Professional Documents
Culture Documents
LTD.
DOC NO:
TITLE:
DANGOTE OIL
REFINING
COMPANY LIMITED.
A545-JNK-121-XX-XX-XXXX
FABRICATION ENQUIRY OF DUCTS AND DUCT SUPPORT
(121-FF-2001 A/B)
OWNER
PMC
DEC
UNIT
: 121-FF-2001 A/B
REV :
DATE :
0
17-02-2016
ISSUED FOR
(3) NOT MEETING SPECIFICATION, RESUBMIT
INFORMATION
APPROVAL
ENQUIRY
ORDER
CONSTRUCTION
REVIEW
NAME
DISCIPLINE
SIGN.
DATE
TA
MS
DS
17-02-2016
Rev.
Description
Prepared By
Reviewed By
Approved By
Approved Date
Rev: 00
Date: 15-02-2016
1. Introduction:
This doument defines the scope of work for procurement, fabrication, modularization, material
handling (Raw and completed modules) for
PFR HEATER - Ducts and Duct Supports
PFR HEATER (121-FF-2001 A/B)
2. Reference Drawings/ Documents
Sr.
No of
Drawing/ Document No
Drawing Document Title
Rev
Remarks
No.
Pages
1
A545-121-05-42-0100
EIL Documents
Foundation Loading Plan
A545-121-05-42-0201
A545-121-05-42-0202
4
5
6
7
8
9
10
11
12
A545-121-05-42-0203
A545-121-05-42-0204
A545-121-05-42-0205
A545-121-05-42-1206
A545-121-05-42-0207
A545-121-05-42-0120
A545-121-05-42-0121
A545-121-05-42-0122
A545-121-05-42-0123
B
B
B
B
B
B
B
B
B
1
1
1
1
1
1
1
1
1
13
6-17-0001
13
14
6-17-0002
12
15
6-17-0003
19
16
6-76-0001
22
17
A 545-999-05-42-SP-12
10
18
19
20
21
7-17-0461
7-17-0456
6-81-0001 & 6-81-0002
3
3
2
22
Painting Specification
8
1
5
18
10
23
A
A
7
5
24
3. Quantum of Work
2
4
5
6
Item Description
Steel Structure - Duct casing,
Stiffeners, doors, support saddles
Open Structure - Duct Supports,
APH Supports, Platforms,
Handrails, Ladders
Instrument Nozzles 2"/3"
Refractory Anchors
Retainer Plates
Lifting and Transportation Steel
Material
Rev: 00
Date: 15-02-2016
UOM Quantum Of Work
Remarks
Grade
S275JR
conforming to
EN10025
MT
374
MT
145
SS310
SS316L
SS310/304
S275JR
Nos
Nos
MT
MT
50
121030
2.5
52
4. Scope of Modularization
1 Ducts to be modularised in length of 10-12m
2 Details of Splices to be provided in Details drawings.
3 Open structure to be modularised in portals and loose beams.
4 Assembly of Opem structure into Modules shall be carried out at Port area or at Site on grade.
5 Platforms to be dispatched in panels along with gratings installed.
6 Gratings shall be FIM
Components to be included in Module and Scope Split
Scope of Supply
Sr.
Item Description
No.
JNK
Vendor
X
1 Engineering Drawings
Steel Structure- Casing Plates, stiffeners,
doors, supprt saddles, all attaching
X
component flanges.
2
X
3 RefractoryInsulation Stud/ Anchors Supply
X
4 RefractoryInsulation Stud/ Anchors Welding
X
5 Refractory/ Insulation
X
6 All Doors
X
7 Instrument nozzles including flanges & fittings
X
8 Instruments
X
9 Support Structure for Transportation
X
10 Lifting Gear for Module Handling
X
11 Lifting Steel
12
13
Enabling Steel
FIM Date
Remarks
Including internal
Transit
Vendor to refer attached drawings for Complete module details. Above mentioned list is not exaustive
All works (Fabrication & Installation) required for completion of the job shall be Vendor's scope.
5. Work Schedule
1. Overall Delivery for all Modules
- 10 Months
10
11
12
13
14
15
16
DATE
REVISIONS
BY
CHKD APPD
1:120
1
10
11
12
13
14
JOB NO.
A 5 4 5
15
UNIT
DIVN. DEPT.
1 2 1 0
DWG. NO.
REV.
1 0
5 4 2 0
16
3-1641-0500 REV.2
A0-1189 x 841
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
DATE
1:50
REVISIONS
JOB NO.
UNIT
NOTES :-
HOLD
BY
DIVN. DEPT.
CHKD APPD
A 5 4 5 1 2 1 0 5 4 2 0 2 0 1
DWG. NO.
3-1641-0500 REV.2
REV.
A0-1189 x 841
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
DATE
SCALE
1:50
JOB NO.
UNIT
REVISIONS
BY
DIVN. DEPT.
CHKD APPD
A 5 4 5 1 2 1 0 5 4 2 0 2 0 2
DWG. NO.
3-1641-0500 REV.2
REV.
A0-1189 x 841
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
DATE
SCALE
1:50
REVISIONS
JOB NO.
UNIT
BY
DIVN. DEPT.
CHKD APPD
A 5 4 5 1 2 1 0 5 4 2 0 2 0 3
DWG. NO.
3-1641-0500 REV.2
REV.
A0-1189 x 841
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
DATE
SCALE
1:50
REVISIONS
JOB NO.
UNIT
BY
DIVN. DEPT.
CHKD APPD
A 5 4 5 1 2 1 0 5 4 2 0 2 0 4
DWG. NO.
3-1641-0500 REV.2
REV.
A0-1189 x 841
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
DATE
SCALE
1:50
JOB NO.
UNIT
DIVN.
REVISIONS
BY
DEPT.
CHKD APPD
A 5 4 5 1 2 1 0 5 4 2 1 2 0 5
DWG. NO.
3-1641-0501 REV.2
REV.
A1-841x594
1614/202
DATE
REVISIONS
BY
CHKD APPD
1614/203
1:20
JOB NO.
A 5 4
UNIT
2 1
DIVN.
DEPT.
DWG. NO.
0 5 4 2 1 2
REV.
0 6
3-1641-0501 REV.2
A1-841x594
1514
5914
4172
2000
5888
2949
2939
4200
2100
2100
5888
2939
2949
2369
2369
6500
2369
2369
VIEW E-E
6500
6500
OC-35
OC-36
OA-35
2500
2500
OA-36
OC-35
OA-35
OC-36
OA-36
1514
5914
4172
2000
8000
5888
2949
4300
4300
2939
4200
4200
2100
2000
2900
2900
2900
2100
2200
2900
5888
2939
5888
4200
5888
5888
4200
2949
4772
5888
VIEW A-A
VIEW C-C
VIEW B-B
4774
CONVECTION MAIN MEMBER CROSS SECTION STEEL FRAME (TYP. ON ALL FOUR COLUMNS)
B
PLAN @ EL+ 24150
CONVECTION PLAN @ EL+ 32700
26
21
26
21
4172
25
22
15
23
11
10078
24
16
15976
23
11
4200
24
16
22
10078
25
12
15
12
DATE
14
13
15
14
11
12
25
16
13
22
24
21
26
23
26
25
24
16
15
14
13
12
11
23
22
REVISIONS
BY
CHKD APPD
21
14
13
PLAN @ EL+ 19450
1:100
JOB NO.
UNIT
DIVN. DEPT.
DWG. NO.
A 5 4 5 1 2 1 0 5 4 2 0 2 0 7
3-1641-0500 REV.2
REV.
A0-1189 x 841
10
11
12
13
14
15
16
NOTES :-
DUCT DETAILS
#
#
CA-1
CA-2
BP-1
HA-1
HA-10
HA-2
HA-4
HA-5
SS
HA-6
HA-7
SS
HA-8
HA-9
HA-9
HA-10
HA-10
HA-7
HA-8
HA-7
SS
HA-10A
HA-8
HA-11
HA-12
HA-12
HA-6
HA-13
HA-5
HA-5
HFG-1
HA-13
HA-11
HA-3
SS
CFG-1
SS
RS
BP-1
MAINTENANCE APPROACH
A
123
MAINTENANCE APPROACH
HA-2
CFG-2
SS
SS
SS
SS
SS
SS
SS
HFG-2
HA-4
HFG-1
CA-1
CA-1
CA-1
RS
CA-1
CA-2
HA-2
HA-1
CA-1
CA-1
BP-1
FS
FS
HA-13
HA-4
HA-5
RS
HA-6
B
122
HA-9
CA-2
HA-10A
HA-10A
E
122
DATE
REVISIONS
BY
CHKD APPD
D
122
C
122
CFG-2
1:100
1
10
11
12
13
14
JOB NO.
UNIT
DIVN. DEPT.
DWG. NO.
A 5 4 5 1 2 1 0 5 4 2 0 1 2 0
15
REV.
16
3-1641-0500 REV.2
A0-1189 x 841
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
HA-3
10
11
12
13
14
15
16
SS
SS
SS
SS
SS
SS
SS
SS
NOTES :-
SS
HFG-3
SS
D
E
F
G
F
123
FS
FS
F
122
F
122
SS
SS
FS
HFG-1
CFG-2
FS
SS
SS
SS
CFG-1
CFG-2
REVISIONS
G
122
BY
CHKD APPD
DATE
1:100
1
10
11
12
13
14
JOB NO.
UNIT
DIVN. DEPT.
DWG. NO.
A 5 4 5 1 2 1 0 5 4 2 0 1 2 1
15
REV.
16
3-1641-0500 REV.2
A0-1189 x 841
G
122
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
SS
SS
SS
SS
10
11
12
13
14
15
CA-1
16
HA-1
NOTES :-
CA-2
CA-1
FS
FS
CA-1
CA-1
CA-2
CA-2
BP-1
VIEW
D
120
VIEW
B
121
E
F
CFG-2
SS
FS
FS
SS
HFG-1
HFG-1
GS
SS
FS
SS
CFG-2
HFG-1
FS
GS
VIEW
F
121
FS
GS
GS
FS
SS
HA-10A
GS
FS
HA-10A
HA-2
GS
BP-1
CFG-1
REVISIONS
BY
CHKD APPD
DATE
HA-11
SS
(A Govt. of India Undertaking)
VIEW
G
121
VIEW
E
120
1:100
1
10
11
12
13
14
JOB NO.
UNIT
DIVN. DEPT.
DWG. NO.
A 5 4 5 1 2 1 0 5 4 2 0 1 2 2
15
REV.
16
3-1641-0500 REV.2
A0-1189 x 841
0475
CFG-2
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
C
120
VIEW
10
11
12
13
14
15
16
C
D
NOTES :-
FS
HFG-2
SS
SS
SS
F
G
SS
F
121
HA-4
HA-9
HA-3
VIEW
HA-10
HA-3
HA-5
HA-5
FS
K
HA-13
FS
HA-2
HA-10A
HA-10A
HA-5
HA-5
GS
GS
GS
RS
HA-7
RS
HA-8
HA-11
RS
HA-6
A
120
DATE
REVISIONS
BY
CHKD APPD
VIEW
1:100
1
10
11
12
13
14
JOB NO.
UNIT
DIVN. DEPT.
DWG. NO.
A 5 4 5 1 2 1 0 5 4 2 0 1 2 3
15
REV.
16
3-1641-0500 REV.2
A0-1189 x 841
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
SS
HA-9
SS
ENGINEERS
INDIA 1JMITED
Govt of Ind.a Undelfakingt
STANDARD SPECIFICATION
FOR STEEL WORK OF FIRED
HEATERS & APH SYSTEMS
6-17-0002 Rev. 5
Page 1 of 12
r~4.1
fwg
Trrw rcifgi
20.03.14
06.09.10
02.04.07
30.01.02
Rev.
No
Date
Purpose
44
KJHN
AP
SC
MK
KJHN/DK
AKG
ND
AP
KJHN/DK
AKG
VC
VM
DC/SKK
Prepared
by
Checked
by
RKA
Standards
Committee
Convenor
GRR
Standards
Bureau
Chairman
Approved by
Format No. 8-00-0001-F1 Rev. 0
Page 476 of 2175
Copyright
Iloizi
$'gz:rr ;Me5
17117R
ENGINEERS
INDIA LIMITED
CA Govt oftl,aunde^aking)
6-17-0002 Rev. 5
Page 2 of 12
Abbreviations:
APH :
:
AS
ASTM :
BIS
:
BOM :
CS
EIC
ETS :
HMTD :
:
IS
ITP
SS
UON
VDR
Air Preheater
Alloy Steel
American Society for Testing and Materials
Bureau of Indian Standards
Bill of Materials
Carbon Steel
Engineer-in-Charge
End Tube Sheet
Heat & Mass Transfer Division
Indian Standard
Inspection & Test Plan
Stainless Steel
Unless Otherwise Noted
Vendor Data Requirements
Convener
Member
Member
Member
Member
Copyright EIL All rights reserved
fa2es
2.1-~ 1,151 JWITA
ENGINEERS
INDIA LIMITED
A Govi of Inda Undeflak,o9)
6-17-0002 Rev. 5
Page 3 of 12
CONTENTS
1.0
SCOPE
2.0
GENERAL
.4
3.0
.4
4.0
MATERIALS
5.0
6.0
FABRICATION DRAWINGS
7.0
FABRICATION
8.0
ERECTION
10
9.0
12
10.0
12
ENG1NEERS
INDIA LIMITED
Govt of indo Undertakog)
6-17-0002 Rev. 5
Page 4 of 12
1.0
SCOPE
1.1
2.0
GENERAL
2.1
Steel work broadly consists of columns, beams, bracings, portals, casing plates, floor,
arch, header boxes, end tube sheets, breeching, off-takes, ducts, stacks, all appurtenances
and fabricated auxiliaries, retainer plates, sleeves, platforms, ladders, stair case, hand
railing etc. and other connected works, including miscellaneous items of AS / SS
wherever required.
2.2
Steel work shall be in accordance with the applicable drawings, standard details,
specifications, and relevant Codes & Standards.
2.3
Approval of Contractor design / documents / drawings and shop / site work at any stage
shall not relieve the Contractor of his responsibilities / guarantees and correctness of work
in any way.
3.0
Compliance shall be ensured to the following Codes & Standards. Equivalent international
codes & standards can be used when specifically permitted in the job specifications :
IS: 210
IS: 513
IS: 800
IS: 808
IS: 813
IS: 814
IS: 816
IS: 1239
IS: 1363
IS: 1364
IS: 1367
IS: 1852
IS: 2016
IS: 2062
IS: 2266
IS: 2315
IS: 2361
IS: 2629
IS: 2633
IS: 3063
IS: 3121
IS: 3138
IS: 3502
IS: 4000
IS: 5372
IS: 5374
IS: 5504
IS: 6745
Format No. 8-00-0001-F1 Rev. 0
Cast iron
Cold rolled low carbon steel sheets and strips
Code of practice for general construction in steel
Dimensions of hot rolled steel sections
Scheme of symbols for welding
Covered electrodes for manual metal arc welding
Code of practice for use of metal arc welding for general construction
in steel
Mild steel tubes, tubulars and other mild steel pipe fittings
Hexagon head bolts, screws and nuts
Precision hexagonal bolts, screws, nuts and lock nuts (M6 to M39)
Technical supply conditions for threaded steel fasteners
Tolerance on dimension of individual rolled steel components
Specification for plain washers
Steel of general structural purposes
Steel wire ropes for general engineering purposes
Thimbles for wire ropes
Bulldog grips
Recommended practice for hot dip galvanizing of iron & steel
Method for testing uniformity of coating on zinc coated iron & steel
articles
Spring washers for bolts, nuts & screws
Specification for rigging screws & stretching screws
Hexagonal bolts and nuts (M42 to M150)
Chequered plates
Code of practice for assembly of structural joints using high tensile
friction grip fasteners
Taper washers for channels
Taper washers for I beams
Specification for spiral welded pipes
Method for determination of mass of zinc coated iron & steel articles
Copyright EIL All rights reserved
$'gar fffieg
ENGINEERS
INDIA LIMITED
IA Govt of InOw Undenaking)
IS: 7215
IS: 12778
ASTM A53
ASTM A105
ASTM A193
ASTM A194
ASTM A240
ASTM A283
ASTM A479
6-17-0002 Rev. 5
Page 5 of 12
4.0
MATERIALS
4.1
All materials shall be new and conform to their respective specifications of BIS, ASTM or
applicable standards and supported with mill test certificates. The use of equivalent or
alternate materials will be considered a deviation which will need prior written approval.
4.2
All materials shall be sourced from approved Vendors as per Vendor List attached
elsewhere in the Package.
4.3
4.4
Structural steel shall confirm to IS2062 Gr.A/B or ASTM A36 UON. For metal
temperatures exceeding 425 degC, alloy or stainless steels shall be used.
5.0
5.1
Design and detailing shall be in accordance with IS: 800. The Contractor shall have
established standard details in line with International norms and good engineering
practices.
5.2
Requirements given in this paragraph shall be followed, unless indicated otherwise in job
drawings. Details shall be provided to show all dimensions, weld sizes, bolt sizes and
proper reinforcement requirements, gussets, stiffeners, bearing plates, pad plates etc. to
develop complete strength of members and also account for local stresses.
5.3
All connections shall be in line with actual design requirements and shall be full strength
connections. Where actual loads are available, the connections may be designed
accordingly. Shop connections shall be of welded type and field connections may be either
welded or bolted, as approved by EIL.
5.4
5.5
All skewed beam to girder connections which support stacks shall have stiffened seat
connections with bent plate connecting beam webs. At deep blocks, the remaining `tee'
section of the beam shall be checked for flexure.
5.6
The minimum size of bolts shall be M16, except where flanges prohibit the use of this
size. Minimum M12 size bolts shall be used for splicing of panels.
5.7
Beam to column connections shall be arranged to facilitate erection without the tilting of
columns. Where seated connections are used, the bottom flange of the beam shall be
connected with a seat angle. In connections to column flanges, `knifed' connections may
be used. At any seat connections, the beam set back shall not exceed 12 mm.
$2zir22'
,--,oloaa, eg
0,1 3~1 I
ENGINEERS
INDIA LIMITED
iA Go, of Ind,o UnoloOak,f,g)
6-17-0002 Rev. 5
Page 6 of 12
5.8
In welded construction, the ends of angle, channel, beam etc. are to be preferably notched
to suit the profile of connecting members. All welded moment resisting connections shall
necessarily have profile cutting.
5.9
Provide minimum 10 mm diameter drain holes at all water traps at suitable locations so as
to ensure effective draining of water without affecting integrity of the structure.
5.10
5.11
Stiffeners on radiant shell (including ones at bracket / knee brace, terminal anchor
locations etc.) convection wall, ducts and at openings shall be provided based on
stiffening requirement and detail engineering.
5.12
All welding on heater casing / ducting shall be continuous on outside and intermittent 50100 on inside. Welds on horizontal channel stiffeners to be continuous on topside and
discontinuous on bottom side. Vertical stiffeners shall be provided with continuous
welding on both sides. Minimum fillet size shall be 5 mm, unless otherwise noted.
5.13
5.14
5.15
Splice Connection
5.15.1
All splice connections shall be submitted for approval indicating locations as well as
details. Splice joints shall be full strength butt welded, single `V' for thickness <16 mm
and double `V' for thickness >16 mm. Additional splice plates shall be provided for 40%
strength of member. These joints shall not be located at maximum bending moment and /
or maximum shear force location.
5.15.2
5.15.3
Flange plate on beams, columns and plate girders shall be shop welded with continuous
fillet welding on all sides. Where beam, column or girder flange exceeds 300 mm, plug
welds shall be used in addition to the above fillet welds to prevent warping of the cover
plates. Plug welds, when required, shall be spaced at a maximum of 450 mm on centers.
5.16
Horizontal Bracing
5.16.1
Wherever possible, bracing shall be connected to both column and beam where the inside
face of the column is used as a working point.
5.16.2
Where the center of a column is used as a working point with beams framing to the flange
and the web of the column, bracing shall be connected to both beams.
