Technical Specification -LPG Heater

7/28/2019 Technical Specification -LPG Heater

1/94

8122-02-PS-001TECHNICAL PROCUREMENT SPECIFICATION

PAGE 1 OF 1

TPS No: 8122-02-PS-001

STATUS ENQUIRY

ORIGINATING DEPT. PCE

P.O / W.O No:

PROJECT LPG BLENDING FACILITY

LOCATION MANGALORE

CLIENT M/s HPCL

PURCHASER

VENDOR

ITEM:

1 E 301 LPG Heater 1 No.

1 Revised SK AAN JK 15.10.09

0 For Enquiry SK AAN JK 24.09.09

Rev. Details By Chkd Apprd Date

FACT ENGINEERING AND DESIGN ORGANISATION


2/94

1

1

Compliance Statement

17 8122-11-SE-E301 2Process Data Sheet

-

-

0

10 02 ES 019 / 94Engg. Spec. for Inspection and Testing of Vessels

and Heat Exchangers18

2 0 1

CHKD APPRD

1 15.10.09 Revised

SK AAN JK

AAN

1

12 02 ES 041 / 94 Engg.Spec for Anchor Bolts 2

2 8122-02-PS-003 SW Scope of Work

TPS No.: 8122-02-PS-001

Doc. No.

1 8122-02-PS-003 SPL Special Requirements of Project - PCE

Rev. No. with Issue

1 2S.No.

3

0

No. of

pages

14

Description

00

0 0

0

ENGINEERING SPECIFICATIONS

Vendor Data Index 14 8122-02-PS-003 VDI

5 8122-02-PS-003 SPR Spares

PRPD

24.09.090 For Enquiry

TECHNICALPROCUREMENT

SPECIFICATION

Rev.No. DATE

9 02 ES 018 / 94

DESCRIPTION


ATTACHMENTS

4

0 1

8122-02-PS-001 AT

PAGE OF Rev.1

4 --

-

14

-

18

-

-

5 - -

- -

-

SK

1. The receipt of all attachments shall be checked and asertained.

JK

-

2. All attachments of this TPS shall be retained since only revised sheets, if any, shall be issued.

-

Engg. Spec. for Tubular Heat Exchanger

02 ES 023 / 97 Engg. Spec. for Painting 13

Vendor Data Submission Procedure

Note :

DESIGN STANDARDS

13 02 ES 022 / 94 Engg.Spec for Packing, Marking & Forwarding

00 ES 001 / 03

PRICE SCHEDULE

3

Price Bid - Supply (Indigenous)

02 DS 025 / 94Design Standard -Saddles Support for Horizontal

Vessels

1

3

Design Standard - Name Plate

9

3

02 DS 002 / 94 Design Standard - Anchor Bolts

16 02 DS 009 / 94 Design Standard - Heat Exchanger Accessories

SCOPE DRAWING

1

20 8122-02-PS-003 SIW 1 0

0 01

1

-

0

19 8122-02-DG-10525 LPG Heater E 301

15 02 DS 006 / 94 Design Standard - Earthing Boss 1 - -

17 02 DS 020 / 94

3

1

8122-02-PS-003 VDR Vendor Data Requirements 1

8

14

11 -

1

21 8122-02-PS-003 RN1 Rate for Addition / Deletion of Nozzles (CS)

122 8122-02-PS-003 RN2Rate for Addition / Deletion of Nozzles (CS + Cu / Ni

Cladding)

-

0

0

1

1

6 8122-02-PS-003 CS


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8122-02-PS-001 SPLTECHNICAL

PROCUREMENT

SPECIFICATION

SPECIAL REQUIREMENTS OF THE PROJECTPage 1 of 4 Rev. 1

1 15.10.09 Revised SK AAN JK

0 24.09.09 Enquiry Release SK AAN JK

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED


Item : L P G HEATER

Item No. : E 301

Project : LPG BLENDING FACILITY

Client : M/s HPCL

Location : MANGALORE


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PROCUREMENT

SPECIFICATION



1.0 GENERAL DESCRIPTION

1.1 M/s HINDUSTAN PETROLEUM CORPORATION LIMITED proposes to set up LPG BlendingFacility at Mangalore. As part of this project, it is proposed to install 1 No. LPG Heater.

