ·~
~hV1Vlt_.tMj .! . .aina1.:U~O j;,,!.;:!. ..;.J.;L ~qi.li'f;r.,.N .;;;::!l l;>! Cc.t."'pU.!lJ dr£.!tl b) f;.l.i.. :..io
r.·;;.< ;.:,
inc \uli• ~ 'l!f llil'r lmi :1 I if • Jilt\i!l";' i ~~·· 1 1'1:--1' PI to-ial j,.:- i'J.H"I"!;l; ,,;' '1'!',:!";'1!: W •:- ..l .'ir'l " ..;1
Dry ~~ shalt 1>e rk'm" sttlll-dt~~~ :usly r..1 t:l•'oi:h shell and '1.-.l."t' side'> Aile .. fiNir•g 1
h;.
~qu1pmeru :.haJJ be i:rged and fi!l.e<l with dry N.,. ar 0.25 kg/cn)l. The eQufp~;n; sh:~!t be
ptovidcd with pre~'Ure gauge to moniror N~ pressure,. and Jh • nonMcccurn V3lve. All
threaded boles, Other ttu:1 tell tale holes for tesung. WU be suitably protected wittl uetl
bar plug$ . All nozzles not prov~ wirh blind Oange :i.halll.x: provided with :«eel covers
and teiDPorary gaskets and bollS.
9.3- The equipment item number, Purchase Order (PO) number and Purchaser name al'\d address
~hal l be painted in bold white paint leuers wriuen with stencil. on the beat exchanger.
No heat exchanger shall be released for $.hipcnent uncil it has been approved by the
Authorised Inspector. Heat e:~chaagers shall be dcspatchc:d after the oper:1.rtlon! as requited
by clauses 9.1 , 9.2 and 9.3 bave been carried out and shall be despatchrd in aHested
0011dition. In c"-"e stacked exchanger shells ate despatched sepanuely the Vendor Sh:\11
provide adcUtional set of gasket!l far ll'lte-reonn«ted nozzles other than the gaskets included
in q>ares. Heat exchangers sh:dl be sc:eurdy anchored for despaich in order to prevent any
slliftirs.g and damage during tr:ansport::tion. Expansion joints and bellows, wherever used
shall be suit~ly protected against any possible damage by providing de bars b¢fore bo.xing
up. Packaging shall be suitable for rail or road transport and also sea worthy if tramponcd
by ses. Spares shall be despa.cched sep:mu.cly in a bo~ and marked with PO nqmber. item
number and Purchaser's name and address.
Sling marlc identification shall be provided by Vendor on all heat exchangers with cespecc
to cente( of gravity of the equipment.
No equipmem shall be despatched umil a written clc:1.ranc<: is obtained from Purchaser or
Cll re8arding Piping CHps and Structural Cleats on individual equip~nen ts.
The Vendor shall be completely responsjbJe fO( the compl iance to Cod~ requiremenl:s.
re$idual design. detailing, fabricalion, mare rials and workmanship of the c:xchanger-1 as per
the stipulalions of the requisition and its attachments. In this regard. it may be noted that
re\•iew by Purctw:er c c £It stull not relieve the Vendor of b.is responsibiUty of meeting all
requicemcnt.s and ensuriog satisfactory performance or the equipment. Guarantee period
shall be as per Cicneral Purchase Conditjon of .Purchaser.
Iw -
" -ENGINEERS INDIA LIMITED
·N£W 0€1.HI
• FOR
HEAT EXCHANGERS
"
•
;
!~ I
.
:' 2 •• .• • .• • ) AND >AS STD
RtVII IOII
~ ....
'"'
e f N G INfERS INDIA lJMiocD
N(W OEl.H>
- STANDARD SPECIFICATION FOR
WELDED
TUBE TO TUB.ESHEET JOINTS
SPECIFICATION
8· 1: . ... ... .
REV
2
-------·
•
~
·~IL Co.''iT£"1 1
-~
q 10 SCOPE
J;;
i:
,.:il
2.0 APPLJCABLE CODES AND STANDARDS
."