5.16.3
Welds in gussets shall be arranged to eliminate eccentricity. Gusset plates in same truss or
girder shall be of uniform thickness.
5.17
Vertical Bracing
5.17.1
At the inter-section of a column, beam and brace, the brace shall be connected to both
beam and column. At the connection to a column flange, the working point shall be the
face of the column flange & the top or bottom of the beam flange, depending upon
whether the brace is above or below the beam. At the connection to a column web, the
ENGINEEFZS
rt_r) INDIA
LIMITED
Og-ar 02-dg
' C
31
1~1el,9,71,151~1)
6-17-0002 Rev. 5
Page 7 of 12
working point shall be the centerline of the column web and the top or bottom flange of
the beam.
5.17.2
For the connection of bracing to beam 300 mm or smaller at the mid-span, the working
point shall be the inter-section of the horizontal centerline of the beam and the centerline
of the bay.
5.17.3
For connection of underlying bracing to beams 350 mm and larger at the mid-span, the
working point shall be taken as 125 mm above the bottom flange of the beam. Similarly,
the working point of overlying bracing for such beams shall be 125 mm below the top
flange of the beam.
5.17.4
5.17.5
At wind moment connections, allowance shall be made for mill overrun in beam depth by
allowing for shims to facilitate erection.
5.18
Trusses
5.18.1
On welded trusses, splices to ship the largest possible shop assembled units shall be
detailed. Splices for welded or bolted joints shall also be detailed. All splice details to be
submitted.
5.19
5.19.1
Unless shown in prefabricated sections on drawings, top rail, middle bar and toe plates
shall be supplied in random length for field welding to handrail posts. Bent section and
posts shall be shop fabricated. Removable sections of handrails shall be furnished with
posts at each end of the removable sections for bolting to supporting clips.
5.19.2
Toe plates shall be provided on walkways and platforms along with all edges protected by
railing, around openings in platforms under equipment where no railing is provided; under
the bottom treads of all stairways which rine from landings; across ladder access openings
and around all openings where the normal clearance between the edge of the floor plate
and the equipment or piping is 50 mm or more.
6.0
FABRICATION DRAWINGS
6.1
EIL steelwork drawings wherever issued are design drawings showing structural member
configuration and sizes. These along with job specifications indicate complete engineering
requirements towards the construction of fired heaters & APH system.
6.2
After completion of the residual design & engineering work, Contractor shall submit the
fabrication drawings for approval, along with supporting calculations wherever asked for.
6.3
The fabrication drawings shall contain the complete information about the fabrication
work to be carried out including connections, splices, welding, BOM, other details etc.
6.4
If deemed necessary, the EIC may ask for review or modification of any drawing,
document or procedure of the Contractor, without any cost / time implications.
6.5
Completion of fabrication or erection shall be carried out as per the approved drawings.
This however, does not prevent the Contractor from going ahead with arrangements for
procuring the required material, or making other arrangements required for fabrication and
erection.
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'
ENGINEERS
INDIA LIMITED
IA GovI al Intlta
underiak.g)
6.6
If any modification is made in the design drawings during the execution of the job, revised
design drawings will be issued to the Contractor. Contractor shall revise his fabrication
drawings and seek re-approvals as required.
6.7
6.8
After the completion of all works, as-built details shall be marked in EIL drawings,
incorporated in Contractor fabrication drawings and submitted to the EIC for certification
& approval of all revisions made before submission of requisite number of copies as per
VDR.
6.9
For detail requirement of fabrication drawing submission refer VDR given in tender
document.
7.0
FABRICATION
7.1
Fabrication shall be in accordance with IS: 800 and standard fabrication practices as
approved by the EIC.
7.2
Fabrication shall be done as per design drawings in conjunction with details / drawings
approved by EIL-HMTD / EIC.
7.3
Welding shall be done as per the requirements of IS: 800, IS: 814 and IS: 816. Surfaces to
be welded shall be free from oil, grease, dirt, scale and other foreign materials.
Composition of welding filler materials shall be in accordance with the base materials
being joined.
7.4
Welding shall be done only by fully trained and experienced welders as qualified and
approved by EIC. Qualification tests for welders as well as tests for approval of electrodes
will be carried out as per IS: 823. The nature of test shall be as advised by EIC.
7.5
Steel work shall be delivered to site in sub assembled units or components as shown in the
detailed drawings. Prior to dispatch, fabricated sections are to be trial assembled in the
shop to ensure correct fit and erection. All mating parts shall be match-marked properly.
All the fabricated and delivered items shall be suitably packed for protection from any
damage during transportation and handling. Fabricated segments and modules liable for
distortion during handling, transportation and erection shall be temporarily cross-braced to
prevent distortion. Temporary stoppers shall prevent movement of tube assemblies
relative to steelwork / housing. The handling direction shall be prominently marked on the
packing to avoid any mishandling during transportation and erection.
7.6
Column bottom / top welded to base plates / cap plates shall be ground fine to bear
uniformly on the connected surface and fitted exactly at 90 degrees.
7.7
All built-up sections are to be fabricated and erected in one piece. Drilling of through
holes in the built-up section to be done after building up the section.
7.8
Platforms, ladders, panel plates and stacks shall be shop assembled in the largest unit
suitable for handling, transportation and erection.
7.9
All welds in stack and shell, both horizontal and vertical are to be full-penetration buttwelds. For plate thickness upto 12 mm thickness single `V' butt weld & for 14 mm and
("ENGINEERS
2151-egWr INDIA LJMITED
31
1.1R7r 2.1~70,
1~1)
6-17-0002 Rev. 5
Page 9 of 12
above double `V' butt weld shall be used. Longitudinal welds shall not be in the same
line. Welds shall not be in line with any opening in stack. No welding shall be carried out
during poor weather condition. For stack shell plate more than 38 mm thick, preheat &
stress-relieving requirement shall be applicable as per ASME code.
7.10
A11 steel surfaces shall be cleaned of all rust, dirt and loose mill scale by wire brushing or
other approved method. Use of box sections for main columns and beams shall be
avoided. While using box or tubular section, the ends shall be properly sealed using end
caps against ingress of moisture. Also before sealing, the inside surface shall be ensured
as dry and shall be primer painted.
7.11
A11 fabrication shall be of rigid construction and care shall be taken against welding
deformation.
7.12
A11 bolt holes shall be sheared only and not gas cut. For matching parts, bolt holes shall be
match marked and holes drilled.
7.13
7.14
Fabricated structures shall be given primer coat compatible with the final painting as per
painting specification, immediat,Aly after completion at site or before dispatch from shop.
7.15
Channels that require rolling / bending may be fabricated out of plates or angles as
approved by EIC.
7.16
For base plate sizes above 300 x 300 mm, grouting holes may be provided at suitable
locations. Such holes shall be indicated in the base plate drawing submitted for EIL
approval.
7.17
Tolerances (in mm) on steel work fabrication shall be as follows unless noted otherwise
on the job documents. Tolerances of all other fabrication shall be as per IS: 7215.
a.
Marking
1.0
b.
Flame cutting
1.5
c.
Shearing (plates)
1.0
d.
0.5
e.
Cold-forming
short radius upto 25 mm
medium radius upto 75 mm
large radius beyond 75 mm
0.5
1.0
1.5
f.
0.5
g.
0.4
h.
0.4
i.
0.2
j.
Length/1500
k.
Length/1500
$'fg-u112- g
ENGINEERS
INDIA LIMITED
IA Govt ot Inct. Unclertak.g)
1.
Length/1000
Straightness of columns (with cap/base plate)
Outer & inner intermediate columns about XX axis 6
Outer & inner intermediate columns about YY axis 3.0
3 .0
Outer & inner end columns about XX axis
3 .0
Outer & inner end columns about YY axis
-
m.
Length/1000
5 (maximum)
n.
2.5
o.
1.0
1.5
2.0
1.0
3.0
2.0
3.0
P.
1/o
5.0 (maximum)
q.
r.
3
6
1.5 (maximum)
s.
7.18
The flatness of individual furnace casing plates after welding of stiffeners shall conform to
the following:
7.18.1
A straight edge (or taut string) shall be laid along the edges and across diagonally opposite
corners of the casing plate. The maximum permissible camber shall not exceed 2 mm per
meter.
7.18.2
The camber at various points on the plate shall be checked with a straight edge (min.
length 500 mm). The maximum permissible camber over a length of 500 mm at any
location and measured in any direction shall not exceed 1 mm.
8.0
ERECTION
8.1
Erection shall be in accordance with IS: 800 and standard erection practices as approved
by the EIC.
8.2
Contractor shall appraise himself completely with the facilities and constraints at site.
8.3
Before preparation of detail drawings / starting erection work, sequence and procedure of
erection shall be prepared and got approved from the EIC.
8.4
The Contractor shall satisfy himself about the levels, alignment etc. for the foundations
well in advance before starting the erection. Minor rectification, if required, shall be
carried out at no extra cost.
8.5
The erection work shall be started only after obtaining permission form the EIC.
ENGINEERS
INDIA LIMITED
Re.j1 054-3
1~29~=~11
6-17-0002 Rev. 5
Page 11 of 12
8.6
Grouting below base plates shall be done as per clause 9.0 of this specification.
8.7
The positioning and leveling of the structure, alignment and plumbing of the stanchions
and fixing every member of the structure shall all be in accordance with the drawings.
8.8
Care shall be taken at all slotted holes connections while tightening of bolts to allow
freedom for expansion. Check nuts with suitable washers shall be used in all such cases.
8.9
Heater shall be of air tight construction and welded throughout, except wherever called for
otherwise. All casing splicing shall be seal welded after erection. In order to minimize air
infiltration into heater, extreme care must be taken to ensure closing of all openings and
crevices after assembly of heater is complete.
8.10
8.10.1
All structural steel and sub-assemblies shall be clearly identifiable and suitably marked to
provide an easy means of erection in the field.
8.10.2
On vertical cylindrical heaters, all columns, and sections shall be marked clockwise from
the 'N' direction.
8.10.3
Wherever there is possibility of erecting the member inverted, the members to be marked
`Top'.
8.10.4
Where a member is shipped in two or more pieces, each piece shall have the same mark
suffixed by a, b, c etc.
8.10.5
All marks shall be painted on the steel in a legible fashion with letters and numerals of at
least 40 mm height.
8.10.6
All rods, turnbuckles etc. are to be tagged and wired firmly together.
8.10.7
All bolts, washers etc. shall be shipped in bags or crates and tagged or clearly marked as
to MOC, size, diameter and length.
8.10.8
Galvanized members (if required) shall be tagged with a metal plate having raised letters
so that the mark will be visible after galvanizing. This metal plate shall be tack welded to
the number prior to galvanizing.
8.11
b.
c.
1.0
d.
2.0
e.
3.0
5gar 92e5
1.1-2,1 cwer,r,
f.
ENGINEERS
INDIA LIMITED
IA Govt ot Inolta Unclettatungt
Clear spans
at beam connection
at Radiant section and columns
Radiant section intermediate columns
-
g.
6-17-0002 Rev. 5
Page 12 of 12
1.0
Span/1000 but max.6
Span/1000 but 6
(max.) from CL
Span/1000
1.0
9.0
9.1
The grouting material shall solidly fill the spaces to be grouted and permanently retain its
original volume so that the base plate will be held firmly in the set position. The amount
of water used in mixing shall be kept to a minimum such that the grout shall not flow.
9.2
After final alignment and plumbing of the structure, the forms shall be constructed allround and joints made tight to prevent leakage. Grouting (under the base plates/shoe
plates including grouting of sleeves & pockets) shall be done with non-shrink grout
having compressive strength (28 days) not lens than 40N/sq. mm Non shrink grout shall be
of free flow premix type and of approvel quality and make.
9.3
9.4
9.4.1
9.4.2
The finished surface shall be floated smooth and shall be suitably sloped away from base
plate.
9.4.3
After the initial set is over the grout shall be kept thoroughly wetted for a minimum of 5
days.
9.4.4
Care is to be taken during grouting so that the base plate Level and alignment are not
disturbed.
10.0
10.1
A11 inspection will be done in accordance with the relevant codes including IS: 800 and
with the specific requirements of the job specifications.
10.2
Contractor shall prepare a detailed ITP for steel work and get it approved from E1L.
10.3
For inspection at any stage of the job, the EIC or his representative shall have free access
to the Contractor's or his sub-contractor's shop as well as in the field for proper execution
of the job.
10.4
Weld joints in stack and shell of shell-designed cylindrical heaters will be subject to 2%
radiography test. Selection of radiography spots and acceptance limit will be as decided by
the EIC / Inspector depending upon the quality of welding required. However, all the `T'
joints shall necessarily be covered for radiography.
Oziei
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99:5,s,
ENGINEERS
INDIA LIMITED
STANDARD SPECIFICATION
FOR ERECTION OF EQUIPMENT
& MACHINERY
STANDARD SPECIFICATION No
6-76-0001 Rev. 3
Page 1 of 22
03.09.2008
DM
PKR
AA
VC
30.05.2008
DM
PKR
AA
VC
25.04.2001
DM
AM
MR
MI
Checked
by
Standards
Committee
Convenor
Standards
Bureau
Chairman
Rev.
No
Date
Purpose
Prepared
by
Approved by
Format No. 8-00-0001-F1 Rev. 0
Page 583 of 2175
zier
SiglIT
far
ENGINEERS
INDIA LIMITED
IA Gobi of India Undetakingi
6-76-0001 Rev. 3
Page 2 of 22
Abbreviations:
ASME
EC
Erection Contractor
EIC
Engineer-in-charge
ELCB
GAD
IS
Indian Standard
NDT
SS
Stainless Steel
fazieT to
Ogelf laliteS
ENGINEERS
INDIA LIMITED
CONTENTS
1.0
2.0
3.0
4.0
10
5.0
16
6.0
EQUIPMENT GROUTING
19
7.0
22
ENGINEERS
INDIA LIMITED
A O,l of India underlakPrigi
Scope
This specification covers technical requirements for erection of all static and rotating
equipment by erection contractor at site. This specification is applicable for all the erection
tenders operated by EIL.
1.2
General
1.2.1
All necessary handling equipments, tools, tackles and precision instruments for carrying out
the works as specified shall be provided by the Erection Contractor (EC) at his cost. EC must
provide all tools and gauges for erection and alignment. Special tools, if any, received as part
of machinery, will be given to EC for erection purposes, which shall be returned in good
condition after use. Suitable deductions will be made by the Engineer-in-Charge (EIC) in
case of loss or damage of the special tools. The value of such loss or damage will be decided
by the EIC and EC shall be bound by such a decision.
1.2.2 Equipment Manufacturer's recommendations regarding preservation during storage at site and
detailed specifications for the installation alongwith layout drawings, general
arrangement/equipment outline drawings and sub-assembly drawings of the various equipment
and machinery will be provided to EC during the performance of work. The requirements
stipulated in these shall be fulfilled by EC in addition to what is stated in this specification.
Erection shall be carried out as per the instructions and supervision of Machinery
manufacturer's representative, wherever such supervisory services are applicable.
1.2.3 All the items of work covered in the tender shall be carried out as per this Specification and
However, EIC reserves the right to give
EC.
other details to be furnished to
additional/alternative specifications and instructions, at any time, for execution of any
particular work and EC shall execute such works in accordance with such
additional/alternative specifications and instructions of the EIC. Such a step taken by the EIC
shall not constitute a breach of the contract.
1.3
1.3.1
EC shall be responsible for organising the lifting of the equipment in the proper sequence, so
that orderly progress of the work is ensured and access routes for erecting the other equipment
are kept open.
Rigging procedure for all the major lifts (above 10 MT) and at maximum crane capacity shall
be submitted by EC for the approval of EIC. However, approval to rigging procedure
proposed by EC shall not relieve EC from his responsibility in following the proper
lifting/erection methods on ensuring orderly .
1.3.2 Orientation of all foundations, elevations, length and disposition of anchor bolts and diameter
of holes in the supports saddles shall be checked by EC, well in advance. Minor rectifications
including chipping of foundations as the case may be, shall be carried out by EC after
obtaining prior approval of EIC. EC shall also be provided with the necessary structural
drawings and piping layouts etc. wherever required for reference. EC shall crosscheck such
piping and structural drawings with actual construction at site and in case of any mismatch
inform the EIC before taking up the erection.
5fgar fakres
ENGINEERS
INDIA LIMITED
IA Govl 01 haw undeptakingl
1.3.3 During the performance of the work, EC shall keep structures, materials or equipments
adequately braced by guys, struts or otherwise approved means which shall be supplied and
installed by EC as required till the installation work is satisfactorily completed. Such guys,
shoring , bracing, strutting, planking supports etc. shall not interfere with the work of other
agencies and shall not damage or cause distortion to other works executed by him or other
agencies.
2.0 ERECTION OF COLUMNS, TANKS, VESSELS AND DRUMS ETC.
2.1
2.2
2.2.1
Unless otherwise specified Columns, Vessels, Drums etc. will be generally supplied to the
Erection Contractor in single piece and EC will not be required to carry out any assembly or
welding. In case column is supplied in multiple pieces and erection of the equipment is not
possible in single piece, EC shall be responsible for lifting the pieces, for aligning, welding
and hydrotest etc. in vertical position under the supervision of column Supplier (Fabricator).
However, EIC shall be responsible for coordination between Erection Contractor &
Fabricator. The schedule of quantities (SO()) for equipment erection enclosed with the tender
document outlines details of each equipment such as diameter, overall height, type of support
(saddle/skirt/leg/bracket), position (horizontal or vertical) and approximate erection weight
etc. However the erection elevation and location of equipment shall be as per the piping
layout drawing enclosed with the tender.
INIFEzie?
SIgt-IT "keg
ENGINEERS
INDIA LIMITED
0 Gov' of Indra Undettakingl
6-76-0001 Rev. 3
Page 6 of 22
2.2.2 Rigging procedures and erection schemes for all the heavy lifts weighing 10 MT & above
shall be prepared by EC and got approved by EIC. Approval by EIC shall not relieve EC of
his responsibilities. The details to be submitted will include the location of equipment from
where it will be lifted, location of crane(s), details of crane(s) (like configuration, boom
length, operating radius, boom point elevation, clearance underside the boom and the
equipment, lifting capacity, counter weights to be deployed, holds on any neighbouring
foundations, structures, equipments etc.), the load chart of the crane(s), design of the lifting
tackles like spreader beam, D-shackles, wire rope slings etc. Unless the erection scheme and
rigging procedures are approved by EIC, erection of such equipments shall not be undertaken
in any case by EC.
2.2.3 Before starting the erection of Columns, Vessels etc., top surface of the foundations is to be
cleared/chipped, roughened to obtain proper bond, while grouting. Also the sleeves are to be
cleaned before erecting the equipments. Line (orientation) and levels are to be marked on all
the foundations to facilitate checking of alignment.
EC shall also check the correct elevation and orientation of civil, structural foundations, before
proceeding with the erection work. Discrepancy, if any, shall be brought to the notice of EIC.
However, minor rectifications and chipping of foundations upto a thickness of 15 mm in
foundation height shall be carried out at no extra cost, by the EC. EC shall be responsible for
supply of levelling plates, (if required) and shall carry out levelling of equipment under the
directions of EIC.
2.2.4 While handling, transporting or erecting the equipments, care shall be taken not to damage the
nozzles, instrument connections, structural clips etc. EC shall also take care of the orientation
of the nozzles and other connections of the equipments while erecting the same and ensure
compliance with the drawings and specifications supplied. Discrepancy, if any, in the
number/orientation of the nozzles, cleats etc. should be brought to the notice of the EIC before
actual erection is started.
2.2.5 Verticality of the Columns, ReactorsNessels shall be checked with theodolites. After erection
the equipment shall be levelled and properly aligned with necessary shims and wedges
supplied by EC, at his cost. After the level, alignment and verticality etc. are checked and
approved by EIC, EC shall carry out grouting.