2.0 SCOPE OF WORK

The scope of work includes but not limited to the following:

2.1 Detailed Engineering of the equipment based on the data sheet, drawing and specifications.

2.1.1 Mechanical design of the equipment including Wind and Seismic analysis based on the datasheet, drawing and specifications listed in the Attachments (Doc. No. 8122-02-PS-001 AT)

sheet.

2.1.2 Impingement plates & Sealing strips shall be provided as per TEMA.

2.1.3 Submission of mechanical design calculations and fabrication drawings as per Vendor DataRequirements for approval to FEDO / HPCL.

2.2 Procurement and supply of all materials and bought-out items such as CS plates & Cu/Ni70/30 plates for cladding / overlay materials, forgings, nozzle pipes and flanges, anchor boltsand fasteners, materials for painting, Anchor Bolts etc.

2.3 Preparation and obtaining approval of Welding Procedure Specification, Procedure

Qualification Record and Welder Performance Qualification.

2.4 Transportation of the equipment to site with all internals.

2.5 Painting of the Equipment and structurals attached to the Equipment.

2.6 Any other items covered in Scope of Work and other documents / drawings attached with theenquiry but not specifically mentioned above.

3.0 DESIGN

3.1 The thicknesses and weights of various parts indicated in the Scope Drawing are indicative

only. Vendors offer shall be based on his design of the equipment in accordance with thecodes / regulations / standards / specified in the equipment drawing / specificationsattached. The saddle support dimensions and size and quantity of anchor bolts shown in theequipment drawing are the minimum requirements and vendor shall include the design of thesame also in the scope.

3.2 Tube thickness specified in the equipment drawing is the minimum required wall thickness.

3.3 Any change in dimensions / weight of the parts required as per codes / standards duringreview of vendors fabrication drawings / strength calculations by FEDO / HPCL and the thirdparty inspection agency, shall be incorporated by vendor without any price or deliveryimplications.

R1

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PROCUREMENT

SPECIFICATION



4.0 MATERIALS

4.1 Vendor shall furnish complete, item wise MTO in the drawing.

4.2 All materials subjected to shell side design temperature (shell, tubesheet, saddle supportsetc.) shall be impact tested as per code.

4.3 Tubes shall conform to SB 111 C 71500 Seamless material.

4.4 All tube side materials shall be cladded with Cu/Ni 70/30 as per the drawing / Processspecification.

4.5 All materials supplied by the vendor shall meet the requirements of applicable codes andstandards. Test Certificates for the materials shall be submitted for approval by M/s FEDO /HPCL.

4.6 Prior written permission shall be obtained from M/s FEDO / HPCL for any change in thematerial specification.

5.0 TESTING & INSPECTION

5.1 M/s FEDO / HPCL or their representative shall have free access to the works of the vendor orhis sub-contractors (if any) to carry out the inspection of all items covered under the scope ofpurchase. Vendor shall submit a detailed quality plan for review and approval by M/s FEDO /HPCL.

5.2 Approval of work by M/s FEDO / HPCL shall in no way relieve the vendor of his responsibilityin meeting all the provisions of the Enquiry conditions.

5.3 Testing of Equipment shall be as per the relevant sections of ASME Sec.VIII Div.1 and TEMAR.

6.0 PAINTING.

6.1 For detailed specification of painting refer FEDO specification for painting 02 ES 023 / 97.

7.0 GENERAL

7.1 Entire work shall be carried out in accordance with relevant standards and accepted codes ofpractices.

7.2 All butt welds shall have full penetration. When welding is carried out from both sides of ajoint, the root of first side shall be dressed back to sound metal before commencement ofweld on second side.

7.3 Structural items shall not be welded directly to the equipment. Pad plates of the samematerial as the shell plate shall be provided for this purpose.