~~
3.0 WELDING PROCESS AND JOINT DETAIL
~~
.ill 4.0 WELDING PROCEDURE QlJALIP!CATION
~~ ~0 WELDERS QUAL!FICATlON
li
~I
6.0 PREPARATION OF TUBES AND TUBESHEET
H 7.0 WELDING
p
~~ 8.0 EXAMINATION OF JOINTS
rJ 9 .0 TUBE EXPANDING
·l
!s 10.0 REPAIRS
~~
':!J 11 .0 TEST AND REPAJR REPORTS
~i
H
.u
APPENDIX· I
JOINT DETAJLS
~ APPEND!X·2
~.
h
&J DETAILS OF TEST SPECIMENS
il
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~.
~8
2
•
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1: ...~.; ... .jo~a..i,-.... u.~~• ... ·~a'J n\li.llll\1• ft ...,..!-hl~~ •.!> d.J..o.~ :t....: ....:.,j.- ; vf u.,._- W llJ~·•I~et
'g 1• an~.S d sh..-11 .fl'l•l ,.ty. Ma:~ ~:<..;! ::;111:~1"3 and Jii" ~)o.l.et<t r. ,,. .tw- 'P·lb!'~!1·'!-r" ,.~::~~::.;o~;!:t, t.:.
L iumJSI' SOUQII le$ free ,omu: FCf me ~ I df .,... :.::3ou'l't, Oc tf:rr.S ·J'-"•~o.l.:O.. ;u,.li
~~ I
i, be CUW.Irual w nac:an •wbe--lo-Rior sheet JOlfllS .. ,
·~
z~
·o 2.0 APPLICABLE CODI?S AND STANDAlUJS
~r:
~~
The lakSI «111Joo O( lbe lllllowlnt codes ond NncUrdl ollall 1>: complied with:
.·-...
=~ c) ASM E Scclloo IX
~ d) TEMA for !Ubular exd>onge"'
-~
n e)
I)
API 661 for alr<:c»ler•
AWS
H
u 30 WELDING PROCFSS AND JOIN!' DETAIL
(
gt 3I M:u~ua l or au1oma1ic Tunasra> laert G.. shielded Are (TJG) welding shall b< used. All joinrs
}J shall be made by usio& minimum IWO weld pa.s.... Tile firol pa•s should be preterably nl:lde
~I withool filler win 10 """''" rooc fus.lon. Tbe oecoad or final pass shall be wilb filler win:. Any
~.I other v.·e1dinJ p~ can be u&cd only after obUiinina wriuen approval t'tom the Authorised
~t
Inspector.
•s 3.2 loiru d<tail &hall be .. indicul«l on the Purtlwer dtaw~n&s by civina ...- 10 UJU"'
!t
:!1g
numbc.n in Appt'l\dix·l of this apedtic:ttion In ibse~ of any Purtb.uer drawrngs oc 1n<hcatlon
regarding lype or joim, Figure 2 "' fiJ!Ure 3 ihliJJ be usod dependin& IIJlQCI Wllclhcr tUbe
tbkkne$$ is .;a. 2 mm or < l mrtl rupa::dvety.
h
H 4.0 W£LOING PROCEDURE QUAUncAnON
u
H
4, I Weldin& PrOCedure SpcclCICallon 511:111 be ~iltd by lbe Fabricalor ond submined to the
AuthoriJod laspeelor for approval be(orc !he quallfi.c:otlon ICSI> are performed. Mock up I(St
•hllll commence only afier awroval i:1 ob<Jined from lbe Aulhorisod l•sp«ror
4, 2 Weldin.& procedure qualification test is required to be carried out if :-
f·
t.t a) A-uthorised Inspector requires the te$t co be carried out
il
•c
p
b) There exiats no prevlous qu.alifico.tioo tests within I&Jil three years t« the propo.'ICd
combination or lube ond m~ P oumber and SJOUP number (as per AS Mil Sccuon
IX), tUbe ou~>ide 4iamttor (00), rube llllckness, tubt$1\ccl thickn<.ss, rube piiCh, tUbe
H2
8
pilch PJUtern, weldin& proeedore andjolnt detaU , All ocber t.:mrs remaloing same, lbe
pr<»«<ur< ""' oced DCX be repeated if lbo job lubeshe<:l thickness exoeeds 40 mm ond
qualification exlsu lor 4() mm or hlch<r 1ubeobt<t dllctneso.
~'
~.
if For plug type
perfomal
~air coolers additional procedure quaJifkadon
ro• any or the lol"""ins oondorions.
tat is CU{Uitod to b:
iJ
c •
i) The joO has iO""" clear..us - lUbe ond any or lbe bead<r plore. Ilk•
toplbottomfend/a:liffcncr/pa.'l.S partition pl1ue CC.lrf'IP<~ff:d to c:arJieJ' lesu.