2.2.6 EC shall produce recent test certificates of the slings which they will be using for erection
work. However, retesting of the slings shall be done at site by EC at his cost, as and when
required by EIC. The weights of test loads shall be as per IS-807. The test loads shall be
supplied by EC at his cost. Tested slings will be punched for test loads and date of testing as
directed by EIC.
2.2.7 EC shall also carry out the assembly, erection, levelling and alignment of all types of weir
plates, baffles, distributors, collectors, spray nozzles, demisters, grids and other internal
fittings etc. Work shall be carried out as per manufacturer's standards/specifications which
shall be made available to EC at the time of erection. Raschig rings, molecular sieves, intalax
saddles packing and other types of tower packings such as sand, catalyst etc. and SS wire
mesh shall be loaded into sections of Vessels, Columns as per specifications and drawings.
Details for internals to be installed by EC shall be as per separate schedule of quantities
enclosed with the tender document. All packings except clay and lime stone shall be washed
with water before filling. Bottom layers, if required, shall be arranged as directed and random
filling shall be done afterwards with equipment filled with water. Installation of packings,
shall be done only after flushing and cleaning of Columns/Vessels and completed to the
satisfaction of EIC.
laratlei
* la g,
ENGINEERS
INDIA LIMITED
6-76-0001 Rev. 3
Page 7 of 22
2.2.8 EC shall carry out minor welding for attachment of prefabricated pipe davit parts such as rain
covers, handles etc. with pipe davit, during or after erection of the same as per the
manufacturer's specifications, at no extra cost to the Owner.
2.2.9 EC shall execute erection of wooden pillow for saddle support for cold horizontal vessels
wherever necessary as indicated on the drawings/ EIL STD 7-12-0003 and as per the
instructions of EIC.
2.2.10 EC shall execute assembly & erection of agitator/mixer along with drive unit including all
accessories as per supplier's instructions, specification drawings & instructions of EIC.
2.3
2.3.1 After the erection, alignment and grouting of these equipments are complete, flushing and
cleaning shall be carried out by EC as per specifications and instructions of EIC.
2.3.2 After flushing, cleaning and draining, equipments shall be dried by compressed air at the
pressure and for duration decided by the EIC. The Vessel interior shall be thoroughly
inspected to the complete satisfaction of EIC before it is finally boxed up. Boxing up of
manholes and handholes shall be leak proof. All joints which need remaking, shall be remade.
Compressed air for drying shall be arranged by EC.
2.4
afarm a ENGINEERS
slig2li EVIeg UINDIA LIMITED
IA Gori al India undenakrnyi
2.5.3 EC shall do the necessary excavation, backfilling and removal of surplus earth at the site as
per the directions of the EIC. EC's rate shall include the excavation, blast cleaning, painting,
wrapping by kraft paper, placing and fixing of Vessels, backfilling and removal of excess
earth.
3.0 ERECTION OF MECHANICAL EQUIPMENT
3.1
3.2
3.3
Technical Requirements
3.3.1 All equipment/machinery erection shall be done by experienced fitters. For this purpose EC
shall employ an experienced erection supervisor and crew who have done similar jobs.
3.3.2 EC shall study the layout drawings, for the machineries and equipments with their auxiliaries,
controls defining scope of supply.
3.3.3 Equipments shall be checked for any damages as a result of transport, handling and defects, if
any, shall be reported to the EIC. Rectification of defects shall be carried out in accordance
with approved procedure.
3.3.4 Correct procedures for handling of equipment & installation on the foundation shall be
followed as given in the manufacturer's manual. In case of non-availability of such
procedures, EC shall develop & submit handling procedures for all equipment weighing more
than 10 metric tonnes. The handling procedure shall be approved by the EIC.
3.3.5 EC shall check the correctness of equipment foundations or supporting structures as per the
drawings. Equipment/Skid foot print dimensions shall be verified to match with the
foundation. Minor chipping of foundation, pockets if required shall be carried out by EC.
3.3.6 All accessories like pressure gauges, seal oil, cooling water & Lube oil headers etc., shall be
tagged and separately kept in Contractor's stores till erection. All flanged connections and
openings shall be kept blanked with dummies, plugs to prevent entry of foreign particles.
3.3.7 Equipments shall be installed on the foundations in proper sequence. Incase the equipments
are delivered in subassemblies, EC shall do the assembly work as per manufacturer's
instructions.
3.3.8 Equipments shall be installed in the correct orientation and alignment.
filPA; ENGINEERS
5ittif EffileS 71? INDIA LIMITED
GoN at India Undenakg,91
3.3.9 After installation and levelling the equipment shall be grouted with the specified grouting
applied to the baseplate and support.
3.3.10 EC shall remove all the packing and protective devices used during transport and handling
from the equipment such as shock absorbent materials from machined faces, blocking of shafts
or rolling bearings & restraining devices from instruments, safety devices and protective
equipments.
3.3.11 After the grouting is set & cured, the foundation bolts shall be checked to make sure that they
are in straight and vertical position and properly tightened. Shims, if used, shall be on either
side of the foundation bolts.
3.3.12 Desiccant, catalyst where supplied loose shall be loaded on to the respective vessels in
specified quantities as per the suppliers instructions.
3.3.13 Internals, where supplied loose shall be assembled as per the drawings and manufacturer's
instructions.
3.3.14 Unless otherwise specified, all the instruments such as pressure gauges, sight glasses
temperature recorders etc. including instrument panels, if any, supplied along with the
equipment with necessary connections, shall be installed by EC as part of Equipment erection.
3.3.15 Equipments shall be checked for final cleanliness before boxing up.
3.3.16 Any interconnected piping & ducting shall be properly installed and supported. EC shall
connect the gas, steam, air, utility piping, instruments, oil piping etc. as per manufacturer's
drawings, specifications and instructions of the EIC.
3.3.17 Safety devices shall be correctly installed.
3.3.18 Ladders, platforms, walkways shall be correctly installed with handrails, and flooring shall be
properly secured.
3.3.19 Field welding, where specified shall be in accordance with the specified procedures and NDT
tests where specified shall be carried out. Results of NDT tests shall be recorded.
3.3.20 Equipment alignment & couplings shall comply with tolerances specified in manufacturer's
drawings and manuals. Provisions of dowel pins or similar arrangements for retaining the
alignment shall be carried out.
3.3.21 After the piping has been connected, the alignment shall be checked by EC again, to ensure
that piping connections do not induce any undue stresses on the Equipments. After making
necessary corrections on the piping, if any, realignment shall be done by EC to ensure that no
undue stresses are induced on the equipment.
3.3.22 Painting, insulation & fireproofing where specified shall be carried out in accordance with the
applicable specifications attached in the tender document.
3.3.23 Any alterations, deviations made during equipment erection with respect to manufacturer's
drawings or instructions shall be duly recorded and approval shall be taken from the EIC.
3.3.24 Any special tools, tackles supplied along with the equipment and used during installation shall
be returned to the stores through the EIC.
3.3.25 Any protection of the equipment after installation, if required shall be carried out in
accordance of the instructions of the EIC.
Format No. 8-00-0001-F1 Rev. 0
Page 591 of 2175
apA ENGINEERS
3.4
IA
Trial Runs
3.4.1 Wherever specified, Machinery & Equipment erected & installed by EC under the supervision
of Machinery/Equipment supplier shall be subjected to trial runs in accordance with clause 5.4
of this specification. Job specific trial run procedure, if specified, supersedes the trial run
procedure as described in clause 5.4.
3.5
System Start-up
During this phase of work, EC shall provide as part of his work necessary skilled personnel as
per requirement of EIC. Any defects noticed in the Equipment shall be made good by EC at
his cost if such defects are attributable to him.
4.1.1 Preparation of erection scheme and rigging procedure and obtaining its approval from EIC
wherever necessary.
4.1.2 Withdrawal of equipment from Owner's storage point, checking and reporting its conditions,
transporting the same to EC's stores and work site including unloading etc.
4.1.3 Preparation of foundation by chipping & installation of base plates for foundations. Minor
rectifications & chipping of foundations up to a thickness of 15 mm due to error in foundation
height, shall be carried out by the EC at no extra cost
4.1.4 Before starting the erection, top surface of the foundations are to be
cleaned/chipped/roughened to obtain proper bond while grouting. Line (Orientation) & Levels
are also to be marked on the respective foundations prior to erection to facilitate checking of
alignment.
4.1.5
4.1.6 Erection on foundations furnished by Owner including aligning, levelling and grouting.
lociMewl
5gTzIT felf5lt
,
ENGINEERS
INDIA LIMITED
A GOY, 0( India Undett.,ng)
6-76-0001 Rev. 3
Page 11 of 22
4.1.7 Assembly and fixing of trays, tower internals (distributor, bed limiter, support plate, chimney
trays, vapour distributor etc.), demisters, grids, internal distributors and other internal fittings
in columns, vessels etc.
4.1.8 Installation of transformers on desalters and their electrical connection to electrode grid etc.
4.1.9 Welding of chimney trays, lattice girders, beams etc. wherever required.
4.1.10 Carrying out minor adjustments, modifications, seal welding of seal plates etc. wherever
necessary during installation.
4.1.11 Checking of installed trays & tower internals and filling of installation formats as referred in
6-14-0016.
4.1.12 Filling of columns, vessels/drums etc. with Raschig rings/Pall rings/ Structured packing, as
required.
4.1.13 Welding of washers for equipment, erection of pipe davit & minor welding of their parts as
per specifications and instruction of EIC.
4.1.14 Hydrotesting of shell and tube heat exchangers if the time gap between last hydrotest is more
than six months or in case it is found to be necessary by EIC. Procedure is given in para 4.3 &
4.4 below. EC to note that any equipment which are refractory lined at shop shall not be
hydrotested.
4.1.15 Flushing, cleaning and drying of equipment using compressed air and blinding to prevent
ingress of rain, dust etc.
4.1.16 Installation of refractory lining, brick lining, ceramic boards etc., as per specifications,
recommendations of manufacturer and instructions of EIC.
4.1.17 Mounting of instruments like safety valves, rupture disks, sight glasses etc as required.
4.1.18 Completing the equipment in all respects for the commissioning of the plant as per drawings,
specifications & instructions of EIC.
4.1.19 Any modification in the equipment to the complete satisfaction of EIC.
4.1.20 In addition to the above EC may be called upon to do other jobs like rectification of defects
etc. as per instructions of EIC.
4.2
4.2.1 All carbon steel components of trays/tower internals shall be cleaned to remove rust
preventive coating.
4.2.2 All welding shall be done by qualified welders only. The electrodes/filler material to be used
shall be compatible with the metallurgy of component and shall be used only after prior
approval of EIC.
4.2.3 A proposed Welding Procedure Specification (WPS) shall be submitted to EIL/ Owner's
Inspector for his approval. On approval, a Procedure Qualification Test (PQT) shall be
conducted which shall be witnessed by EIL/Owner's Inspector. On acceptance of all tests as
per ASME Section IX, a final WPS along with Procedure Qualification Record (PQR) shall be
submitted. Production welding shall start only after approval of final WPS/PQR and
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qualification of welders as per ASME Section IX. EIL/Owner's Inspector may accept
previously qualified WPS/PQR at his sole discretion.
4.2.4 Lattice girders wherever provided for supporting tray & tower internals have been designed in
such a way that various components pass through column manway. Components/parts of
lattice girders are to be welded inside the column as per respective drawings. EC shall also
ensure that all parts of lattice girder are properly welded & levelness of the lattice girder shall
be checked before & after the welding. The limits of levelness as mentioned in GA drawings
shall be adhered to.
4.2.5 The rigging procedure shall include the following as a minimum:
Location of equipment from where it will be lifted, location of crane(s), details of crane(s)
(like configuration, boom length, operating radius, boom point elevation, clearance underside
the boom and the equipment, lifting capacity, counter weights to be deployed, holds on any
neighbouring foundations, structures, equipment etc.), the load chart of the crane(s), design of
the lifting tackles like spreader beam, D-shackles, wire rope slings etc. Unless the erection
scheme and rigging procedures are approved by the EIC, erection of equipment shall not be
undertaken in any case by the EC.
4.2.6 While handling, transporting or erecting the equipment, care shall be taken not to damage the
nozzles, instrument connections, structural clips, refractory lining etc. EC shall also take care
of the orientation of the nozzles and other connections of the equipment while erecting the
same and ensure compliance with the drawings and specifications supplied. Discrepancy, if
any, in the number/orientation of the nozzles, cleats etc. should be brought to the notice of the
EIC before actual erection is started.
4.2.7 After erection, the equipment shall be levelled and properly aligned with necessary shims and
wedges supplied by EC, at his cost. After the level, alignment and verticality etc. are checked
and approved by EIC, EC shall carry out grouting.
4.2.8 EC shall produce recent test certificates of the slings which they will be using for erection
work. However, retesting of the slings shall be done at site by the EC at his cost, as and when
required by the EIC. The weights of test loads shall be as per IS-807. The test loads shall be
supplied by EC at his cost. Tested slings will be punched for test loads and date of testing as
directed by ETC.
4.2.9 EC shall also carry out the assembly, erection, levelling and alignment of all types of weir
plates, baffles, distributors, collectors, spray nozzles, demisters, grids and other internal
fittings etc. Work shall be carried out as per manufacturer's standards/specifications which
shall be made available to EC at the time of erection. Raschig rings/Pall rings/Structured
packing, molecular sieves, intalox saddles packing and other types of tower packing such as
sand, catalyst etc. and SS wire mesh shall be loaded into sections of vessels, columns as per
specifications and drawings. Details for internals to be installed by EC shall be as per separate
schedule of quantities enclosed with the tender document. All packing except clay and lime
stone shall be washed with water before filling. Bottom layers, if required, shall be arranged as
directed and random filling shall be done afterwards with equipment filled with water.
Installation of packing, shall be done only after flushing and cleaning of columns/vessels and
completed to the satisfaction of EIC.
4.2.10 EC shall carry out minor welding for attachment of prefabricated pipe davit parts such as rain
covers, handles etc. with pipe davit, during or after erection of the same as per the
manufacturer's specifications, at no extra cost to the Owner.
4.2.11 EC shall install base plate over the sliding end foundation before erection of shell and tube
exchangers.
Format No. 8-00-0001-F1 Rev. 0
Page 594 of 2175
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6-76-0001 Rev. 3
Page 13 of 22
4.2.12 Levelling and plumbness shall be approved by EIC and shall be checked using theodolite
before grouting and final finishing of the foundations. The record of the same shall be
maintained.
4.2.13 EC to ensure that shell and tube exchangers shall be firmly bolted down to foundations at the
fixed end. Further EC to ensure that foundation bolts at the sliding saddle end are at the centre
of slotted holes & nuts at sliding end are only hand tightened. Projected bolt threads shall be
properly protected by application of grease etc. to avoid rusting and for facilitating free
movement of nuts.
4.2.14 EC shall ensure that no equipment is subjected to any corrosion during any stage during his
period of work till handling over to EIC/Client.
4.2.15 Instruments, as required, shall be mounted by EC. On instructions of EIC, EC shall also
remove and hand over the instruments to EIC for calibrations. During this period, EC shall
cover all openings to protect the equipment.
4.2.16 Before transportation to site, EC shall check and report to EIC on the condition of equipment,
specifically highlighting the nitrogen pressure indicated in the nitrogen gauges and the absence
of blinds on any of the nozzles.
4.2.17 In case the shell and tube exchangers are to be stacked, but have been stored as single shells at
the store, then EC shall erect the bottom most shell, then erect other shell(s) sequentially using
the nozzle gaskets/bolting and saddle bolting supplied by owner. Additional shims, if
necessary, shall be supplied by EC. If the exchangers do not have interconnecting nozzles,
then nozzle elevations shall be maintained as per piping GAD.
4.2.18 All equipment, consumable and other accessories required for completion of the job shall be
arranged by the EC. This would include but not limited to cranes, tools and tackles,
manpower etc; machinery for cutting, grinding , drilling etc. of base plates; instruments like
dumpy level, plumb lines, Engineer's levels, precision levels, theodolite, straight edges etc. for
checking the alignment/erection accuracy, hydrostatic testing pumps, potable water for
hydrotesting, necessary materials including making the arrangements for hydro-testing, hoses,
compressed air supply, pressure gauge, sealing taps, blinds, shims and wedges for alignment
etc.
4.2.19 EC shall execute the erection of wooden pillows for saddle supports for cold equipment as
indicated in schedule of quantities, EIL standard 7-12-002 and instructions of EIC.
4.2.20 For bought out items like plate exchangers, plate fin exchangers, electric heater, etc. vendor's
instructions shall be followed.
4.2.21 For erection of piping of ejector system, EC shall follow relevant erection specification of
piping for the project.
4.2.22 EC shall check the health of the equipment refractory lined at shop on receipt and shall report
any defect or damage in the same to EIC. During installation all precautions shall be taken to
avoid any damage to refractory lining. Any damage to refractory during erection shall be
repaired by EC at his own cost without loss of time.
4.2.23 Wherever equipment with refractory are bolted or welded at the girth joints, the gaps between
the refractory shall be suitably filled with ceramic fiber of suitable grade as given in the
drawings or other relevant documents of the equipment.
4.2.24 Refer section 1.0 (General) for additional requirements.
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INDIA LIMITED
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6-76-0001 Rev. 3
Page 14 of 22
4.3
4.3.1
These shall hydrotested at site using potable water. Hydrotesting of both shell and tube sides
shall be carried out as per procedure given below or as per instructions of EIC. For
exchangers fitted with SS bellow or SS part, potable water with max. 25 ppm chlorides shall
be used for hydrotesting.
4.3.2 Suitable pump set, piping, test pressure gauges and other instruments, water-hoses, temporary
gaskets, metallic blinds, bolts, nuts, consumable and other temporary arrangements and
equipment for testing shall be provided by the EC at his cost. Test pressure gauges shall be
calibrated by the EC and got approved from EIC.
4.3.3 Stacked exchangers shall be hydrotested in stacked conditions.
4.3.4 Test pressure shall be as indicated in the name plates mounted on each exchangers. Duration
of hydrotest shall be at least one hour. Test pressures and duration of hydrotest may be
reduced by EIC. Minimum test water temperature shall be 20C.
4.3.5 Any defects noticed during hydrotesting shall be repaired by EC as per the procedure
approved by EIC. Cost for rectifying defects, not attributable to the EC shall be paid
separately.
4.3.6 No equipment shall in general form part of the piping loop during hydrotesting and shall be
blinded off, except when instructed otherwise by EIC.
4.3.7 EC to take adequate care during pressurising & depressurising the equipment. EC shall also
take care of any instruction given regarding hydrotest in the exchanger drawing.
4.4
Hydrotesting Procedure
4.4.1
Shell side & tube side shall be hydrotested separately, unless specified otherwise. If both sides
are to be tested together, a warning plate would be fixed to the exchanger, and the instructions
given therein are to be followed.
4.4.2 The side, shell or tube which ever to be tested at higher pressure shall be taken first.
4.4.3 During hydrotest all gasket joints should be checked for any leakage. In case of leakage from
any gasket joint, bolting at that joint shall be further tightened following proper tightening
sequence (bolts should not be overtightened or tightened by hammering). In case it is not
possible to stop leakage by bolt tightening, drain the water in exchanger & replace gasket at
that joint by new gasket (gasket will be supplied by owner). After replacing gasket exchanger
must be again hydrotested with same procedure to ensure leak tightness.
4.4.4 In case of floating head heat exchangers, if it is found during hydrotest that the pressure is
dropping, while the external gasketed joints are not leaking, this could be due to floating head
gasket joint leakage. This shall be further investigated, by removing shell cover &
pressurising tube side to check the floating head gasket joint leakage. In case of leakage
observed at floating head flange joint, replace floating head gasket by new gasket. After
replacing gasket exchanger must be again hydrotested first on tube side & then on shell side
with same procedure to ensure leak tightness of gasket joints.
In case of heat exchangers with shell side hydrotest pressure higher than tube side, it is
possible that above procedure (with tube side hydrotest to detect floating head gasket leakage)
may not help. Absence of leakage during this test is not conclusive in such a case, as the shell
side pressure was dropping during hydrotest. In such a case, floating head gasket shall in any
case be replaced and then equipment retested to ensure leak tightness.