7.4 Earthing Boss (2Nos.) shall be provided on equipment as per FEDO standard 02 DS 006/ 94.

7.5 Name Plates shall be provided on equipment as per FEDO standard 02 DS 020/ 94.

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PROCUREMENT

SPECIFICATION



8.0 EXCLUSIONS

8.1 All civil works are excluded from the scope of the vendor. However foundation-loading datashall be furnished by the vendor.

9.0 GUARANTEE

9.1 The equipment and parts shall be guaranteed against defects in design, materials,workmanship and performance for a period stipulated in the commercial conditions of thisenquiry.

10.0 DOCUMENTS TO BE SUBMITTED ALONG WITH THE OFFER

10.1 Dimensioned sketch of the Equipment (General Arrangement drawing with detailed Bill of

Materials) along with the loading data.

10.2 Quality Assurance Plan.

10.3 Proposal for transportation of the Equipment to site.

10.4 Duly filled Scope of Work. (Doc. No. 8122-02-PS-001 SW).

10.5 Duly filled Spare Parts List. (Doc. No. 8122-02-PS-001 SPR).

10.6 Duly filled Vendor Data Requirements. (Doc. No. 8122-02-PS-001 VDR).

10.7 Duly filled Compliance Statement. (Doc. No. 8122-02-PS-001 CS).

10.8 Rate for Addition / Deletion of Nozzles. (Doc. No. 8122-02-PS-001 RN 1 & 2).

***********************


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00F

T013/9

00FT013/9

8122-02-PS-001 SWTECHNICAL

PROCUREMENT

SPECIFICATION

SCOPE OF WORK

HEAT EXCHANGER PAGE 1 OF 2 Rev. 1

ITEM: LPG HEATER (space for vendors name, signature & seal)

EQPT. Nos. 1. E 301

The scope of work for the equipment listed above shall include design, manufacture, supply of material and engineering work as tickmarked below. Vendor shall fill in the column marked as offer from vendor and return the same along with the offer, without whichthe offer will be considered as incomplete.

1 15.10.09 Revised SK AAN JK

0 24.09.09 For Enquiry SK AAN JKREV.

NO.DATE DESCRIPTION PRPD CHKD APPRD


Sl.No

Description Reqd. Offer from vendorSl.No

Description Reqd. Offer from vendor

1 Detailed design YES 23Supply of spares as perspare part list

YES

2 Drawing Preparation YES 24 Inspection YES

3Submission ofdocuments as per VDR

YES 25 Third party inspection YES

4Procurement ofmaterials

YES 26Drawings for CCE

ApprovalNO

5 Fabrication YES 27 Calibration NO

6 Testing and Inspection YES Equipment components:

7 ASME Code Stamping NO 28Shell, Channel & Channelcover

YES

8 Shop assembly YES 29 Tube sheets YES

9 Site assembly NO 30 Body Flanges YES

10 Equipment erection NO 31Tie Rods, spacers, Bolts& Nuts

YES

11 Internal liningChannel side Cu/Ni70/30 cladding

YES 32 Dummy Tubes YES

12External surfacepreparation

YES 33 Sealing Strips YES

13 Painting YES 34Guide Rails for Tuberemoval

NO

14Corrosion inhibitor forinernal surface

NO 35Companion flanges /bolts / nuts / gaskets fornozzles

YES

15Corrosion inhibitor forexternal surface

NO 36 Bolts, nuts & gaskets YES

16 Pickling NO 37 Nozzle pipes & Flanges YES

17 Passivation NO 38 Saddle Supports YES18 Hydro test at shop YES 39 Anchor bolts / Nuts YES

19 Hydro test at site NO 40Supporting frame forconnected eqpts.

NO

20 Pneumatic test at shop YES 41 Stairway NO

21 Pneumatic test at site NO 42 Sliding Plates YES

22Packing, marking &Forwarding

YES 43 Rollers NO

R

R

R

R

R


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8122-02-PS-001 SWTECHNICAL

PROCUREMENT

SPECIFICATION

SCOPE OF WORK

HEAT EXCHANGER PAGE 2 OF 2 Rev. 1


Sl.No

Description Reqd. Offer from vendorSl.No

Description Reqd. Offer from vendor

Internals:

44 Wire mesh NO

45 Demister & supports NO

46Impingement Plates &Sealing strips

YES

47 Vortex Breaker NO

48Internal clips / anchorsetc. for lining

NO

49Refractory / castablelining

NO

External attachments:

50 Insulation clips NO

51 Fire proofing clips NO52 Platform & ladder clips NO

53 Pipe support clips NO

54Support clips & bracketsfor other eqpt.