JJ•• h) Tbe JOb has I0\1.-et plug .site for the same rube s-tze c:ornp•red 10 earlier ft".Sts.
\
d' .
a STANDARD S PECIFICATION FOR S PECIFICATION 'l REV
•
ENOINEERS INOlA LIMITEO
1\eeYIO£\..HI
WElDEO
TUBE TO TUBESHEET J OINTS
1---::-==::-::--
&-, S-OOOJ
, ... 3.1 8
I
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2
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d: !:' re~\J.!r;.-.! ?.S p~ I .l. Jbc··'~ . !he f<;)brx:~wr ~r.a!i prrf1."'!m :1. prr...'C~re c:cl.l :t:-.;:~th.:n ~e:lt . :.:! !e:t.S:
two weds bt'fo~ fho: ~~lt~:t.!u!ed be-ginnifl$-t of producllOl\. Procedure :sh.JH be qu!lii6t"'l fot the
r·~
~m
ON
5•
. o
l;;
same hand posicion as is being pro0posed foe production Procedure resl sh.aii coruiSJ oi ttl€
welding of nine lllbcs for sq u~re :pti.Ch and e ~gilt lUbe'S, {U\n:e, two and three rubes per row
•rrtUl~fAknt)if .:>n a triru1gutar pircb. This shall be dooe for ea.ct, set of combiu::uion of rube aod
rubesbeet P number ~nd group number, wddiog procedure:, joim deulil. rube 00. cube
'Z~ thickness. tube pitch, tube pitch pattern. tubesheet tl1ictoess. Additionally for air cooler, rests
•E shall be done for t".IIC·h tube siu with lowest plu~ site, lowe$t clearence between tube and any
·~
•o of the heao.:h:r plates, and t1te lowes.:r plugsheet thickness robe used on the job. Thickness of the
: .,:.
-~
rubt:sbeet usee.J for procedure 1es1ing sb3.ll be= samt !tS U:ied for job, cx.cc:pt that for t:lrbon :iteel
·:~
~~" - and austenitic st:tinless st~l materials. it need nor ellceed 40 nlm, unless otherwiSt: indjc21ed.
·-..
Reter AppeodixM2 of this specification tOr test specimen de!ails.
~"'.
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4.4 The following (!3[3 repcm (~ix copies) sho:ll be furnished fer review to Authorised ln.'ipeclot with
=#
o, the weld $iimpl<i >< outlined below.
Q.
..
!~
~t b) Mechantcal prope:n ies and chemical compositinn of rubesheet. tubes and filler metal.
i?
-l~ c) The ha.-dnes..~ of tile weld, the tube, the rubesheet heat affected zooe and the rv.besheet
•l
-
••
! -
base metal after each pass.
~~ d) Tht romptete 1.e3t sample shali be CUI (by sawing) as per Appendix 2 of this
· <
s~ !tpeeif:caticn. These shaJJ then be wbjetted to \'1rioo:s test! etc. as outlined below:
'.
~!
.c: '=
- E
iii) A section lO nun thick: conuaio.ing the tul;le end welds shall be sa\\'ed from
seccjon 3 and rll(liqgrilJlhtd for weJd quality. Tbe radiograph shall b¢ $Ubmitted
~i
co Autbori~ ]nspector. No cracks or crack: like or visuaJ defects are
-f:'
.!11!
acceptable. Accept;m;e shaU be llS p~;:r Appendilt 4 of ASME Section VIII
Division L Jn case the radiograph is not acceplable, weldjng procedures shait
-,-·-
~~
••
<'
be suitably modified so lhat proper weld and acceptable radiographs are
obtained. These shaH be proved by relcsts.
·~ .s
&- iv) Sec-tion 4 sb.ill be etched 1rrd polished and :.iven 10 Authorised Inspector.
·i ~
-8 ~
.' .,
~11
e) A tension ~tn:na,th test shall be carried out JS per ASME Section Vlfl Division I
Appendix A. This strc:ng1h teSt shall be performed at room temper3rure for each
combination set of tube and lUbesheet P number and groop number. tube 00. wbe
~·
H thJcknes.s and j oint decai.l , The· breaking loads shalt be at leasl equal to the load req-uired
o.i
• .