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4.4.5 When hydrotested as per above procedure after floating head gasket replacement, if it is
observed that test pressure is still dropping, this could mean leakage from tube to tubesheet
joint. For such cases matter shall be reported to EIC for further investigations/instructions.
4.5
4.5.1 After the erection, alignment and grouting of these equipment are complete, and after
hydrotest if any, flushing and cleaning shall be carried out by EC as per specifications and
instructions of the EIC.
4.5.2 After flushing, cleaning and draining, equipment shall be dried by compressed air at the
pressure and for duration decided by EIC. The equipment interior shall be thoroughly
inspected to the complete satisfaction of EIC before it is finally boxed up. Boxing up of
manholes and handholes shall be leak proof. All joints which need remaking, shall be remade.
Compressed air for drying shall be arranged by EC at his cost.
4.6
ENGINEERS
INDIA LIMITED
G.v, 1^dia Undertak.11
6-76-0001 Rev. 3
Page 16 of 22
shall be complied with. Inspection aids for carrying out the inspection of internals shall also be
provided.
5.0 ERECTION OF ROTATING EQUIPMENT
5.1
5.2
5.2.1 All Rotating Equipment erection shall be done by experienced fitters. For this purpose EC
shall employ experienced and suitably qualified erection supervisor and crew who have done
similar jobs.
5.2.2 The Rotating Equipment manufacturer's instructions as available regarding installation and
trial runs will be passed on to EC during the course of work. The requirements prescribed
therein shall be met in addition to what is stated in this specification. Erection shall be carried
out as per instructions of the Rotating Equipment manufacturer's representative and under
their supervision whenever the manufacturer is present at site. In all other cases instructions
of the EIC, regarding procedure/sequence of erection shall be binding on EC.
5.2.3 For all Rotating Equipment, EC shall follow the proper sequence for assembly and erection.
For Rotating Equipment received along with driver in coupled condition, the coupling bolts
shall be dismantled by EC, and alignment shall be rechecked. Realignment, if required, shall
be done before recoupling.
Where drivers and couplings are provided separately, drilling and tapping of holes in the base
plates for fixing drivers, fixing of couplings on shafts, after enlarging the pilot bores to the
correct size with key way etc. and dowelling including provision of dowel pins, alignment
screws, jack-up screws or similar arrangements for retaining the alignment shall be carried out
by EC as part of erection work. Shims & wedges as required for alignment shall be supplied
by EC.
5.2.4 Process and utility (such as cooling water, steam flushing, quenching, lubricating oil, sealing
etc.) connections connected with rotating equipment and its auxiliaries shall be fabricated
and/or installed by EC from materials supplied by the Owner as per drawings, specifications
and instructions of the EIC.
5.2.5 Piping and accessories supplied with the rotating equipment such as seal oil/Gas system,
cooling water system & Lube oil system etc. shall be tagged separately and kept in EC's stores
till erection. All flanged connections and openings shall be kept blanked with dummies/plugs
to prevent entry of foreign matter.
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ENGINEERS
INDIA LIMITED
IA Gan of India UndettaMingl
6-76-0001 Rev. 3
Page 17 of 22
5.2.6 The local mounted instruments such as pressure gauges, sight glasses, temperature gauges etc.
and Local instrument panels, if any, with necessary connections, shall be installed by EC as
part of rotating equipment erection.
5.2.7 After initial alignment, the Rotating Equipments shall be properly grouted. Grouting shall be
carried out as per this specification. Wherever grout holes are provides in the base plates,
grout shall be filled through them also.
Epoxy grout where recommended by the rotating equipment manufacturer, shall be provided
by EC and shall be as specified in this standard.
5.2.8 Alignment between the Driver and driven equipment shall be done without connecting the
equipment nozzles to respective piping. After completion of alignment, the equipment shall
be connected to Piping. After the piping has been connected, the alignment shall be rechecked by EC, to ensure that piping connections do not induce any undue stresses on the
Rotating Equipments. After making necessary corrections on the piping, if any, re-alignment
shall be done by EC and he will ensure that no undue stresses are induced on the Rotating
Equipment.
5.3
Special Instructions
EC in addition to general instructions for erection as out lined in para 5.2 above, shall also
follow the following special instructions.
5.3.1
Pumps
Depending upon the size of equipment, Pump train will be supplied for erection in any of the
following modes :
(a) Pumps with drivers and accessories fully assembled on a common skid (Base plate).
(b) Pumps mounted on base plate and couplings and driver supplied loose in separate packs.
(c) Various major components such as pump, drivers, couplings, gear boxes & base plates
auxiliary systems like lube, seal flush equipment in separate packs.
5.3.2
5.3.2.1 Reciprocating compressors may be supplied for erection in knocked down condition in
multiple packaged subassemblies such as frame assembly, distance pieces, fly wheels, cylinder
block assemblies, valve assemblies etc. and other accessories such as, drivers, couplings, gear
boxes (if any), control panels, gauge boards, coolers, lube oil systems, cooling water systems,
etc. would be in separate packages.
Besides the above there would be other packages for loose supplied items such as instruments,
pre-fabricated piping, and piping/tubing in commercial lengths.
Lifting devices for erection shall be arranged by EC depending on the weight of packages and
elevation of installation.
5.3.2.2 In case of Rotating Equipments received in knocked down condition, the various parts shall be
assembled as per instructions of the EIC and as per manufacturer's instructions. All parts of
the Compressor shall be thoroughly cleaned with solvents to remove protective compounds if
any, before assembly.
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5.3.2.3 The compressor, driver and other accessories shall be erected on their respective foundations
and the compressor, couplings, gear box and driver shall be aligned and grouted as per the
manufacturer's instructions and instructions of EIC and the manufacturers supervisor (when
present). There-after all process and utility, drain & vent connections shall be completed as
per the relevant drawings/instructions of equipment manufacturer and advice of EIC.
5.3.2.4 Final alignment shall be done after all the piping connections such as water, steam, drains and
Tolerances for alignment shall be maintained as
connection to coolers etc. are made.
specified in the Manufacturer's Instruction Manual. To ensure that piping connections do not
induce any undue stresses on the Rotating Equipment, the alignment shall be checked once
again by EC after the piping has been connected. Any correction necessary for proper
alignment shall be done by EC.
5.3.2.5 EC shall carefully study the vendor drawings, manuals and other data before start of the job to
ensure correct erection, alignment and commissioning.
5.3.3
5.3.3.1 Centrifugal Compressors are supplied for erection in multiple packages such as,
Compressor casings
Drivers (Electrical motors, Steam/Gas turbines -.)
{. : Steam/Gas turbines would be further supplied in multiple packages}
Base plates (or skids)
Lube oil/control oil systems
Sealing systems
Air filters (for gas turbines & compressors for air service)
Temporary strainers
Couplings
Gear boxes
Coolers
Gauge boards
Control panels
Lube & Seal Oil tanks
Fire systems (for gas turbines)
Condensers (for steam turbines)
Condensate systems (for steam turbines)
Loose supply items
Pre-fabricated & Commercial lengths piping, tubing.
Other miscellaneous packages
5.3.3.2 Other requirements shall be same as defined in para's 5.3.2.2 to 5.3.2.5 above.
5.4
5.4.1
Any construction defects shall be intimated to EIC before start-up. All protective and safety
guards shall be installed and rotating equipment shall be checked for free movement by
manual barring over. All foundation bolts and alignment shall be checked before starting the
trial runs, if damaged, rotating equipment may have to be opened and repaired as directed by
EIC. Prior to carrying out the trial runs, the rotating equipment will be subjected to necessary
checks by the EIC and the trial runs shall be commenced only after the approval of the EIC.
ENGINEERS
INDIA LIMITED
IA Gov/ 0/ India llndenalong/
5.4.2 Unless otherwise specified, all the rotating equipment will be subjected to trial runs for a
continuous operation of 72 hours. In case of motor driven rotating equipments, motors shall
be decoupled and turned over to other agencies doing electrical work for testing and no load
running of motors. After the no load runs of motors are satisfactorily completed, EC shall
recouple the motors to the rotating equipment and recheck the alignment. The trial run of the
rotating equipment shall be started only after the above is completed. EC shall provide, as part
of his work, necessary skilled personnel (excluding the operating personnel) for conducting
the trial runs round the clock during the trial runs period. The duration of trial run may be
extended if it is considered necessary in the opinion of EIC and EC shall provide personnel for
such extended period also. Final inspection of bearing etc. shall be carried out by EC after the
Machinery had gone through the trial run and defects, if any, shall be made good for rendering
the rotating equipment ready for start up.
5.4.3 During the trial runs, readings of bearing temperature, cooling water inlet and outlet
temperatures, lube oil inlet/outlet temperature and pressure, rotating equipment discharge
pressure and temperature, starting in current, no load/full load current etc. shall be recorded,
wherever necessary, by EC. Trial reports shall be prepared in the approved proforma by EC
containing all the above details and submitted to the EIC as part of completion documents.
5.4.4 EC shall also provide necessary improvised fencing and watch & ward personnel as safety
measures during trial runs.
5.5
System Start up
During start-up, EC shall provide necessary skilled personnel as per requirement of EIC, to
rectify defects noticed in the rotating equipment, if such defects are attributed to him.
Type of Grout
Non shrink
cementitious grout
Application
All static and rotating equipments, unless covered in 2)
below, viz Static equipments like tall columns, vertical silo,
blender etc. and horizontal vessel, drum, sphere, bullets,
filter, heat exchangers, coolers etc. and other similar
equipments, steel stack/chimney, furnace etc.
Low frequency, medium frequency, high frequency rotating
machines like compressors (centrifugal, reciprocating,
diaphram, screw, gear type etc.). Induced draft fan, forced
draft fan, air blowers, pumps (centrifugal, reciprocating,
diaphram, gear type etc.), expanders, turbine, generator,
diesel generator, air coolers (fin fan cooler) and other
similar equipment.
Machine like screen vibrator, extractor, centrifuge
pulverizer, dryer, drop hammer, ball mill, crushers, bagging
machine and general workshop equipment.
Epoxy grout
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INDIA LIMITED
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Grout (Material)
All material used for grout shall be in EC's scope. Only approved grout material shall be
used. EC shall submit details of grout materials for prior approval of EIC.
3 days
7 days
28 days
25 N/mm2
2
30 N/mm
40 N/mm2
28 days
3.5 N/mm2
7 days
12 N/mm2
2 hours
4%
2000 kg/m3
Min. Density
6.1.2 Epoxy Grout
Epoxy grout shall consist of epoxy resin base, hardener and filler component like graded and
blended aggregate. Components of epoxy grout shall be of desired grade and mixed in
proportion recommended by manufacturer such that it is injectable under base
plate/frame/saddle etc., has low viscosity to meet the flow distances according to dimensions
of base plate saddle/frame, it is suitable for the desired thickness, it is homogenous, free from
segregation, attains high early and high final strength. It shall have minimum Pot life of 30
minutes. It shall have all the features as specified in clause 6.1.1 except for expansive
properties.
It should have the following physical properties :
Min. compressive strength at
1 day
7 days
75 N/mm2
85 N/mm2
7 days
25 N/mm2
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6.2
Grouting (Placement)
6.2.1
Surface Preparation
6-76-0001 Rev. 3
Page 21 of 22
Prior to positioning of equipment/machine etc. over concrete pedestal, foundation, slab, beam,
etc. all laitance & loose material shall be removed by wire brushing & chipping. The bearing
concrete surface shall be sufficiently levelled, hacked with flat chisels to make it rough, clean
(using compressed air). Additional chipping, if required, to suit level of base plate and/or
minimum thickness of grout shall also be done. In case of use of cementitious grout surface
shall be thoroughly wet. All pockets for anchor bolts shall also be similarly cleaned. Any
excess water shall be removed. In case of use of epoxy grout, it shall be ensured that
surface/pocket to receive grout is totally dry. After erection, alignment/plumbing of
equipment/machine in required level, orientation and plumb and installation of sliding plate.
Forms shall be constructed around and joints made tight to prevent leakage of the grout.
6.2.2
Preparation of Grout
6.2.2.1 In case of premix type of grout water shall be added in required quantity as specified by
supplier and/or EIC. Any specific instruction of manufacturer will be strictly followed.
6.2.2.2 In case of epoxy grout required quantity of all constituents shall be mixed in proportion
recommended by manufacturer/supplier and/or EIC. All specific requirements of
manufacturer/ supplier shall be strictly followed.
6.2.2.3 Required quantity of grout shall be made considering initial setting/pot life of grout. Any
grout not used within initial setting time/pot life shall be rejected and in no case used for
grouting.
6.2.3
Placement of Grout
6.2.3.1 Placing of grout shall be taken up only after level, orientation, alignment of
equipment/machine has been approved by EIC and anchor bolts are placed in pocket.
6.2.3.2 In case of epoxy grout EC shall give details of grouting scheme and get approval of EIC.
6.2.3.3 The grout mixture shall be poured/injected continuously (without interruption till completion)
by grouting pump/injecting gun from one side of base plate and spread uniformly with flexible
steel strip and rammed with rods till the space is filled solidly and grout mixture carried to the
other side of base plate and fill all pockets. Any specific requirement of manufacturer/
supplier shall be strictly followed. Epoxy grout shall be done by or under supervision of
manufacturer/supplier and/or agency having adequate experience in this field as per direction
of EIC.
Total work shall be done under supervision and direction of EIC and care shall be taken that
alignment of equipment/machine is not disturbed.
6.2.3.4 Grout mixture shall be allowed to harden for a period of minimum 7 days or as required by
manufacturer/supplier of grout and/or as decided by EIC. At the end of this period, the
shims/edges/pack plate may be removed and anchor bolts tightened uniformly. Alignment of
equipment/machine shall be rechecked and if found correct, the voids left by the removal of
shims/wedges/pack plate (if removed) must be filled up with a similar mixture of grout. In
case after checking, serious misalignment is indicated, the grout shall be removed completely
and fresh grouting is done after making appropriate correction of alignment.
6.2.3.5 Minimum thickness of grout shall be 25mm for all types of grout and maximum thickness
shall be 40mm for non-shrink grout. For epoxy grout the maximum thickness shall be as per
manufacturer's recommendation and/or as specified in drawing.
Format No. 8-00-0001-F1 Rev. 0
ladaa4
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ENGINEERS
INDIA LIMITED
oA Gov' of India Undo( taningf
6-14-0011
6-14-0016
6-79-0011
6-79-0020
7-12-0001
Vessel Tolerances.
7-12-0002
7-12-0003
7-12-0004
7-12-0024
7-14-0001
SPECIFICATION FOR
QUALITY CHECKS FOR
FABRICATION ERECTION AND
EXECUTION OF FIRED
HEATERS
EMPLOYER :
PROJECT
0
Rev.
No
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 1 of 45
07.03.2015
Date
AS
Prepared
by
RP
Checked
by
AP
Approved
by
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 2 of 45
CONTENTS
S.NO.
DESCRIPTION
1.0
PURPOSE4
2.0
REFERENCES4
3.0
DEFINITIONS............................4
4.0
SCOPE5
5.0
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 3 of 45
PURPOSE
This document covers the minimum inspection requirements and quality checks for
Fired Heater Systems during the construction & prior to commissioning of heater
systems.
In order to ensure overall quality during execution, it is Package Vendors
responsibility to meet the specified technical requirements and execute the job as
per applicable documents issued by PMC as well as PMC approved documents
prepared by the Package Vendor. Records of all quality checks shall be maintained
by the Package Vendor duly counter checked by Engineer-in-Charge.
2.0
REFERENCES
Following shall be considered as reference documents for carrying out the work:
i)
All Technical documents issued along with Tender & Agreed Variations (if
any).
ii)
iii)
iv)
3.0
DEFINITIONS
3.1
Package Vendor means the person(s), firm, company, organization from whom
PMC procured products/services on behalf of Employer.
3.2
3.3
Specialist means the nominated personnel of PMC from Heater group / SMMS
Refractory group, assigned to perform the review of Heater System site execution at
identified stages.
3.4
Punch List means a list of comments given by Specialist after shop / site review
which needs to be attended for necessary rectifications by the Package Vendor
under direction of Engineer-in-Charge.
4.0
SCOPE
4.1
PACKAGE VENDOR
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 4 of 45
4.1.1
Execution of work defined in Scope para of job specification and specification 6-170001 issued with tender document. The detail concerning different portions of work
are covered in separate technical specifications e.g. Steel Work, Coil, Refractory etc.
Inspection & Test requirements for different portions of work are covered in these
separate Technical Specifications and the compliance of the same is Package
Vendors responsibility.
4.1.2
Prior to usage, Package Vendor shall ensure that all the material / sub-assemblies
being used for Job execution are in good condition & meeting the specification
requirements.
4.1.3
4.1.4
Maintaining the Records of all Tests & Inspections in line with requirements of
Technical Specifications shall be Package Vendors responsibility. Wherever
required the same shall be got witnessed / counter checked from Engineer-inCharge. Tests / Inspection Records shall include but not limited to following:
i)
ii)
Steel work erection tolerances as per para 8.11 of Spec. 6-17-0002, UON.
iii)
Steel work weld joint inspection as per para 10.4 of Spec. 6-17-0002.
Hydrotest at site for Coil Assembly - indicating test pressure, holding time and
remarks, if any.
vi)
vii)
viii)
All material test reports including special tests such as WPS/PQR, hardness
tests, radiography, DP / MT test, UST etc.
Prior to erection of tube support castings Package Vendor shall re-verify at shop /
site, that Tube support casting (including Convection Intermediate Tube supports)
are as per para 5.1 of Spec 6-17-0007, UON.
4.1.5
HOLD POINTS
Clearance to be sought from Engineer-in-Charge at following critical stages of job:
i)
Prior to starting refractory lining of Radiant Shell (to avoid hot work after lining
and to ensure check stage A).
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 5 of 45
ii)
Prior to start of refractory lining of Convection Box (to avoid hot work after
lining).
iii)
Prior to Erection of Coil within Radiant Box (to inspect refractory lining).
iv)
v)
vi)
Prior to lifting of tubed & lined convection box wherever the same is envisaged
(to ensure readiness of convection box, completion of convection supporting
steel work & adequacy of lifting arrangement).
vii)
viii)
Prior to Stack Erection (to ensure completion of stack support steel work and
adequacy of lifting arrangement).
ix)
x)
Prior to providing various seals on tubes, sleeves, spigots etc. (to ensure
correct positioning of coil parts in cold condition).
xi)
Prior to erection of flue gas ducts connected to Heater (for ensuring support
requirements at both ends).
xii)
xiii)
Prior to box up of heater (i.e. closing of all doors, header boxes, panel covers
etc.) (to ensure completeness check).
4.1.6
4.1.7
Conduct a smoke test (pressure test) for furnace & ducting to check for all leakage
points.
4.2
ENGINEER-IN-CHARGE
4.2.1
Maintaining a list of all applicable documents, drawings etc. with Revision Nos.
which are being followed for execution of heater work and ensuring that the same
are as per PMC drawings / vendor drawing index. (A typical documentation check list
is enclosed for reference - Annexure-I).
4.2.2
Stage wise & final inspection of execution of site work in compliance with applicable
specifications and drawings.
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 6 of 45
4.2.3
Ensuring that all hot work is performed on steel work surfaces before the same is
released for refractory lining.
4.2.4
4.2.5
4.2.6
Review & approval of Package Vendors Quality Assurance Plan for stage wise /
final inspection & the same shall be sent to Heater Specialist for information.
4.2.7
4.2.8
Organizing specialists Stage wise / final checks and providing all facilities e.g.
approach, lighting, safety gadgets for conducting site checks.
4.2.9
Attending to Punch Lists provided by specialist at the end of his review and ensuring
that these are attended to by the Package Vendor. Engineer-in-Charge shall intimate
the specialist through Projects, when all points listed in punch list are attended to.