NO

55Manhole/hand holedavit/hinge

NO

56 Name plate with bracket YES

57 Earthing boss YES

58 Channel cover davit YES

59 Level Gauges NO

60Relief valves / breathervalves

NO

61 Stairways NO

62 Platforms / Ladders NO

63Test Rings wherevers ecified

YES

64 Jack Screws YES

65 Dowel Pins YES

66 Lifting Lugs YES

67Pulling Eyebolts & Plug forremovable bundles

NO

68 PWHT (as per code) YES

69 Warning Plate for StressRelieved Items (as percode)

YES

70 Radiography (as per code) YES

71

Guarantee for design,materials and wokmanshipfor the period specified inthe commercial terms.

YES

R

R

R

R


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1 2

STATUS ENQUIRY COMMITMENT 1

Legend : Group code : A For review and detailed engineering, B- For review,

Document type : R - Reproducible, P - Print, M - Microfilm. F- floppy disc.

Notes : * Vendor shall fill in proposed lead time if different from the required lead time.

REV.

f. Tube Vibration Analysis

Foundation loading data

a. Shell, Channel, heads & Body Flanges

Design calculations for the following

Assembly drawing

Packing list

c. Tube Sheet & Baffles

WPS & PQR

Manufacturing Procedure

Inspection and testing procedure

h. Lifting provisions

8

6P

Each set of final documents shall be submitted in a folder. Two such folders shall be packed and

despatched with the equipment. Balance documents shall be forwarded to FEDO.

Pert chart of shop activities

j. Earthing boss

e Nozzles and Flanges

6P

i. Name plate & bracket

d. Nozzle & Flanges

e. Stiffener Rings & Special attachments

6P

6P

10

6P 16

6

B

g. Lifting provisions

b. Tube Sheet

c. Saddle Support design & stress analysis

B 6

6P

6P 4

6P

6P

OF

6P

6P

6P

R 1

6P

Qty. of final

**

PAGE

PO No.

TPS No.

6P

6P

6P

6P

6P

AAN

8122-02-PS-001 VDR

JK

6P 8

JK

Description

AAN

Qty.with

offer

b. Shell, Channel, heads & supports

a. Equipment proper

Detailed fabrication drawings

Sl.

No.

Grp

Code


0

1

00FT017/00

DATE DESCRIPTION PREPARED

24.08.09 For Enquiry SK

Revised

After Commitment

AgrdPropd *

Lead time in weeksQty.

Reqd.

A

APPROVEDCHECKED

4

10

**

12

8

10

9

11

13

3 A

4

5

14

15

16

B

4

6P 6

k. Miscellanious items

B

B

B

A

B

B

B

6P 6

6P 14

6P

6P

6P

6P

6P

6P

6P 4

4

15.10.09 SK

Heat treatment procedure if applicable

Spare part list with sketch

Packing/marking/forwarding instructions with sketches.

Installation & maintenance procedure

6P

6P

16 6P

1 B Vendor data index

Dimensioned outline drawing2

f. Other Internals

d. Tie Rods, Spacers Dummy Tubes, etc.

B

A

6P

g. External attachments

VENDOR DATA REQUIREMENTS

TECHNICAL

PROCUREMENT

SPECIFICATION

LPG BLENDING FACILITY

M/s HPCLCLIENT :

PROJECT : ITEM: LPG HEATER (E 301)

8122-02-PS-001

67 B Quality Assurance Plan


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2 2


6Pf. Rubbing of Name Plate

6P

e. Third party inspection records 6P

d. Inspection/test records

6P

1 c. Material test reports 6P

b. Manufacturing records

6P+Softcopya. As built drawings

17 C

Data folder in addition to the documents mentioned in

sheet 1

Sl.