...
5>
.oi'
fo r break:ing lhe tube using the minhoom specified ultimate tensile strength of cube as
indicated in ccrt.iflcates issued by the tube supplier. When tu~ material is 10 a
spc:c:iOcation which does not c._ll (or tn(:(:hal'\jcal teslS to be performed. ultim~~tc tensile
~ 8
.N
·~
"' Ill
s.s
4 ..S Fabricacor islldviSOd to utisiy lumsell mr.t lbe prccedures c:mp!oyed are the IJe•• for tl"' Joe :uld
""'"ld <nable hitn to alve workmallllhip au:u~ for 1be oqulpmed<. Alllllo<isal lft!pcao<'s
~~ llllP<oY>I sboll in no w:ay t<l.,..lhe Flbncaor olhis respo!!$ibili<y nnd auar•n•oe 10 :lllpply me
i~ equapmcnr 33 per the coodiflons of t.ht purcba.se ordt:r
e
~ ~
(
H
H
qu>litication. Welding opet1IIQI1 may be qualified based on para ~.4 d (i). 4.4 d (li). and 4.4
d (IIi) above only, provided """" welding 1111Chin<1 & welding proc<dlir<S arw ll.l<d. This
~ldina operalt>t qualllicadon lest obould also be carried out if tlJe weldinJ operator has noc
executed sirnilor welding sla moncb.• prior 10 prodllCIIM. R<pca<...,. may be tailed for in lbe
H course of rnanufacalre to determine the COtUim.ncy of operntor or f'h;Jchlne to produce SQU.nd
H
iJ
welds.
il 6. 2 Prl<)r co as.<embly, cbe IUbtobeec :ond rube ends (inside :ond outSide ior a d•swcc equal to the
u-·
§I
rube$hect chlcknesa + 30 nun) !ball be cleaned and degreased ro free from~ Itt, ,,.... et< lc
1$ W'Jllild lllat tbe solvent used for dqreaslna be cbJoridc ~and sulflde free <nd non rt<tdue
fonnlna. The solvenr should noc lead to a.ny JlOIISiblc fire ha!Jird.
·-
>J
!:: ..
. §!
63
6.4
Tho rubes sball be positioned in cbc cub«beet> by 30' tapered driR pin.
Before weldiiiJl rube 10 tubetilleet, lbe wbeih<ets shall be bcued co a lt04"'<awn u required 10
\. 0.1 remo\'t any lUI t:nc:a of mobwre or solvent Whicb may remain ;~fter tbe c:l ~nina ope: ration.
il Any specific requirtmentle< appliatioo of preli<:U sb>ll be <mblished u a pan~ tbe weld.ln&
procedure qualification cesr and should 110001101 for lncrea:!td l'e$tralnt offered by tbe larger
assembly during produelion.
H
H
~!
7,0 WELDING
Tubes $lUll be individually welded.uaing lhe prooedun: approved by cbe Aucl1ori!led l~peccor .
~' Sysremar!c weldin,c procedure shAll be adopted so as ro resuh in minimum rubnberc" dlitonion
H AJI rube$ uc co have lnirial pus C0£1'1)letely cleaned u nectssary. vi5ua1Jy examined and te~aed
• • per para 8. 1 below. If required, before subseq..,tlayen areopplied. Welds s!lall be suilably
fmlshed lind my spillage OO'sparter on tube<heelromoved. SpillAge ol wei~ ""'"'l inro UJc hon:s
i1 of robe Is n01 penniucd.
~·
ill
r1 \
H REV \
STANDA~D SPECIACATION FOR SPECIACATION
A ENGINEE~S INDIA LIMITED 1--""='"'==-=--+--l
...,. NEWOEI.HI
WELDED
TUBE TO TUBES HEfT JOINTS B·1 S.OO~! 5 ol 8 2 I
v~•l ....._, • ......,__ ,.._ ._ . ....! '"'" .u~ 1i1.M . . ~ ~ -~ ~Lo.. .1!• ..L.