4.2.10 Any problem, if faced during rectification, may be referred to specialist for opinion.
4.2.11 It is the responsibility of the Engineer-in-Charge to see that the heater is constructed
strictly to the design requirements. Proper inspection requires regular checks as it
progresses.
Following Inspection / Checks shall also be carried out and recorded:
i)
ii)
iii)
iv)
v)
Ensuring that proper preheating and post weld heat treatment are carried out,
wherever specified.
vi)
vii)
Checking of the layout and dimensions of all parts strictly as per the drawing.
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 7 of 45
viii)
ix)
Ensuring that all structurals, specially the load bearing structurals are in
accordance with approved drawings.
x)
Checking the quality of external insulation material and weather proofing (i.e.
aluminum cladding etc.).
xi)
Ensuring that all painting jobs are done after adequate surface preparation
and the paints meet the specifications.
xii)
Ensuring that explosion doors are seating properly and are operable without
hindrance.
xiii)
xiv)
4.2.12 For all refractory related work, following are some of important checks which shall be
carried out by Engineer-in-Charge and a record shall be kept for reference:
i)
ii)
Verify the tie back anchors details e.g. material, shape, dimensions etc.
iii)
iv)
Verify proper welding of tie back anchors/studs on furnace casing and ducting,
prior to lining.
v)
vi)
vii)
Where brick lining is used, the laying of brick & quality of mortar should be
ensured as per PMC approved procedure.
viii)
ix)
x)
In case of ceramic fiber blankets lining verify that edge distance of top blanket
layer from the first stud is not more than 76 mm / 50 mm as permitted in
drawings.
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 8 of 45
xi)
Verify the overlap of top most blanket layer with respect to flow direction so
that it does not permit flue gas ingress within the lining.
xii)
Verify that the Ceramic fiber module orientations are as per approved
refractory drawings.
xii)
Ensure that Refractory Dry Out is done as per PMC approved procedure.
During dry out check heater casing and stack shell temperatures and record
for verification by Specialist.
4.2.13 Engineer-in-Charge shall also ensure that all checks are made as per CHECK LIST
Annexure-III, by Package Vendor and witnessed by Engineer-in-Charge as routine
checks and same are kept as RECORD. Heater specialist shall review the same and
carry out some random checks.
4.2.14 A critical review by Engineer-in-Charge is required at following stages of work:
(A)
When Package Vendor informs the readiness to begin Radiant Section lining.
(B)
After Radiant Coil erection work including jump-overs between Radiant Tubes
is completed but the approach scaffoldings inside radiant shell are not
removed
(C)
i)
ii)
iii)
(D)
(F)
(2)
4.2.16 The stage wise/ final checks by PMC-Heater specialist at site are defined in this
specification. For Stage wise review / check listing by PMC- Heater specialist at
shop in case of modular construction are as defined below:
Page 172 of 2175
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
i)
ii)
iii)
Page 9 of 45
For convection section modules after erection of Tube support casting inside
the modules before refractory lining.
When modules with coils are nearing completion at shop / fabrication yard.
Completely modularized Fired Heater where major fabrication activities are to
be performed at shop.
PMC- Heater specialist checking shall be done after confirmation that all checks
as per requirements of specifications have already been carried out by the
Package Vendor as per the various defined stages. In case the actual dimensions
/ tolerances are not meeting the tender requirements the same shall be rectified
by Package Vendor before offering the Heater for PMC- Heater specialist
checking.
4.2.17 For the fabrication work carried out at shop outside the refinery premises, all the
quality formats shall be duly signed by Package Vendor and the inspection agency.
And the same shall be made available along with the Inspection Release Note at the
time of bringing the modules / panels inside the refinery premises.
4.2.18 Incase of modular construction it shall be the responsibility of the Package Vendor to
prepare and transport the foundation templates to the Package Vendors shop so as
to ensure correct interfacing / seating of the modules at foundations.
4.3
ii)
iii)
iv)
v)
vi)
vii)
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 10 of 45
ANNEXURE I
FOR
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
DOCUMENT
Page 11 of 45
DOCUMENT NO.
REMARKS
Job Specification
(b)
(c)
(d)
(e)
(f)
2.
3.
3.1
Index of Drawings
4.
5.
6.
7.
8.
9.
10.
11.
12.
Document
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 12 of 45
ANNEXURE - II
REPORTING FORMATS
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 13 of 45
PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............
REFERENCE SPEC./PARA :
COLUMN GRID NO.
PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
REMARKS
Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 14 of 45
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up for various stages of fabrication (panels, modules
and at site ).
JOB NO. . . . . . . . . . . . . . . . .
....
PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............
REFERENCE SPEC./PARA :
BEAM GRID PLANE
ELEVATION
OUT OF STRAIGHTNESS
LONGITUDINAL
PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
REMARKS
LATERAL
Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 15 of 45
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up for various stages of fabrication (panels, modules
and at site ).
JOB NO. . . . . . . . . . . . . . . . .
....
PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............
REFERENCE SPEC./PARA :
ELEVATION
ERECTION
6-17-0002/8.11(b)
OUT OF VERTICAL (mm)
w.r.t. GRADE
REMARKS
PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
Engineer in Charge . . . . . . . . . . .
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 16 of 45
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up for various stages of fabrication (panels, modules
and at site ).
JOB NO. . . . . . . . . . . . . . . . .
....
PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............
REFERENCE SPEC./PARA :
ORIENTATION
REMARKS
0o
45o
90o
135o
180o
225o
270o
315o
Note: 1. Level shall be measured along all defined Radial lines with respect to floor centre in
case of VC heater & with respect to centre of each floor segment in case of Box heaters.
2. Level must be achieved perfect across the burner cut out openings.
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 17 of 45
Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up for various stages of fabrication (panels, modules
and at site ).
JOB NO. . . . . . . . . . . . . . . . .
....
PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............
REFERENCE SPEC./PARA :
DEGREE
STACK ERECTION
6-17-0002/8.11(a)
REMARKS
0o
45o
90o
135o
180o
225o
270o
315o
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
Page 18 of 45
Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up for various stages of fabrication (modules and at
site).
JOB NO. . . . . . . . . . . . . . . . .
....
HEATER NO. . . . . . . . . . . . .
PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............
REFERENCE SPEC./PARA :
DEGREE
SHELL FABRICATION
6-17-0002/7.17 (q)
REMARKS
0o
30o
60o
90o
120o
150o
180o
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 19 of 45
210o
240o
270o
300o
330o
PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up for various stages of fabrication (panels, modules and
at site).
JOB NO. . . . . . . . . . . . . . . . .
....
HEATER NO. . . . . . . . . . . . .
PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............
REFERENCE SPEC./PARA :
PITCH NO.
COIL FABRICATION/ERECTION
6-17-0003/2.3
REQUIRED AS PER
DRAWING (mm)
REMARKS
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 20 of 45
NOTE:
1.
Pitch Nos. shall be counted starting from 0 and moving in clock wise direction for
VC heater.
For Box heaters pitch no. shall be counted starting from bottom most pitch.
2.
PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up in case of modular construction and at site after
fabrication & erection.
JOB NO. . . . . . . . . . . . . . . . .
....
PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............
REFERENCE SPEC./PARA :
ORIENTATION
COIL FABRICATION/ERECTION
6-17-0003/2.3
REMARKS
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 21 of 45
0o
45o
90o
135o
180o
225o
270o
315o
NOTE:
1.
TCD shall be measured at least at four locations along the height of Radiant
Section.
2.
This Format is applicable for Vertical as well as Helical Tube Radiant Section.
PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up in case of modular construction and at site after
fabrication & erection.
JOB NO. . . . . . . . . . . . . . . . .
....
PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............
COIL ERECTION
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
6-17-0003/2.3
REQUIRED
DIMENSION
(mm)
ORIENTATION
NOTE:
Page 22 of 45
REMARKS
1.
Tube No. in case of VC heater shall be counted clockwise starting from 0o. For Box
heater Tube No. to be counted from Bottom to Top.
2.
Four No. equi-spaced point location for measurement shall be selected along tube
length.
PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up in case of modular construction and at site after
erection.
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 23 of 45
PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............
REFERENCE SPEC./PARA :
TUBE NO.
NOTE:
1.
2.
COIL ERECTION
6-17-0003/2.3
OUT OF PLUMB (mm)
REMARKS
Readings shall be recorded in coil free condition before restraining the spigots.
Readings shall be recorded after removal of all temporary supports (if used) e.g.
incase of CCR heater coils.
PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 24 of 45
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up in case of modular construction and at site after
erection.
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 25 of 45
PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............
REFERENCE SPEC./PARA :
TUBE NO.
PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
REMARKS
Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 26 of 45
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up for various stages of modular construction and at
site.
HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............
REFERENCE SPEC./PARA :
SUPPORT CASTING
S.NO.
ALIGNMENT OF
CASTING
PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
TUBE RESTING
CHECK
REMARKS
Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
DOCUMENT No.
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Page 27 of 45
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up in case of modular construction and at site after
erection.
JOB NO. . . . . . . . . . . . . . . . .
....
HEATER NO. . . . . . . . . . . . .
PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............
REFERENCE SPEC./PARA :
TERMINAL
/
PASS NO.
INLET/
OUTLET
CENTRELINE
ELEVATION
DIST. OF FACE OF
LATERAL POSITION OF
FLANGE
TERMINAL
FROM HEADER
BOX/SHELL
BEFORE
AFTER
BEFORE
AFTER
COLD PULL COLD PULL COLD PULL
COLD
PULL
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 28 of 45
Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up in case of modular construction and at site after
erection.
JOB NO. . . . . . . . . . . . . . . . .
....
HEATER NO. . . . . . . . . . . . .
PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............
REFERENCE SPEC./PARA :
ITS
NO.
LENGTH OF ITS (
outer edge to outer
edge )
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
Page 29 of 45
Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
ANNEXURE - III
CHECK LIST
FOR
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 30 of 45
NAME OF CHECKER: . . . . . . . . . . . . . .
...
HEATER: . . . . . . . . . . . . . . . . . . . . . . . . . . .
S. No.
DESCRIPTION
A.
1.
2.
B.
1.
2.
3.
4.
5.
REMARKS/
COMMENTS
ALL
B, D
D
B, D
B, D
B, D
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
DESCRIPTION
Page 31 of 45
REMARKS/
COMMENTS
B, D
B, D
B, D
B
D
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
18.
19.
20.
21.
22.
DESCRIPTION
Page 32 of 45
Convection/convection jumpovers
Convection/Radiant crossovers
23.
24.
25.
26.
27.
Inlet/Outlet
terminal
before
connecting to transfer line.
(The above can be ensured by checking
the positioning of connected tubes before
and after cold pull duly recorded and
signed as per prescribed Format).
Check all coil tubes coming out of the
furnace are having their openings sealed
using asbestos/ceramic cloth as per
Standard 7-17-0322. Also ensure that
slotted sleeves on End tube sheets are
also provided with sealing inside Header
boxes.
Check convection section studded tubes
are straight, do not foul/touch with the
refractory on the sides, specially on
corbel side.
Check projection of Thermowell flange
connection in the coil for weldolet type
connection. (min 200 mm above tube OD
is required).
Flange rating of Thermowell and
Pressure gauge tapping to be same as
coil process rating. Check flange facings
also.
Check for all other tapping points like
REMARKS/
COMMENTS
B, D
B, D
B, D
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
DESCRIPTION
Page 33 of 45
REMARKS/
COMMENTS
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
B, D
B, D
B, D
B, D
B, D
C, D
C, D
C, D
C,D
C,D
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
DESCRIPTION
Page 34 of 45
REMARKS/
COMMENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13
D
A
B, C
B,D
C
B, D
B
B
B, D
B
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
14.
DESCRIPTION
D.
REFRACTORIES
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Page 35 of 45
Expansion joints
REMARKS/
COMMENTS
B, C
B, C
D
D
C, D
D
D
D
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
11.
12.
13.
14.
15.
DESCRIPTION
B, C
B,D
17.
19
E.
REMARKS/
COMMENTS
16.
18
Page 36 of 45
B, C
B, C
1.
2.
A, B, C
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
DESCRIPTION
Page 37 of 45
REMARKS/
COMMENTS
A, B, C
4.
5.
B, C
F.
STEEL WORK
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
ALL
ALL
ALL
D
B, C, D
D
D
ALL
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
11.
12.
13.
14.
15.
16.
17.
DESCRIPTION
18.
19.
B, C
20.
21.
22.
Page 38 of 45
REMARKS/
COMMENTS
D
ALL
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
24.
25.
DESCRIPTION
ALL
26.
Page 39 of 45
REMARKS/
COMMENTS
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39
DESCRIPTION
Page 40 of 45
REMARKS/
COMMENTS
C, D
C
D
ALL
D
D
D
D
D
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
40
41
DESCRIPTION
Page 41 of 45
G.
MISCELLANEOUS
1.
REMARKS/
COMMENTS
- Dampers
- Soot Blowers
Ensure all major equipment dimensions /
locations are as per layout/ drawings.
2.
3.
4.
5.
6.
D
D
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
DESCRIPTION
Page 42 of 45
REMARKS/
COMMENTS
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 43 of 45
Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up in case of modular construction and at site after
erection.
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 44 of 45
ANNEXURE - IV
QUALITY CHECK
DESCRIPTION
Remarks
Following checks shall be performed by the Heater Package Vendor before final dispatch of the
Modules to site. Package Vendor to prepare requisite format duly approved by Engineer in
Charge/ specialist / Inspection agency.
1
Verification of Module to As a minimum following is to be
module match marking
included:
-Match marking of base plate
of module with
foundation
template
-Match marking / trial assembly
for interfacing modules
-Flatness of the interfacing
flanges / members connecting
two modules.
2
Verification of Numbering Modules shall be numbered for -Packing list shall be
of modules
easy identification at site.
prepared
with
proper
identification of modules.
-Document of Rigging /
erection
scheme
shall
identify the modules with
part numbers.
2
Verification of Erection
For
lifting, -Package Vendor is
aids (like spreader
transportation/shipment
and responsible for design
beams/lifting frames/ lugs erection as per the rigging / adequacy
etc.)
erection scheme proposed by -Document of Rigging /
Package Vendor
erection scheme shall also
identify the erection aids
which are to be removed
after erection.
3
Verification of
Preservation for refractory / To avoid damage from
preservation procedure
insulation, pressure parts
handling
during
adopted for safe transit of
transportation /shipment &
modules and safe storage
erection and weather
till erection.
4
Verification of provision of Module to module connection in Duly
approved
Sealing
sealing arrangement.
erected condition at site.
arrangement.
DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
QUALITY CHECK
Verification of dryout of
castable lined module
before dispatch
Verification of modular
stacking /placement
scheme for transportation
/ shipment of modules.
DESCRIPTION
Page 45 of 45
Remarks
As per duly approved dry
out procedure
STANDARD No.
PlafAieENONEERS
a taRegwe INDIA LIMITED
7-17-0454 Rev. 3
0412M
Page 1 of 5
HANDRAIL
0 00
0 0
HANDRAIL
STANDARD
PLATFORM
ir
o
CD
z
rD
0
0
5 STEEL CHAIN
COMPLETE WITH
6 EYE BOLT AND
SAFETY SNAP HOOK
(REFER NOTE-5)
PROVIDE 2300 HIGH
ACCESS OPENING AT
INTERMIDIATE LEVELS
PLAN-CC
C
A
75X10,
FLAT tit
;)
INTERMEDIATE BRACING
IF REQUIRED SEE
DETAIL-13
DETAIL-10
tsi
DETAIL-1
PLAN-BB
DETAIL-2
741)
U S OF
LADDER BASE 1
SID
z
460
30X6 FLAT
TYP
TOP LEVEL
DETAIL I 1
INTERMEDIATE
LEVEL DETAIL-12
M
M
HOOPS 50x6
CONTINUOUSE
FLAT (TYP.)
RUNGS
PLAN-AA
TOP &
BOTTOM
POSITION OF LADDERS
ELEVATION OF PLATFORMS SERVED
STAIR DETAILS
CIRCULAR PLATFORMS (CHEQ. PLT.)
7-17-0455
7-17-0456
7-17-0457
3
2
30.01.2012
17.11.2006
Rev.
No.
Date
7-17-0458
7-17-0459
7-17-0460
PLAN-BB
7-17-0461
ALTERNATI
COMPANION STANDARDS:
LADDER (STEP THROUGH)
NTINU
MEMBER
(FOR USE AT CORNERS OF PLATFORMS)
SS $1.
SS
Prepared
by
lafteLrah ENGINEERS
STANDARD No.
7-17-0454 Rev. 3
Page 2 of 5
STRINGER
22 DIA. SLOTTED
HOLE
18 DIA HOLE
PLUG WELD
AND GRIND
FLUSH
ISA150X75X10/1
45
16 DIA. NUT
AND WASHER
DETAIL-2
DETAIL-1
STRINGER
HANDRAIL
STAND RAD
16 DIA. NUT
AND WASHER
DETAIL-3
REFERENCE NOTES :
DETAIL-4
GENERAL NOTES:
FOR GENERAL NOTES AND UST OF COMPANION
DRAWINGS SEE SHEET NO. 1.
COMPANION STANDARDS:
SEE SHEET NO. 1
tikPACJH \\err
Pri
30.01.2012
SS/K
17 11 2006
SS
MKIDK
Rev.
No.
Date
Prepared
by
Checked
by
Purpose
C=Son-4---
Aialt3--.
AKG
Stds. Committee
DM
VC
Stds. Bureau
Convenor
Chairman
Approved by
18ffil-aq Ea ENGINEERS
51gZIT Mieg giLY INDIA LIMITED
(+Merl elEteReetniAl
IA Geri of India Undertakongj
STANDARD No.
7-17-0454 Rev. 3
Page 3 of 5
STRINGER
STRINGER
Irmo
"
2M16
21 1
2 rI
HANDRAIL
STANDARD
6
RUNGS
16 DIA. NUT
AND WASHER
DETAIL-6
DETAIL-5
CAGE HOOP
CAGE HOOP
2M12 ROUND
HEAD BOLTS
14 DIA. SLOTTED
HOLE
2s
12 DIA. WASHE R
d 12 DIA.
ROUND HEAD
DETAIL-8
DETAIL-7
GENERAL NOTES:
REFERENCE NOTES :
COMPANION STANDARDS:
,-,
30.01.2012
". (16./KJH
54,1111....)
17.11.2006
SS
MK/OK
Prepared
by
Checked
by
Rev.
Date
No.
Format No. 6-00-0001-F4 Rev.0
Page 377 of 2175
Purpose
AK
AK
2 wi...-
DM
AKG
VC
Stds. Committee
Stds. Bureau
Convenor
Chairman
Approved by
lalen ERMI7M3O111)
STANDARD No.
r
8111=
4-44 th
ENGINEERS
zfga tViewer WA LIMITED
IA Go .4 of lochs Undedalong)
7-17-0454 Rev. 3
Page 4 of 5
3 SIDES
50 X50 X 6L
S.O. P.
rn
RUNGS
50 X50 X6L
La
P T.
6 la
GUSSET
2M16 BOLTS
PLATFORM
MEMBER
DETAIL-10
6 THK. BENT
PLT. GUSSET
32 II 12
DETAIL-9
0
N
PLATFORM MEMBER /
(EXTENDED)
.--6-1
OP FLANGE
AND WEB IF
PLATFORM
MEMBER
22 DIA. SLOTTED
HOLE
DETAIL-12
DETAIL-11
REFERENCE NOTES :
SEE SHEET NO. 1
GENERAL NOTES:
FOR GENERAL NOTES AND LIST OF COMPANION
DRAWINGS SEE SHEET NO. 1.
COMPANION STANDARDS:
SEE SHEET NO. 1
3
30.01.2012
REVISED & ISSUED AS STANDARD
2
17.11.2006
REVISED & ISSUED AS STANDARD
Rev.
Date
Purpose
No.
Format No. 8-00-0001-F4 Rev.0
Page 378 of 2175
ir
S4/ /54,/KJH Woe
SS
Prepared
by
MK/DK
Checked
by
l(1
AKG
Stds. Committee
Z411-4-VC
Stds. Bureau
Convenor
Chairman
Approved by
Safrae?ift ENGINEERS
Meg',"If WA UNITED
Govt M India undeareng)
16 DIA. NU
AND WASHER
STANDARD No.