No.

Grp

CodeDescription

Qty.

with

offer

8122-02-PS-001 VDR

After CommitmentQty. of final

**Qty.Lead time in weeks

Reqd. Propd * Agrd

TECHNICAL

VENDOR DATA REQUIREMENTSPROCUREMENT

SPECIFICATION PAGE OF R 1


11/94

812202PS001 VDITECHNICAL

PROCUREMENTSPECIFICATION

VENDOR DATA INDEXPAGE 1 OF 1 R 0

PROJECT: LPG BLENDING FACILITY AT HPCL, MANGALORE PROJECT NO. : 8122 VENDOR:

ITEM: LPG Heater (E 901) P.O NO.: DATE:

Sl.

No.Doc. / Drawing No. Description

Rev. 0

Date

Rev. 1

Date

Rev. 2

Date

Rev. 3

Date

Rev. 4

Date

Rev. 5

Date

Relevant to

This issue

ISSUE NO.

DATE

SIGNATURE

FACT ENGINEERING AND DESIGN ORGANISATION00FT020/94


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8122-02-PS-001 SPRTECHNICAL

PROCUREMENT

SPECIFICATIONSPARES

PAGE 1 OF 1 R0

Sl.

No.Description Quantity Unit Price Total Price

1 GASKETS 100%

2 BOLTS, NUTS, WASHERS , CLAMPS 10%

( MINIMUM 2 NOS OF EACH SIZE)

ABOVE SPARES SHALL BE APPLICABLE FOR ALL THE

NOZZLES INCLUDING NOZZLES WITH BLIND

FLANGES

0 24.09.09 For Enquiry SK AAN JK

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

00FT022/94



13/94

8122-02-PS-001 CSPROCUREMENTSPECIFICATION

COMPLIANCE STATEMENTPAGE 1 OF 1 R 0

TPS NO. 8122-02-PS-001

We state that our Quotation No. is in full compliance with the documents issued against the EnquiryNo. ..except for the deviations listed below.

LIST OF DEVIATIONS

Sl.No.

Description Reasons for Deviation

FACT ENGINEERING AND DESIGN ORGANISATION00FT014/94

Name of vendor:

Date Name and designation Seal & signature


14/94


15/94


16/94

00ES001/03ENGINEERINGSPECIFICATION

VENDOR DATA SUBMISSION PROCEDUREPAGE 1 OF 4

PRPD.BY:- CHKD.BY:- APPRD. BY:- ISSUED ON:-


CONTENTS

1.0.0. SCOPE

2.0.0. VENDOR DATA REQUIREMENTS

3.0.0. CLASSIFICATION OF DOCUMENTS

4.0.0. VENDOR DATA INDEX

5.0.0. QUALITY OF VENDOR DRAWINGS

6.0.0. CONDITIONS OF FEDO REVIEW


17/94

00ES001/03ENGINEERING

SPECIFICATIONVENDOR DATA SUBMISSION PROCEDURE

PAGE 2 OF 4


1.0.0. SCOPE

1.1.0. This document together withVENDOR DATA REQUIREMENTS

(VDR) defines FEDOs requirementsfor vendor drawing and data for anyenquiry, work order or purchaseorder.

1.2.0. Bidders unable to comply with theserequirements must detail allexceptions in their proposal. Thetimely delivery of quality drawingsand data is as crucial as delivery ofthe equipment itself and hence thesame shall be strictly adhered to after

commitment.

1.3.0. Failure to provide adequatepreliminary data / drawing mayrender a proposal non-responsive andhence may be rejected. Aftercommitment failure to providedocuments as per purchase order maydelay progressive payments andadversely affect future invitation to

bids.