,..,. .,
~....,. ~ ""
•' 1.110
ol •I A .;:.....fF -.a· •• l.ol \,: }infl.l~ ; tb tl ~ j,.,. 1. ~~
•
3.2. ,\,U:I ..v o>ll)lcu\Jd u( w~IJ 1 U)!, t.llt ru00b«( f.x.c, t!'IC wci J~ Wll.l utten ut rube .m·f.ll.\."1 iu .t
dJ.stai!Ce or 2S mm beyuod tbc iuswn line mu~' bt ( le;utcll tbocougbly by wire brll.:il'lin& ::ukl
ex.tmiocd ..:arefully folr surface llefects. D..!f.::Cl'l &U:Ch ~~ <:mck:;, surt':K:e b~ting poruslty, s.l.li
inclusioM and lack of fusion are not llctepll\blc.
8.3 Atler the vi.sunl in~tJ()O , a liqui<l penelr•m eJmmltunlon m acc6rdancc w1th ASMI: Scctlon
Vln Oivi.Jlon I. Appendix 8 & Section V, 1\nic:le 6 'hi ll be doot. Before conductin, this t« t.
lbe faces 0 1 me a rl)r)n 5t.c:cJ w bc:sheeu !halt be t lelnod lborougbiy by wtre brush and ~I vent<
co renlOve all ~ld slaJ . rust aod seal~.
8.4 Wb<n specified on tlx dn.,iags or requisirioa. • IWJdc 1<>1 sball b< per1crm<d '""' tlx O<SIJ
.. per para 8. 1, 8.2. and 8 .3 ...,._ bave been ......,.. ~Jiy ~- - PrOCCO!res for llolicto:,...
shill bt ll per ASME Sec!Joo V. Anicle 10. Appendll • lll llalogeo diodecl<!leclor probe ldl
8.5 After lhe final Nbc expanding (refer pant 9.0) has bten completed, cbe liquid penetrant
ex.~~.m in ation as outlined in para 8.> ~bovc:: 8hall be rept:~ted .
8.6 Whenever n halide test has been specitied, an envelope t.:M shall aJso be done as a further test
for le3ks after t1na1 tube expJnding. Fo r this ttS1, tubesh«t.s shaiJ be: securely wnpptd m plastic
!hteU and fhe shell allowed to rero~in undtr test pressure with halogen tracer. for a period or
lO to ll hours. Then with L~ deu~etion se1 a1 a maxtmum Jetuitivit)', the probe 5h.lll be cnsencd
tbrougb the plastic cove:r 11 the boOOm of Lhc: tut!Qheets &Dd reldings take~~ to observe if any
~ ba> OCCUrt<d
8.7 F1nal accq>UnC< hydnuh< P""""' lest slull b< condlloltd ofa:r wb< ·~ a1 h~
p=urt ror 01 It~ Oil< bour.
9.0 TUBE EXPANDING
After chc rc.st:s l'lo\ltllne:d in 8.1 , 8. 2, 8.3, and 8.4 have been su~css fuliy complet.ed and all
!coking weldJ repoirod. the Wbe! shall be ·contact c>l)'lllded" with a PARALLEL type
expander. Contact expanding is int·ended co brlng the tube 00 into contacc with the mbc hole
ContaCt cxp:tndin~ &hall begin 12 rnm fl"am the rubeshCf:t far;e and extend tO l nun (rom the
back f3Cc:. Tile CCXIIOCI expansion shall have lhlnnllli Of 3-5$ wbkb sl!atl be <""'red b)
m:asurint: the Inside diameter of rubes,
10.0 REPAIRS
If leaks are found durin& IDY o( lhe ~e tt1olin& proccdurn lbe:Jc shall be rq»>O'Ud CO It~
Aulhoriled lnspe<IDr and alter ob'"ln!ng his "''''roval. reptlti Wll bt ~by removini lhe
defects down tO sound parent meal and repc:auna the quaJified weld prcxedures. All weld
repairs shall be retdted in ::K.COCdatx:e with procedures w tlincd in para 8.0 abo\le.
Test and repair reports shall be included in the OtUI Folder. These repon:s sb•ll also indicate
the number of leaks dlliCO\'tred oo: each cesc and che txtenr the: rep~ir dOne. or
FIG.-5
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FIG.·S
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FIG-11 FIG· 12
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·-·- THE WDO<UP ASSO.IBLY SHOl.lD HAvt 111£
D ¥ EHSIONS/THICKN£SS ....ulK£0 ' • ' AS PER JOB
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lauNDLE SIDE
FIG-14 FIG-16
LECENO
1. FOR MICROPHOTOGRAPHIC EXA""'"TION
2. FOR TEAR rEST
3. FOR RADIOGRAPHIC FXAMINA.TION