7-17-0454 Rev. 3
Page 5 of 5
22 DIA
HOLE
HOLE
II 6 THK. PLT.
(.6
CASING PLATE
(MAY BE FLAT
OR CURVED)
IX 0
J Z
Ls1 L. LI
IJJ
0
z
< 7
Ia
sl CC
CC
RUNGS
6
_q_LADDER
1111
114
DETAIL-13 (PLAN)
(INTERMEDIATE BRACE TO BE USED
IF DISTANCE BETWEEN PLATFORMS
EXCEEDS 6100)
REFERENCE NOTES
SEE SHEET NO. 1
:-
UST OF COMPANION
DRAWINGS SEE SHEET NO. 1.
SSI**'
SS
Prepared
by
WP/KJH
MK/DK
Checked
by
I"
AKG
AKG
Stds. Committee
.27t14-CDM
VC
Stds. Bureau
Chairman
Convenor
Approved by
lafrae et ENGINEERS
173Mar=
111
INRl1Ramiu)
HANDRAIL
STANDARD
PLATFORM
UM* r:
7R
DETAIL-3
7-17-0455
Rev. 3
Page 1 of 3
DETAIL-4
U
C
STANDARD No.
0
re
0_
0_
B
0
ce
0
0
(f)
00
0
0
0
L0
0
50 STEEL CHAIN
COMPLETE WITH
60 EYE BOLT AND
SAFETY SNAP HOOK
(REF. NOTE-6)
PLAN C-C
0En
U
A
INTERMEDIATE BRACIN
IF REQUIRED SEE
DETAIL-5
75X10 FLAT
RUNGS
ox
DETAIL-2
330
DETAIL-1
lul
30X6 FLAT
(TYP.)
U/S OF LADDER BASE
POSITION OF LADDERS
ELEVATION OF PLATFORMS SERVED
COMPANION STANDARDS:
LADDER & CAGE DETAILS (SIDE STEP TYPE) 7-17-0454
STAIR DETAILS
7-17-0456
CIRCULAR PLATFORMS
7-17-0457
(CHEQ. PLT. FLOORING)
7-17-0458
RECTANGULAR PLATFORMS
(CHEQ. PLT. FLOORING)
CIRCULAR PLATFORMS
7-17-0459
(OPEN TYPE FLOORING)
RECTANGULAR PLATFORMS
7-17-0460
(OPEN TYPE FLOORING)
HANDRAIL DETAILS
7-17-0461
TOP &
BOTTOM
PLAN A-A
30.01.2012
S81/
17.11.2006
SS
MK/DK
Rev.
No.
Date
Prepared
by
Checked
by
Purpose
YAID/KJH \NeriAK
AKG
Stds. Committee
(2i!b2,1_
DM
VC
Stds. Bureau
Convenor
Chairman
Approved by
Copyright EIL - All rights reserved
agtzleitl-h ENNEERS
GI
STANDARD No.
7-17-0455 Rev. 3
Page 2 of 3
22 DIA. SLOTTED
HOLE
PLUG WELD
AND GRIND
FLUSH
18 DIA. HOLE
20 DIA RUNG
ISA 150x75x10/
24 DIA. HOLE FOR
M20 BOLTS OR
HOLDING DOWN
BOLTS AT GRADE
DETAIL-1
100x6 THK. TOE PLT.
CONTINUOUS ACROSS
LADDER ACCESS
16 DIA. HUT
AND WASH
Ir
71.
DETAIL-2
STRINGER
ns.
6 THK. PLATE
PLATFORM MEMBER,
2M16 DIA BOLTS
RUNGS
HANDRAIL
STANDRAD
HANDRAIL
STANDRAD
2M16 BOLTS
DETAIL-4
DETAIL-3
REFERENCE NOTES :-
GENERAL NOTES:-
COMPANION STANDARDS:
30.01.2012
SS
17.11.2006
SS
MK/DK
Rev.
No.
Date
Prepared
by
Checked
by
Purpose
_An^
AK 4 . V
AKG
Stds. Committee
C)erIA
DM
VC
Stds. Bureau
Chairman
Convenor
Approved by
STANDARD No.
airaegallE
a NGINEERS
laIWIeu/iffir INDIA LIMITED
b Gov
India Undertak.9)
7-17-0455 Rev. 3
Page 3 of 3
tc.1
cn
75
18 DIA. HOLE
STRINGER /
i 22 DIA. HOLE
SHOULDER BOLT\
NUT AND WASHER
AS ABOVE
LADDER
DETAIL-5 (PLAN)
(INTERMEDIATE BRACE TO BE USED IF DISTANCE
BETWEEN PLATFORMS EXCEEDS 6100)
GENERAL NOTES:-
REFERENCE NOTES:-
30.01.2012
17.11.2006
Date
Purpose
DM
4:W/KJH.\rGler I "
MK/DK
AKG
VC
SS
Stds.
Committee
Stds.
Bureau
Prepared
Checked
Convenor
Chairman
by
by
Approved by
Copyright Ell- All rights reserved
STANDARD No.
OlfragfitENGINEERS
EitAewer INDIA IJMTED
NPR eRMIPJ9m1
IA Goo
7-17-0461 Rev. 3
HANDRAIL DETAILS
1nata Uncienakongj
Page 1 of 1
1830
41
0
0
In
HANDRAIL STANDARD
ISA 50x50x6
AT TOE PLT.
JOINT
FLOORING
DETAIL OF HANDRAIL
10 THK.
L CLEAT
M16 DIA
3 CLEAR
BOTTOM OF TOE
PLT. LEVEL WITH
TOP OF FLOORING
CHEQ. PLT. OR
OPEN FLOORING
PLATFORM MEMBER
HANDRAIL STANDARD
HANDRAIL
STANDRAD
II
PLATFORM MEMBER
DETAIL OF CONNECTION
TO I OR 3 PLATFORM MEMBER
COMPANION STANDRAD:
7-17-0454
LADDER (SIDE STEP)
7-17-0455
LADDERS (STEP THROUGH)
STAIR
7-17-0456
7-17-0457
CIRCULAR PLATFORM (CHEQ. PLATE)
7-17-0458
RECTANGULAR PLATFORMS (CHEQ. PLATE)
CIRCULAR PLATFORM (OPEN TYPE FLOORING) 7-17-0459
RECTANGULAR PLATFORM (OPEN TYPE FLOORING) 7-17-0460
GENERAL NOTES:-
SS
17 11 2006
SS
MKJDK
Rev.
No.
Date
Prepared
by
Checked
by
Purpose
AKG
DM
AKG
VC
Stds. Committee
Stds. Bureau
Chairman
Convenor
Approved by
(an oliftof(eityzasn)
STANDARD No.
STAIR DETAILS
(FOR USE WITH CHEQUERED
PLATE OR GRATING PLATFORMS)
aRZIeTa ENGINEERS
1ga faReZWIll INDIA LIMITED
IA Govt of Ind* Unciedalang)
7-17-0456 Rev. 3
Page 1 of 5
DETAIL
DETAIL-7
fogy
Pr
OBSTRUCTION
DETAIL-5
tt
760
1..305
(MIN.)
DETAIL-2
o
0
r DETAIL-1
(TREAD)
GRADE LEVEL V
V a
ELEVATION
ELEVATION
gam*
PLAN
PLAN
(STRAIGHT RUN OF
STAIR WITH LANDING)
REFERENCE NOTES :-
COMPANION STANDARDS:-
30.01.2012
SS
/KJH
17.11.2006
SS
MKJDK
Rev.
No.
Date
Purpose
Prepared
by
Checked
by
DM
AKG
VC
Stds. Committee
Stds. Bureau
Chairman
Convenor
Approved by
Copyright EIL - All rights reserved
Isv-ziet
ENGINEERS
9 t 04z)
.
!ND)"
A , LIMITJD
STANDARD No.
STAIR DETAILS
(FOR USE WITH CHEQUERED
PLATE OR GRATING PLATFORMS)
7-17-0456 Rev. 3
Page 2 of 5
2111__
?-
CHECKEREAD PLATE
NOSING
750
DETAIL-1
33 0 D 3.2 THK.
01
12
20
POST
L-50x50x6
MID RAIL
50x6 THK. FLAT
TYPICAL FOR
HANDRAIL STDS.
SECTION A-A
N
750
MC 200
STRINGER
"N,L-50x50x6
36.8'
(MAX.)
. 4 65
2M20 DIA
BOLTS
.
H.D. BOLT
L-100X75X10 CLEAT 1-24 DIA
HOLE FOR M20 DIA HOLDING
DOWN BOLT.
150 1 254
t HOLD NG
DOWN BOLTS
V 11;.
DETAIL-2
REFERENCE NOTES :
GENERAL NOTES:
FOR GENERAL NOTES SEE SHEET NO. 5
4 *QH
17.11.2006
SS
MK/DK
Rev.
No.
Date
Prepared
by
Checked
by
Purpose
Z1/2"--`
AKG
VC
Stds. Committee
Stds. Bureau
Convenor
Chairman
Approved by
Copyright EIL - All rights reserved
Gat 0
kicha
STANDARD No.
STAIR DETAILS
(FOR USE WITH CHEQUERED
PLATE OR GRATING PLATFORMS)
INWIE4iSENONIEERS
5gar laigIeglit INDIA LIMITED
Unclenakm
7-17-0456 Rev. 3
Page 3 of 5
SETTING OUT j
LINE
S0P
65
SAME
AS TREAD
S.O.P.
STRINGER
STRINGER/
FULL
STRENGTH
DETAIL-4
3 SIDES
115i
NOSING SAME
AS TREAD
DETAIL-3
(MOMENT CONNECTION)
65
S0P
S.O.P.
NOSING SAME
AS TREAD
NOTCH STRINGER
NOTCH
INTO PLATFORM
MEMBER
STRINGER /
STRINGER
PLATFORM
MEMBER
PLATFORM
MEMBER
ANGLE CLEAT
(SIZE TO SUIT)
2M20 DIA BOLTS
ANGLE CLEAT
(SIZE TO SUIT)
2M20 DIA BOLTS
DETAIL-5
DETAIL-5
Seit1/4-4./
SS
Prepared
by
DM
V.DXP/KJH\c\47,r,
Arr
AKG
VC
MK/DK
Stds.
Committee
Stds.
Bureau
Checked
Convenor
Chairman
by
Approved by
STANDARD No.
STAIR DETAILS
(FOR USE WITH CHEQUERED
PLATE OR GRATING PLATFORMS)
aRZIeYgla ENGINEERS
lig-adaMagWVINDIA LIMITED
IA Goa of lode Undedaking)
7-17-0456 Rev. 3
Page 4 of 5
SETTING
OUT LINE
,/
POST L-50x50x6
100x6 TOE PLATE
WELD TO STRINGER
BOTH SIDES
0
o
to
STRINGER
3 SIDES
ANGLE CLEAT
ASIZE TO SUIT)
__Fh7-M20 DIA BOLTS
MC 200
STRINGER
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90x60x6 THK.
PLATE
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S.O.P
DETAIL-7
10 THK .PLATE
WELDED TO TOES
OF JOIST
3 SIDES
ANGLE CLEAT
SIZE TO SUIT)
/2-M20 DIA BOLTS
DETA L-6
(WITH JOIST MEMBER)
RFFERENCE NOTES :-
SEE SHEET 5
COMPANION STANDARDS:3
2
SEE SHEET
Rev.
Date
No.
Format No. 8-00-0001-F4 Rev.0
Page 386 of 2175
Purpose
4-SS
Prepared
by
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MK/DK
Checked
by
"
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DM
AKG
VC
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Convenor
Chairman
Approved by
zSi1151-aget ENGINEERS
$1g-9 tafaeg we iDIA LIMITED
Goof of Inda Undertalongl
STAIR DETAILS
(FOR USE WITH CHEQUERED
PLATE OR GRATING PLATFORMS)
STANDARD No.
7-17-0456 Rev. 3
Page 5 of 5
33 0 D 3.2 TH1
L-50x50x6 STIFFENING
BRACING TO BE PROVIDED
FOR STAIR WITH MORE
THAN 20 RISERS
NOSING SAME AS
S Al:
BRACING
L-50x50x6
DETAIL-8
1.
REFERENCE NOTES :-
GENERAL NOTES:-
POSITION OF STAIRS.
DIMENSIONS OF RISES AND TREADS.
DIMENSIONS OF SETTING OUT POINTS.
TYPE OF TREAD IF OTHER THAN GRATING.
R5. TYPE OF PAINTING AND/OR GALVANISING.
COMPANION STANDRADS:
CIRCULAR PLATFORMS WITH
CHEQUERED PLATE FLOORING
RECTANGULAR PLATFORMS WITH
CHEQUERED PLATE FLOORING
CIRCULAR PLATFORMS WITH
OPEN TYPE FLOORING
RECTANGULAR PLATFORMS WITH
OPEN TYPE FLOORING
3
2
Rev.
No.
30.01.2012
17 11 2006
7-17-0457
7-17-0458
7-17-0459
7-17-0460
Date
Purpose
SS I,
SS
Prepared
by
0/KJH
MK/DK
Checked
by
91,in.A
AK
DM
AKG
VC
Stds. Committee
Stds Bureau
Convenor
Chairman
Approved by
Copyright EIL - NI rights reserved
tg
si
151fRiseA
at efaleg
ENGINEERS
INI NA LIMITED
/A nul
na. Lnden.,),
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION (PMI) AT
SUPPLIER'S WORKS
6 - 81 - 0001 Rev. 2
Page I of 8
covingii 4
,flcomoict) TIPTth LI 111
c 1T
f'6g
itta-vr
STANDARD SPECIFICATION
FOR
POSITIVE MATERIAL
IDENTIFICATION
(PMI)
AT SUPPLIER'S WORKS
40D ., 15,
2
20.10.11
15.07.08
07.12.00
Rev.
No
Date
Purpose
NKR
SSL
AKC
AKB
Prepared
by
Checked
by
AKC
DM
SKP
VC
AKB
MI
Standards Standards
Committee
Bureau
Convenor
Chairman
Approved by
- le.' ENGINEERS
151Mae?
yin eRaWanJelwill
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION (PM I) AT
SUPPLIER'S WORKS
6-81-0001 Rev. 2
Page 2 of 8
Abbreviations:
American Petroleum Institute
Alloy Steel
Lump Sum Turn Key
Positive Material Identification
Schedule
Stainless Steel
Third Party Inspection Agency
API
AS
LSTK
PMI
Sch
SS
TPI or TPIA
Mr.AK Chaudhary
Members:
Mr. SS Lotay
Mr. SC Gupta
Mr. RK Singh
Mr. Rajeev Kumar
Mr. Anoop Goel
Mr. G Suresh
Mr. G Poornachandra Rao
Mr. MP Jain (Projects)
151M4-e?fte ENGINEERS
Ogrir tfigtegW INDIA LIMITED
Gorl of India undertaking}
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION (PMI) AT
SUPPLIER'S WORKS
6-81-0001 Rev. 2
Page 3 of 8
CONTENTS
SCOPE
2.0
REFERENCE DOCUMENTS
3.0
DEFINITIONS
4.0
PMI EXAMINATION
5.0
6.0
7.0
8.0
MARKING
1.0
ft/ ENCJNEERS
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION (PMT) AT
SUPPLIER'S WORKS
6-81-0001 Rev. 2
Page 4 of 8
1.0 SCOPE
1.1
This specification applies to the requirements for Positive Material Identification (PMI) to be
performed at the Supplier's works on Metallic Materials procured either directly by the
Owner/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 the
Deviation/ 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 the
chemical composition of the material is consistent with the material specifications as specified
in 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 Material
Identification (PMI) to be performed on Materials listed below:
1.4.1
1.4.2
1.5
All grades of material supplies including Stainless Steels shall be liable for PMI test at site. In
case of any defective materials being found at site, the Supplier shall be responsible to effect
replacement of such defective materials at project site without any delays to the satisfaction of
EIL site RCM (Resident Construction Manager).
2.0
REFERENCE DOCUMENTS
2.1
API Recommended Practice 578 (First Edition, May 1999) - Material Verification Program for
New 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 referred
items. This definition shall also include any sub-Supplier or manufacturer on whom a sub-order
is placed by the Supplier.
SaIRCIELM; ENGINEERS
Par taiReZ VW INDIA LIMITED
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION (PM I) AT
SUPPLIER'S WORKS
6-81-0001 Rev. 2
Page 5 of 8
3.2
Inspection Lot: A group of items offered for inspection covered under same size, Heat and
Heat treatment lot.
3.3
Alloy Material: Any metallic material (including welding filler materials) that contains
alloying elements such as chromium, nickel, molybdenum or vanadium, which are intentionally
added 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 this
Specification Approval of PMI Procedure shall be obtained from Owner/EIL/TPIA prior to
commencing manufacture/ inspection of product.
4.2
4.3
The Supplier shall identify all incoming alloy materials and maintain full traceability of all alloy
materials, including all off-cuts. Transfer of identification marks shall be undertaken prior to
cutting to ensure maintenance of identification on off-cuts.
4.4
The Supplier shall ensure that all alloy materials are segregated and stored in separately
identified locations to prevent the mix up of materials of different alloy specifications or alloy
material with carbon steel. Non ferro-magnetic materials shall be segregated at all times from
ferro-magnetic materials.
4.5
5.0
5.1
The method used for PMI examination shall provide a quantitative determination of the alloying
elements 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 elements
present.
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 within
specified range.
5.4
Chemical spot testing, magnets, alloy sorters and other methods using eddy current or
triboelectric testing methods are not acceptable for PMI examination.
5.5
The PMI instrument used shall have the sensitivity to detect the alloying elements in the
specified range.
5.6
All PMI instruments shall have been serviced within a 6 month period of the time of use to
verify the suitability of batteries, sources etc., and the data of the last service shall be stated on
the PMI Report Form (Sample enclosed).
5.7
Each analyzer must be calibrated according to the manufacturer's specification at the beginning
and end of each shift. Instrument must be checked against known standard for each alloy type
to be inspected during the shift.
ISillaZreq e ENGINEERS
INDIA UMITED
s'Ig7e2eg
Govt a Inaa Undenakingi
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION (PMI) AT
SUPPLIER'S WORKS
6-81-0001 Rev. 2
Page 6 of 8
5.8
Certified samples, with full traceability, of a known alloy materials shall be available for use as
a random spot check on the instrument calibration.
5.9
The surfaces to be examined shall be prepared by light grinding or abrasive paper and solvent
cleaner. Evidence of Arc burn resulting from examination shall be removed by light grinding or
abrasive paper. No permanent marks, which are injurious to the usage of product in service, are
acceptable.
5.10
Alloy Steel ring type joint Gaskets shall be inspected by using portable X-Ray fluorescence
instrument.
5.11
Testing shall be done as per the procedures outlined by the manufactures of alloy analyzer
being 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 of
Owner/EIL/TPIA visiting engineer. If the Supplier has qualified operator on their rolls, he may
perform the examination. Otherwise PMI examination shall be sub-contracted to an independent
testing agency approved by EIL.
5.13
Whenever material is identified as not meeting requirements by the visiting engineer a rejection
note shall be issued.
6.0
100%
Pipes
Fasteners
C.
Lot Size
Sample Size
Upto 100
101 to 500
501 and above
2% (Min 2)
1% (Min 3)
0.5% (Min 5)
Note:
For Welded Pipes and Fittings, PMI shall be performed on Base Metal as well as
weldments.
Whenever any sample drawn to PMI test on the basis of percentage selection in B & C
above, fails to meet specification requirements, 100% of items of lot shall be tested for
PMI.
i.311-aelti
ogrir EiRtegi
7.0
ENGINEERS
INDIA LIMITED
IA Go' at India Undertaking)
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION (PMI) AT
SUPPLIER'S WORKS
6-81-0001 Rev. 2
Page 7 of 8
The results of PMI examination shall be recorded in a Report Format as enclosed with this
specification.
8.0
MARKING
8.1
All alloy materials tested by PMI shall be identified using either of the following methods by
indicating "PMI OK"
Bar Code/Hologram Sticker
A low stress stamp marking
012-ael ie ENGINEERS
undertakng)
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION (PMI) AT
SUPPLIER'S WORKS
6-81-0001 Rev. 2
Page 8 of 8
Page
of
Job No.
Project:
Client
Supplier/Sub-Supplier
Testing Agency
Purchase
Requisition No:
PMI Location
Element
Cr
Mo
Ni
Remarks
Accept/Reject
Specified Range
Actual observations
Instrument Type / ID
Last Service Date
Inspection Agency
Witnessed By
lafraeAa ENGINEERS
,t *Peg '4IW INDIA LIMITED
II
19Trfur
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES
6-82-0002 Rev. 2
Page 1 of 9
WIN *
STANDARD SPECIFICATION
FOR
POSITIVE MATERIAL
IDENTIFICATION
AT
CONSTRUCTION SITES
14/11/2011
02/01/2007
0
Rev.
No
9i7w-A
1,1"141t
)!
SM
SM
Mk-t
DM
AS
MPJ
VNP
VC
22/07/2002
MPJ
MPJ
Date
Purpose
RSG
Standards
Committee
GRR
Standards
Bureau
Prepared Checked
by
by
Convenor
Chairman
Approved by
45401-45 PS ENGINEERS
sig:ar ElfakegiS
INDIA LIMITED
Gov't of India underlain%)
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES
6-82-0002 Rev. 2
Page 2 of 9
Abbreviations:
API
ASM
ASME
ASTM
BV
Bureau Veritas
CELL
DNV
EIL
ITP
PMI
RTJ
TPI/TPIA
Members :
ISM-a-daft ENGINEERS
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES
6-82-0002 Rev. 2
Page 3 of 9
CONTENTS
1.0
SCOPE
2.0
DEFINITIONS
3.0
SPECIFIC APPLICABILITY
4.0
REFERENCES
5.0
GENERAL REQUIREMENTS
6.0
EXTENT OF PMI
7.0
8.0
TESTING METHODOLOGY
9.0
CHARACTERISTIC ELEMENTS
10.0
CALIBRATION
11.0
12.0
PERSONNEL QUALIFICATION
13.0
ACCEPTANCE CRITERIA
14.0
REJECTION CRITERIA
15.0
DOCUMENTATION
SalMileitelk
- ENGINEERS
LIMITED
EA G., d the. Und.t..9)
cif miaowINDIA
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES
6-82-0002 Rev. 2
Page 4 of 9
1.0
SCOPE
1.1
This specification applies to metallic alloy materials as well as carbon steel materials as
defined in this document used in piping, heater coils, storage tanks, vessels etc. at
construction sites. Positive Material Identification (PMI) is to be carried out on Owner
supplied material as well on materials purchased by the contractor.
1.2
Any deviation from this specification must be approved by Owner/EIL in the prescribed
format.
2.0
DEFINITIONS
2.1
3.0
SPECIFIC APPLICABILITY
3.1
The following items require PMI unless specifically exempted through a Concession/
Deviation permit by Owner/EIL.
3.1.1
All pressure containing piping components including, thermowells instrument manifolds, RTJ
gaskets, fasteners etc..
3.1.2
3.1.3
Pressure - containing instrument housings (e.g. gauge glass housings, orifice meter tubes).
3.1.4
Internal metallic linings/cladding, and weld overlay, done at site, used for protection against
corrosive environments.
3.1.5
Tubing
3.1.6
3.1.7
Plates
3.1.8
3.1.9
3.1.10 any other components or materials specifically designated for PMI on the purchase
order/contract.
3.2
Exclusions
The following items are exempted unless specifically designated for PMI in the purchase
order/contract:
15101-ad
09eu WV
ENGINEERS
INDIA LIMITED
IA Govt of India
uneensmg)
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES
6-82-0002 Rev. 2
Page 5 of 9
3.2.1
3.2.2
3.2.3
3.2.4
Internal non pressure - containing baffles, trays, tray clips, supports, pall-rings, support rings,
etc.
3.2.5
Electrical components.
3.2.6
3.2.7
Compression-type ferrules and fittings for use with 3/4 inch (19mm) outside diameter and
smaller tubing.
3.2.8
All carbon steel piping components (including carbon steel pipe supports) other than those
specified at 3.1.9.
3.2.9
4.0
REFERENCES
American Society of Mechanical Engineers (ASME) BPV Code Section-II Part A, B, C and D
ASME B 31.3
American Society for Testing and Materials (ASTM): As applicable
Material Verification Program for New and Existing Alloy Piping Systems: API RP 578
Any other material specification referenced by the Purchase Order/Contract.
IS 1239, IS 3589 and other relevant BIS codes.
5.0
GENERAL REQUIREMENTS
5.1
The test methods outlined in this specification are intended to identify the nominal
composition of alloy/Carbon steel materials. These test methods are not intended to establish
the conformance of a material to a particular specification.
5.2
PMI shall not be considered as a substitute for required mill test reports listing chemical
composition. In addition, mill test reports shall not be considered as confirming
alloy/composition verification.
5.3
The PMI activity shall be included in the overall quality plan and Inspection & Test Plan for
fabrication/erection. The contractor shall submit to EIL/Owner, a procedure for PMI to
comply with the requirements of this specification. Approval of PMI procedure shall be
obtained from Own er/EIL prior to commencement of fabrication/erection as the case may be.
5.4
Contractor shall engage reputed TPIA (BV, Lloyds, CEIL, DNV) with prior approval to
witness inspection at site prior to hydrotesting, and accordingly submit ITP for review of
owner/EIL.
5.5
N
lalfr231Eg ift ENOEERS
5`Ig7 Wag WY INDIA LIMITED
GOA at roam UncleflOong)
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES
6-82-0002 Rev. 2
Page 6 of 9
5.6
5.6.1
5.6.2
5.7
After acceptance, all components shall be marked with a suitable paint mark. Markings must
be permanent and readily visible. These markings are in addition to markings required by
other codes/specifications/Technical Notes.
5.8
Controls shall be established to keep the non conforming items identified till proper resolution
of non conformity.
5.9
EIL/Owner shall have the right to witness the performance of any PMI test.
6.0
EXTENT OF PMI
PMI shall be done on each component (100 percent PMI inspection) including welds, unless
specifically exempted by Owner/EIL
PMI shall be done on pipe supports (welded/bolted) such as pads, saddles, dummy pipes etc.
(100 percent PMI inspection) in all piping systems of alloy material
PMI shall be done on all bolts and nuts (100 percent PMI inspection) of flange joints in all
piping systems of alloy material.
7.0
PMI testing (irrespective of PMI done at earlier stages) shall be carried out when piping
loops/heater coils have been cleared for hydrostatic testing by EIL/Owner. Hydrostatic
Testing shall be carried out only when non conforming components have been
replaced with conforming components and subsequent Non Destructive Testing, Post Weld
Heat-Treatment, Hardness checking etc., as required by specifications have been completed.
PMI records shall form a part of piping/heater inspection records. Contractor shall
demonstrate to EIL that each & every component of the piping system and heater coils has
been subjected to PMI by providing line wise records of PMI duly endorsed by TPIA
8.0
TESTING METHODOLOGY
8.1
The method used for PMI examination shall provide a quantitative determination of the
alloying elements like chromium, nickel, molybdenum or vanadium in alloy steel items for the
characteristic elements specified in clause 9.0
latazretjak ENGINEERS
SgartegtegW
INDIA LIMITED
CA GOA
of Inclo Undept009)
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES
6-82-0002 Rev. 2
Page 7 of 9
8.2
Instruments or methods used for PMI examination shall be able to provide quantitative,
recordable, elemental composition results for positive identification of elements.
8.3
The acceptable instruments for alloy analyzer shall be either "portable X-ray Fluorescence" or
"optical Emission type each capable of verifying the percentage of elements within specified
range The instruments must have the printout facility and sensitivity to detect the elements in
the specified range.
8.4
Chemical spot testing, magnets, alloy sorters and other methods using eddy current or
triboelectric testing methods are not acceptable for PMI examination.
8.5
All PMI instruments shall have been serviced within a 6 month period of the time of use to
verify the suitability of batteries, sources,etc, and the date of the last service shall be stated on
the PMI report form.
8.6
The surfaces to be examined shall be prepared and cleaned by suitable means before PMI so
that surface be free from grease, oil, paint or oxides. Testing shall be done after proper
surface cleaning and other requirements as outlined by the manufacturer of the portable alloy
analyzer. Modification, if any, of these procedures must be approved by Owner/EIL.
8.7
Alloy steel ring type joint gaskets shall be inspected by using portable X-ray fluorescence
instrument.
9.0
CHARACTERISTIC ELEMENTS
Material Specification
ASTM A 335
ASTM A 312
Gr P1 1
! (Jr P5
! GrP22
t Gr p9
Type 304
Type 316
Type 321
Type 347
Characteristic Elements
Cr, Mo
_Cr, Ni
Cr, Ni, Mo
I Cr, Ni, Ti
Cr. Ni, Columbium, Tantalum
9.1
Carbon Steel materials shall be checked for Cr, Ni, Mo, Cu and Va as per clause no: 13 .3.
9.2
Characteristic elements for materials not listed above shall be proposed by the contractor for
approval of the Owner/EIL
10.0
CALIBRATION
10.1
Instruments used for PMI shall have the sensitivity to detect the alloying elements in the
specified ranges. Instruments or methods used for examination shall be of the type that will
provide quantitative, recordable, elemental composition results for positive identification of
the alloy elements present.
10.2
Each alloy analyzer shall be calibrated using known alloy standards for intended materials to
be checked by PMI. A calibration certification from the Manufacturer or his authorized
agency shall be submitted to EIL/Owner for records.
1512zr&eENGINEF_RS
lgt-9 ENegviiir INDIA LIMITED
IA GAN of XIda
unaenakam
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES
6-82-0002 Rev. 2
Page 8 of 9
10.3
EIL/Owner shall review the procedure and qualification and witness sample alloy/carbon steel
materials verification tests to confirm that the procedures, equipment and personnel are
capable of providing consistent and accurate results. Certified samples, with full traceability,
of a known alloy materials/carbon steel materials shall be available for use as a random spot
checking on instrument calibration.
11.0
12.0
PERSONNEL QUALIFICATION
The persons performing the PMI test should be knowledgeable about properties of material,
all aspects of operation of PMI equipment including the method of testing.
Qualification/experience documents of the person performing the PMI test including his
training and experience shall be submitted to EIL/Owner for review and approval.
13.0
ACCEPTANCE CRITERIA
13.1
Base Metal
PMI test results showing presence of characteristic elements upto 10% less than the minimum
specified value in the material specification and upto 10% more than the maximum specified
value in the material specification shall be acceptable.
13.2
13.3
14.0
REJECTION CRITERIA
14.1
If the PMI test results fall outside the acceptable range as given in 13.0 above, the contractor
shall obtain a quantitative check analysis performed by a laboratory acceptable to EIL/Owner
for a complete chemical analysis. Results of this analysis shall be submitted to EIL/Owner,
with contractor's recommendation, for final decision.
Decision of EIL/Owner shall be final in this regard.
14.2
If any material component or weld is found unacceptable, all other represented materials ( e.g.
in case of fasteners, supports) or welds shall be considered suspect. In such cases, the
contractor has the following options:
14.2.1 Scrapping all those represented materials or components and replacing with new components
or welds.
Format No. 8-00-0001-F1 Rev. 0
OM-a-Eta ENGINEERS
seigTrr Wag's, INDIA LIMITED
STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES
6-82-0002 Rev. 2
Page 9 of 9
14.2.2 Performing 100% examination of the remainder of the represented materials/ components and
replacing each item that fails the PMI check.
14.2.3 If the performance of any verification activity is unacceptable to EIL/Owner or if any material
has been incorrectly identified, all further tests shall be subject to EIL/Owner approval until
the problem is corrected.
15.0
DOCUMENTATION
15.1
Print out from alloy analyzer, in original, duly certified by the contractor/ PMI agency.
15.2
15.3
Basis and action for resolving and documenting PMI non conformances.
15.4
Contractor shall demonstrate to EIL/Owner that all components requiring PMI have been
subjected to PMI testing and accepted.
15IrazIeqtt ENGINEERS
Ig7E1PreglilW INDIA LIMITED
Gow II16a thlthillSONO
DOCUMENT NO.
POSITIVE MATERIAL
IDENTIFICATION TEST REPORT
Page 1 of 1
REPORT NO:
Contractor
Date of PMI
Project
Inspection Agency
Location
PMI Agency
Job No.
Sr.
No.
Part Identification
(PMI AGENCY)
Material
As per Drg./spec
(CONTRACTOR)
Material
as per PMI
Result
(Accepted/Rej ected/
Retest)
(TPI AGENCY)
(EIL/OWNER *)
*When material is supplied by Owner
JNK HEATERS
CO. LTD.
DOC NO:
TITLE:
DANGOTE OIL
REFINING
COMPANY
LIMITED.
PAINTING SPECIFICATION
OWNER
PMC
DEC
UNIT
ISSUED FOR
0
15/02/2016
REV :
DATE :
INFORMATION
APPROVAL
ENQUIRY
ORDER
CONSTRUCTION
REVIEW
NAME
DISCIPLINE
SIGN.
DATE
TA
MS
DS
15/02/16
Rev.
Description
Prepared By
Reviewed By
Approved By
Approved Date
JNK HEATERS
CO. LTD.
DOC NO:
TITLE:
DANGOTE OIL
REFINING
COMPANY
LIMITED.
PAINTING SPECIFICATION
REV :
DATE :
0
15/02/2016
TABLE OF CONTENT
Section
DESCRIPTION
PAGE NO.
Introduction
Reference Documents
Scope of Work
Surface Preparation
Painting
Documentation
JNK HEATERS
CO. LTD.
DOC NO:
TITLE:
PAINTING SPECIFICATION
DANGOTE OIL
REFINING
COMPANY
LIMITED.
REV :
DATE :
0
15/02/2016
1. Introduction
This specification covers the minimum requirements for the Painting of Fired Heaters of Dangote Refinery and
Petrochemicals Project for Dangote Oil Refining Company Ltd., Nigeria.
This document briefly specifies scope of work, requirements for surface preparation, selection and application of
paints on equipment, piping and steel structures etc.
2. Reference Documents
Specification for Surface Preparation and Protective Coating A545-000-07-41-SP-01121-Rev 0
3. Scope of Work
3.1. Extent of Work & Supply
The following surfaces and material shall require shop, post-erection and field painting
3.1.1. All uninsulated carbon steel and low alloy steel and related piping, fittings and valves (including
painting of identification marks), Heater ducts and stacks, Heaters etc.
3.1.2. All insulated parts of piping & ducting.
3.1.3. All structural steel work, pipe, structural steel supports, walkways, handrails, ladders, platforms etc.
3.1.4. Identification of colour bands on all piping as required.
3.1.5. Supply & application of all types of primers, Intermediate/finish paints as per Annexure-1 with paint
required for repair at site.
3.1.6. Painting under insulation for carbon steel, alloy steel and stainless steel as specified.
3.1.7. Quality control, testing and inspection during all stages of work (surface preparation, application of
coating and testing of furnished coating).
3.1.8. For fabricated box section & construction of similar nature, primer coat shall be given in the inside
surfaces before fabrication.
JNK HEATERS
CO. LTD.
DOC NO:
TITLE:
PAINTING SPECIFICATION
DANGOTE OIL
REFINING
COMPANY
LIMITED.
REV :
DATE :
0
15/02/2016
5.2. Fire extinguishers or sand and water for emergency firefighting operations shall be provided near storage
area at easily accessible place for use, in case of fire.
5.3. Warning Boards and signs shall be exhibited around the storage area.
5.4. Also Refer Specification for Surface Preparation and Protective Coating A545-000-07-41-SP-01121Rev 0
7. Painting
JNK HEATERS
CO. LTD.
DOC NO:
TITLE:
PAINTING SPECIFICATION
DANGOTE OIL
REFINING
COMPANY
LIMITED.
REV :
DATE :
0
15/02/2016
7.1.5. A Caution board indicating wet paint shall be posted after painting is over and kept till the curing time is
completed.
7.1.6. For painting of multiple coating, each coat shall be applied only after sufficient curing time has elapsed
after the previous coat, as recommended by manufacturer.
7.1.7. All painted surfaces shall have a uniform and smooth regular finish.
7.1.8. The surfaces shall be free from foreign particles, brush marks, bristles, ridges, waves, laps wrinkles etc.
If such surface defects occur, the same shall be removed by using abrasive paper/cloth and re-painted.
7.1.9. Surfaces inaccessible after assembly shall be painted to requirement before assembly.
7.1.10. Any imperfect or damaged layer/coat shall be repaired before subsequent coating.
7.1.11. At places where welding is to be carried out at field after assembly, a space of 100 to 200 mm width
shall be left unpainted on both sides of the welding joint.
7.1.12. Field welded areas shall be thoroughly cleaned as required in clause 4.0 and painted in the same
manner as the remaining area.
7.1.13. When successive coat of same color have been specified, alternate coat should be tinted sufficiently to
produce enough contrast to indicate complete coverage of the surface.
7.1.14. Pipes shall be painted only after mechanical completion and testing.
7.1.15. Also Refer Specification for Surface Preparation and Protective Coating A545-000-07-41-SP-01121Rev 0
JNK HEATERS
CO. LTD.
DOC NO:
TITLE:
PAINTING SPECIFICATION
DANGOTE OIL
REFINING
COMPANY
LIMITED.
REV :
DATE :
0
15/02/2016
8.1.10 Test mentioned in Specification for Surface Preparation and Protective CoatingA545-000-07-41-SP01121-Rev 0
JNK HEATERS
CO. LTD.
DOC NO:
TITLE:
PAINTING SPECIFICATION
DANGOTE OIL
REFINING
COMPANY
LIMITED.
REV :
DATE :
0
15/02/2016
9. Documentation
Following documents shall be prepared and maintained:
Painting Inspection Report.
Attachment
Annexure 1 Painting Specification Table
Annexure 1
Painting Specification Table (As per Specification A545-000-07-41-SP-01121-01-Rev 0)
PRIMER 1
Table
10.3
10.2
Sr.
No
Radiant
Section,
convectio
n Section
& Stack
All Steel
Structure,
Platforms,
Duct/APH
, Supports
etc
3
8.1
10.2
Surface
of
Applicati
on
Handrails,
Posts, toe
Guard,Sta
irways,
Gartings
and
Ladders
Cold Air
Duct
(Internal)
10.2
Cold Air
Duct
(External)
15.1.2
APH by
pass air
duct
15.1.1
Hot Air
Duct from
SAPH to
CAPH
(External)
Material
Grade
S275 JR
Grade
S275 JR
Grade
S275 JR
Grade
S275 JR
Grade
S275 JR
Grade
S275 JR
Grade
S275 JR
Service
Temper
ature
Range
in o C
81 to
400
-14 to
80
Up to 60
-14 to
80
-14 to
80
121 to
540
-45 to
120
Surface
Prepara
tion
SSPCSP-10
SSPCSP-10
SSPCSP-10
SSPCSP-10
Type
Two Component
Inorganic zinc
silicate coating (F9)
Two Component
Inorganic zinc
silicate coating (F9)
N
o.
O
f
C
o
at
s
DFT
Each
Coat
(Micro
ns)
Two Component
Inorganic zinc
silicate coating (F9)
Two Component
Inorganic zinc
silicate coating (F9)
SSPCSP-10
Two component
Heat resistant
Silicone Aluminium
paint (F12) (*)
Two component
Epoxy phenolic
coating cured with
Polyamine adduct
hardener system
(F15) (*)
N
o.
O
f
C
o
at
s
DFT
Each Coat
(Microns)
FINISH COAT 1
DFT
Each
Coat
(Micr
ons)
Type
HEATER STRUCTURE
Two component
Heat resistant
silicone
Aluminium paint
(F12)
65-75
65-75
Two
component
Epoxy Zinc
Phosphate
Primer cured
with polyamine
hardener (P6)
SSPCSP-10
SSPCSP-10
PRIMER 2
Two
component
Epoxy Zinc
Phosphate
Primer cured
with polyamine
hardener (P6)
65-75
65-75
Two
component
Epoxy Zinc
Phosphate
Primer cured
with polyamine
hardener (P6)
20
75
Two
component
Epoxy
phenolic
coating cured
with
Polyamine
adduct
hardener
system (F15)
40
40
Two component
Acrylic
Polyurethane
finish paint (F2)
40
Two component
Heat resistant
Silicone
Aluminium paint
(F12).
75
Two component
Epoxy phenolic
coating cured with
Polyamine adduct
hardener system
(F15)
FINISH COAT 2
No.
Of
Coat
s
DFT
Each
Coat
(Micro
ns)
DFT
Each
Coat
(Micro
ns)
Total Avg
DFT in
Microns
Colour Shade
Type
No.
Of
Coat
s
20
105-115
Heat resistant
aluminium
100
Two
component
Acrylic
Polyuretha
ne finish
paint (F2)
40
345-355
40
160-165
100
Two
component
Acrylic
Polyuretha
ne finish
paint (F2)
50
215-225
Black
100
Two
component
Acrylic
Polyuretha
ne finish
paint (F2)
40
345-355
Black
20
60
Black
Hold
Hold
Duct/APH/Piping
Supports- Black
Handrail-Signal
Red
Stairways, Grating,
Ladder- Black
Remarks
Hold
Hold
Hold
Hold
Hold
2
75
300
Black
15.1.2
15.1.1
10
10.2
Hot Air
Duct from
CAPH to
Burner
(External)
Cold Flue
Gas Duct
(External)
Hot Flue
Gas Duct
(External)
Grade
S275 JR
Grade
S275 JR
Grade
S275 JR
121 to
540
-45 to
120
-14 to
80
SSPCSP-10
SSPCSP-10
SSPCSP-10
Two component
Heat resistant
Silicone Aluminium
paint (F12) (*)
Two component
Epoxy phenolic
coating cured with
Polyamine adduct
hardener system
(F15) (*)
Two Component
Inorganic zinc
silicate coating (F9)
20
75
65-75
Two
component
Epoxy
phenolic
coating cured
with
Polyamine
adduct
hardener
system (F15)
Two
component
Epoxy Zinc
Phosphate
Primer cured
with polyamine
hardener (P6)
Two component
Heat resistant
Silicone
Aluminium paint
(F12).
20
60
Black
75
Two component
Epoxy phenolic
coating cured with
Polyamine adduct
hardener system
(F15)
75
300
Black
40
100
Two
component
Acrylic
Polyuretha
ne finish
paint (F2)
40
345-355
Black
Hold
Base
HEATER PIPING
11
15.1.1
12
Fuel (Oil)
Piping
(Main &
Pilot)
CS
15.3.2
Fuel
(Gas)
Piping
(Main &
Pilot)
Stainles
s Steel
15.1.2
Process
Inlet/
Outlet
CS/ Low
Alloy
Steel
13
15.3.3
14
15.3.4
15.1.2
15
16
-45 to
120
0 to 125
121 to
540
SSPCSP-10
Two component
Epoxy phenolic
coating cured with
Polyamine adduct
hardener system
(F15) (*)
SSPCSP-10
Two component
Epoxy phenolic
coating cured with
Polyamine adduct
hardener system
(F15) (*)
SSPCSP-10
Two component
Heat resistant
Silicone Aluminium
paint (F12) (*)
20
125
125
Process
Inlet/
Outlet
SS
126 to
400
SSPCSP-10
Engineered Epoxy
poly Siloxane
Coating or high
build cold applied
inorganic copolymer based
aluminium coating
(F16) (*)
Process
Inlet/
Outlet
SS
401 to
600
SSPCSP-10
SSPCSP-10
Two component
Heat resistant
Silicone Aluminium
paint (F12) (*)
Snuffing
Steam
CS
121 to
540
Two
component
Epoxy
phenolic
coating cured
with
Polyamine
adduct
hardener
system (F15)
Two
component
Epoxy
phenolic
coating cured
with
Polyamine
adduct
hardener
system (F15)
75
80
20
75
Two component
Epoxy phenolic
coating cured with
Polyamine adduct
hardener system
(F15)
80
Two component
Epoxy phenolic
coating cured with
Polyamine adduct
hardener system
(F15)
Hold
Hold
Band
Hold
2
75
300
Black
1 Yellow
Hold
1
80
240
Orange
1
Aluminiu
m
20
60
Dark
admiralty
Grey
1 Red
125
250
Dark
admiralty
Grey
1 Red
Amercoat 738
125
250
Dark
admiralty
Grey
1 Red
Hold
Two component
Heat resistant
Silicone
Aluminium paint
(F12)
20
60
Off white/
Aluminiu
m
1 light
green
Hold
Two component
Heat resistant
Silicone
Aluminium paint
(F12).
Engineered
Epoxy poly
Siloxane Coating
or high build cold
applied inorganic
co-polymer based
aluminium coating
(F16)
Hold
Hold
15.1.2
17
Cross
Over
Cross
Over
15.3.3
CS/ Low
Alloy
Steel
Stainles
s Steel
121 to
540
126 to
400
SSPCSP-10
Two component
Heat resistant
Silicone Aluminium
paint (F12) (*)
SSPCSP-10
Engineered Epoxy
poly Siloxane
Coating or high
build cold applied
inorganic copolymer based
aluminium coating
(F16) (*)
SSPCSP-10
Two component
Heat resistant
Silicone Aluminium
paint (F12) (*)
18
15.1.2
10.2
19
20
Soot
Blower,
Atomizing
steam
CS
Instrumen
t Air
CS
121 to
540
20
125
20
Two component
Heat resistant
Silicone
Aluminium paint
(F12)
20
Engineered
Epoxy poly
Siloxane Coating
or high build cold
applied inorganic
co-polymer based
aluminium coating
(F16)
125
Two component
Heat resistant
Silicone
Aluminium paint
(F12)
20
Galvanized pipes shall be coated with zinc by hot dip process conforming to ASTM A 153
60
Dark
admiralty
Grey
1 Red
250
Dark
admiralty
Grey
1 Red
60
Off white/
Aluminiu
m
1 Red
Hold
Sea
Green
1 Black
Hold
Hold
Hold
Hold
Hold
REV : A
TITLE: INSPECTION TEST PLAN FOR STEEL STRUCTURE FOR RADIANT, CONVECTION, STACK & DUCTS AT SHOP
ITP NO: -
DATE : 15-02-2016
OWNER
PROJECT
CONSULTANT
LSTK CONTRACTOR
CONTRACTOR'S PROJECT NO
XXXX
REF. NO.
XXXX
XXXX
DORCL PO NO.
XXXX
TPIA
XXXX
INSPECTION CATEGORY
CATEGORY A
R
ISSUED FOR
A
INFORMATION
INQUIRY
CONSTRUCTION
LEGENDS :
I
APPROVAL
ORDER
REVIEW
Existing approved WPS/PQR/WPQ will be submitted to EIL for review & approval.
HP - Hold Point, W - Witness Point, Rw- Review Of Contractor's documentation, S - Surveillance Inspection by Ower/EIL, WC- 100% Examination by Contractor.
WPS - Welding Procedure Specification, PQR - Procedure Qualification Record, WPQ - Welder Performance Qualification
AJ
CL
DS
15-Feb-16
REV
DESCRIPTION
PRPD BY
CHKD BY
APRD BY
DATE
Page 1 of 4
SR. NO.
ACTIVITY DESCRIPTION
REFERENCE DOCUMENT
EXTENT OF INSPECTION
MFG
1
2
PRIOR TO FABRICATION
Incoming Material Inspection
Welding Filler Material Approval/Qualification
a) Review of materials test certificate/ Documents
b) Laboratory testing, if any
i) Carbon Steel
ii) Alloy Steel/ Stainless Steel
TPI
INSPECTION BY
REMARKS
MFG
JNK
TPI
EIL/ DORCL
100%
100%
HP
WC
Rw
HP *
100%
100%
HP
WC
Rw
100%
100%
HP
WC
100%
100%
HP
WC
Rw
HP
100%
100%
HP
WC
HP
100%
100%
HP
WC
HP
100%
100%
HP
WC
HP
100%
100%
HP
WC
Rw
HP
100%
100%
HP
WC
100%
100%
HP
WC
Rw*
HP
Test Certificates
Test Certificates/ Project
Specs
Test Certificates/ Project
Specs
Note 1
WPS/PQR
a) Review of Proposed Procedure
Page 2 of 4
Note 2
SR. NO.
ACTIVITY DESCRIPTION
Layout Checking
FABRICATION ACTIVITIES
Materials as per design drawing
Check straightness and non-warping of members
Dimensional & fit-up checks including provision of
slopes for deflection wherever required
Visual check for welding
NDT
EXTENT OF INSPECTION
INSPECTION BY
REMARKS
MFG
TPI
MFG
JNK
TPI
EIL/ DORCL
100%
100%
HP
WC
Rw
HP
100%
100%
HP
WC
100%
100%
HP
WC
Rw
HP
100%
HP
WC
Test Certificates
100%
100%
HP
WC
Rw
100%
100%
HP*
Rw
Rw
100%
100%
100%
10%
HP
HP
WC
WC
Rw
W
Rw
S
100%
10%
HP
WC
As per Spec.
100%
10%
HP
WC
100%
HP
WC
100%
100%
HP
WC
100%
10%
HP
WC
100%
10%
HP
WC
1
2
REFERENCE DOCUMENT
ii) RT Interpretation
b) Ultrasonic Testing (as applicable)
c) Penetrant Testing (as applicable)
Page 3 of 4
Note 3
SR. NO.
ACTIVITY DESCRIPTION
REFERENCE DOCUMENT
EXTENT OF INSPECTION
INSPECTION BY
REMARKS
MFG
TPI
MFG
JNK
TPI
EIL/ DORCL
As per Spec.
100%
10%
HP
WC
100%
100%
HP
WC
Rw
100%
10%
HP
WC
As per drawings
100%
100%
HP
WC
10
As per drawings
100%
10%
HP
WC
11
As per drawings
100%
10%
HP
WC
As per drawings
100%
100%
HP
WC
Rw
Rw
As per PO
As per PO
100%
100%
100%
100%
100%
-
HP
-
Rw
Rw
-
Rw
Rw
HP
Rw
Rw
12
12
Notes:
1)
For Alloy Steel & Stainless steel welding filler metals chemical analysis to be carried out for every batch.
2)
3)
4)
10% Extent of Inspection for TPI means,10% of each item (Radiant, Convection, Stack, Duct).
Page 4 of 4
REV : A
TITLE: INSPECTION TEST PLAN FOR STEEL STRUCTURE FOR APH, PIPE & OPEN SUPPORTS AT SHOP
ITP NO: OWNER
DATE : 15-02-2016
PROJECT
CONSULTANT
LSTK CONTRACTOR
CONTRACTOR'S PROJECT NO
: XXXX
: XXXX
REF. NO.
DORCL JOB NO.
: XXXX
: XXXX
DORCL PO NO.
TPIA
: XXXX
: CATEGORY B
INSPECTION CATEGORY
DOCUMENT SUBMISSION STATUS - JNK
R
ISSUED FOR
A
INFORMATION
INQUIRY
CONSTRUCTION
LEGENDS :
I
APPROVAL
ORDER
REVIEW
Existing approved WPS/PQR/WPQ will be submitted to EIL for review & approval.
HP - Hold Point, W - Witness Point, Rw- Review Of Contractor's documentation, S - Surveillance Inspection by Ower/EIL, WC- 100% Examination by Contractor.
WPS - Welding Procedure Specification, PQR - Procedure Qualification Record, WPQ - Welder Performance Qualification
AJ
CL
DS
15-Feb-16
REV
DESCRIPTION
PRPD BY
CHKD BY
APRD BY
DATE
Page 1 of 3
SR. NO.
ACTIVITY DESCRIPTION
REFERENCE DOCUMENT
EXTENT OF INSPECTION
INSPECTION BY
REMARKS
MFG
TPI
MFG
JNK
TPI
EIL/ DORCL
100%
100%
HP
WC
Rw
HP
100%
100%
HP
-
WC
-
Rw
-
S
-
PRIOR TO FABRICATION
1
Test Certificates
Test Certificates
Test Certificates
As per ASME Sec IX
100%
100%
100%
100%
100%
100%
HP
HP
HP
WC
WC
WC
Rw
Rw
W
Rw
W
HP
100%
100%
HP
WC
W*
Layout Checking
100%
100%
HP
WC
Rw
Test Certificates
100%
100%
HP
WC
Rw
100%
100%
HP*
Rw
Rw
100%
100%
100%
10%
HP
HP
WC
WC
Rw
W
Rw
S
100%
10%
HP
WC
As per Spec.
100%
10%
HP
WC
2
3
FABRICATION ACTIVITIES
Materials as per design drawing
Check straightness and non-warping of members
Dimensional & fit-up checks including provision of slopes for
deflection wherever required
Visual check for welding
NDT
1
2
3
Page 2 of 3
Note 1
Note 2
SR. NO.
ACTIVITY DESCRIPTION
REFERENCE DOCUMENT
EXTENT OF INSPECTION
INSPECTION BY
REMARKS
MFG
TPI
MFG
JNK
TPI
EIL/ DORCL
100%
100%
HP
WC
100%
100%
HP
WC
100%
10%
HP
WC
100%
10%
HP
WC
As per Spec.
100%
10%
HP
WC
100%
100%
HP
WC
Rw
100%
10%
HP
WC
ii) RT Interpretation
As per drawings
100%
10%
HP
WC
10
As per drawings
100%
10%
HP
WC
As per drawings
100%
100%
HP
WC
Rw
Rw
As per PO
As per PO
100%
100%
100%
10%
100%
-
HP
-
WC
Rw
-
W
Rw
HP
Rw
Rw
11
12
Notes:
1)
Review of TPI for existing WPQ .
2)
3)
10% Extent of Inspection for TPI means,10% of each item (APH, Pipe & Open Supports).
Page 3 of 3
REV : A
TITLE: INSPECTION TEST PLAN FOR PRESSURE PART COIL WORKS (HEATER INLET FLANGE TO OUTLET FLANGE)
ITP NO: -
DATE : 15-02-2016
OWNER
PROJECT
CONSULTANT
LSTK CONTRACTOR
CONTRACTOR'S PROJECT NO
XXXX
REF. NO.
XXXX
XXXX
DORCL PO NO.
XXXX
TPIA
XXXX
INSPECTION CATEGORY
CATEGORY A
R
ISSUED FOR
INFORMATION
APPROVAL
INQUIRY
ORDER
CONSTRUCTION
LEGENDS :
REVIEW
Existing approved WPS/PQR/WPQ will be submitted to EIL for review & approval.
HP - Hold Point, W - Witness Point, Rw- Review Of Contractor's documentation, S - Surveillance Inspection by Ower/EIL, WC- 100% Examination by Contractor.
WPS - Welding Procedure Specification, PQR - Procedure Qualification Record, WPQ - Welder Performance Qualification
AJ
CL
DS
15-Feb-16
REV
DESCRIPTION
PRPD BY
CHKD BY
APRD BY
DATE
Page 1 of 5
SR. NO.
ACTIVITY DESCRIPTION
EXTENT OF INSPECTION
REFERENCE DOCUMENT
MFG
1
2
PRIOR TO FABRICATION
Incoming Material Inspection
Welding Filler Material Approval/Qualification
a) Review of materials test certificate/ Documents
b) Laboratory testing, if any
i) Carbon Steel
ii) Alloy Steel/ Stainless Steel
TPI
INSPECTION BY
REMARKS
MFG
JNK
TPI
EIL/ DORCL
100%
100%
HP
WC
Rw
HP *
100%
100%
HP
WC
Rw
100%
100%
HP
WC
100%
100%
HP
WC
Rw
HP
100%
100%
HP
WC
HP
100%
100%
HP
WC
HP
100%
100%
HP
WC
HP
100%
100%
HP
WC
Rw
HP
100%
100%
HP
WC
100%
100%
HP
WC
Rw*
HP
100%
100%
HP
WC
Rw
HP
100%
100%
HP
WC
100%
100%
HP
WC
Rw
HP
100%
100%
HP
WC
Rw
Test Certificates
Test Certificates/ Project
Specs
Test Certificates/ Project
Specs
Note 1
WPS/PQR
a) Review of Proposed Procedure
Page 2 of 5
Note 2
SR. NO.
ACTIVITY DESCRIPTION
FABRICATION OF COIL
a) Materials as per specification ( check w.r.t.
approved colour coding procedure) and material
traceability
b) Dimensional checks
c) Fit-up checks for butt joints and socket joints
d) Fit-up checks for branch joints
EXTENT OF INSPECTION
REFERENCE DOCUMENT
INSPECTION BY
REMARKS
MFG
TPI
MFG
JNK
TPI
EIL/ DORCL
100%
10%
HP
WC
100%
10%
HP
WC
100%
10%
HP
WC
100%
10%
HP
WC
100%
100%
HP
WC
Rw
100%
100%
HP
WC
Rw
100%
HP
WC
100%
HP
WC
Baking of Electrodes
100%
HP
WC
100%
10%
HP
WC
Rw
100%
10%
HP
WC
100%
100%
HP
WC
Rw
Page 3 of 5
SR. NO.
ACTIVITY DESCRIPTION
Hardness check
i) For CS Coils
ii) For AS Coils
10
EXTENT OF INSPECTION
REFERENCE DOCUMENT
INSPECTION BY
REMARKS
MFG
TPI
MFG
JNK
TPI
EIL/ DORCL
100%
100%
HP
WC
Rw
100%
10%
HP
WC
100%
10%
HP
WC
NDT
a) Penetrant Testing/ Magnetic Particle Testing ( as
applicable).
100%
10%
HP
WC
100%
10%
HP
WC
ASME B31.3
100%
100%
HP
WC
HP
c) Radiography Interpretation/Review
d) Check Shot for Radiography, if applicable
100%
10%
HP
WC
Rw
100%
10%
HP
WC
100%
10%
HP
WC
HP
100%
10%
HP
WC
100%
100%
100%
100%
HP
HP
HP
WC
WC
WC
W
Rw
Rw
S
HP
Rw
100%
100%
HP
WC
Rw
HP
PMI Reports
100%
100%
HP
WC
Rw
Rw
100%
HP
WC
100%
100%
HP
WC
Rw
Rw
12
13
Hydrotest
a) Procedure Review
b) Correctness of Testing Arrangements
c) Scrutiny of test Packs for Mechanical & NDT
Clearance
d) PMI as per specifcation after completion of
installation
Page 4 of 5
SR. NO.
ACTIVITY DESCRIPTION
REFERENCE DOCUMENT
EXTENT OF INSPECTION
INSPECTION BY
REMARKS
MFG
TPI
MFG
JNK
TPI
EIL/ DORCL
100%
100%
HP
WC
Rw
HP
Test Certificates
100%
100%
HP
WC
Rw
HP
Test Certificates
100%
10%
HP
WC
100%
10%
HP
WC
100%
10%
HP
WC
HP
100%
10%
HP
WC
100%
10%
HP
WC
100%
HP
WC
100%
100%
HP
WC
Rw
Rw
100%
10%
HP
WC
100%
100%
HP
WC
Rw
Rw
As per drawings
100%
10%
HP
WC
100%
100%
Rw
Rw
Rw
HP
Rw
14
15
16 IRN Issue
100%
Notes:
1)
For Alloy steel & Stainless steel welding filler metals, chemical analysis to be carried out for every batch.
2)
3)
10% Extent of Inspection for TPI means,10% of each item ( Radiant Coils, Convection Coils, Crossovers, Inlet and Outlet Manifolds.)
Page 5 of 5