2.0.0 VENDOR DATAREQUIREMENTS (VDR)

2.1.0 FEDO will provide a partiallycompleted VDR form along with eachenquiry. This form explains groupcode of the document, quantity ofeach document required and lead timefor submission. Columns areavailable for the vendor to fill in hisdeviations, if any, from FEDOsrequirements.

2.2.0 The vendor shall forward a filled-inVDR form along with his offer, if hehas got any deviation from FEDOsrequirements. In the absence of afilled-in VDR form along with theoffer, it will be presumed that thevendor is accepting FEDOsrequirements specified in the VDR.

3.0.0. CLASSIFICATION OF

DOCUCMENTS

3.1.0. Documents are classified based ontheir status and nature of content.

3.1.1. Status of documents:

1. Preliminary documentsrequired along with the offer.

2. Documents to be submittedafter commitment.

3. Final documents.

3.2.0. The documents are further classifiedinto Groups A,B and C, depending onthe nature of the documents asexplained below.

3.2.1. Group A requirements

These documents are urgent in natureand contain information that isrequired for proceeding with thedetailed engineering of surrounding /down stream equipments in the plantand hence are to be submitted on

priority basis.

3.2.2. Group B requirements

These documents are to be reviewed

by FEDO for compliance with thepurchase order / work orderspecifications but are not essential forother engineering activities of FEDO.

3.2.3. Group C requirements

Documents in this group containsdata / information / records which arefinal in nature and that are requiredfor the equipment user and need not

be reviewed by FEDO.

4.0.0. VENDOR DATA INDEX (VDI)4.1.0. Vendor shall forward a filled up and

updated VDI along with each vendordata transmittal. VDI shall list out alldocuments that are being prepared forthe particular order, their currentrevision status and indicate thedocuments included in the presenttransmittal. A blank VDI is attachedalong with this document, which shall

be used for this purpose.


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PAGE 3 OF 4


5.0.0. QUALITY OF VENDORDRAWINGS

5.1.0. Vendor drawing and data shall besupplied in full size drawings,

reproducible and CDs as specified inthe VDR.

5.2.0. All drawings / documents shall beclear, legible, right reading and madeout of originals prepared in black ink.English language and metric unitsshall be used for the preparation of alldocuments.

5.3.0. The documents shall be prepared nany of the following standard sizes.

5.3.1. A1: 594 mm x 840 mm5.3.2. A2: 420 mm x 594 mm5.3.3. A3: 297 mm x 420 mm5.3.4. A4; 210 mm x 297 mm

5.4.0. All documents submitted to FEDOshall be folded into A4 size (210 x297 mm) except originals / re-

producible which may be rolled. Allreproducible shall be in high quality

polyester films. Soft copies shall be

furnished in CD for final drawings /documents.

5.5.0. Each drawing / document shall have atitle block at the right hand bottomcorner with the followinginformation.

5.5.1. Name of Vendor.5.5.2. Drawing title.5.5.3. Name of Project, Owner and location.5.5.4. Name of Consultant: FEDO5.5.5. FEDO Purchase Order Number.5.5.6. Equipment name & Number5.5.7. Drawing number, revision and page

number.

5.6.0. All drawings shall be drawn to somestandard scales only and the sameshall be indicated in the drawing.

5.7.0. The status of the document likePRELIMINARY, FINAL, FORREVIEW etc. shall be stamped on

all copies forwarded to FEDO.

5.8.0. All documents shall have a block of100 mm x 100 mm space left vacantfor FEDO to put their stamp afterreview.

5.9.0. All drawing/document shall have arevision block explaining revisionnumber, revision description, data ofrevision, revision authorization etc.When the revised drawings aresubmitted all currently revised areashall be clearly demarcated byclouding. Any revisions made onother parts of the documenting willnot be reviewed by FEDO.

5.10.0. When drawings are received back

from FEDO with comments, vendorshall incorporate all the commentsand resubmit the same. If the vendoris not in a position to incorporatecertain comment made by FEDO,then the reason for such deviationshall be highlighted in the forwardingletter to FEDO.

5.11.0 The respective engineeringspecification and other purchase order

spec. Will explain the minimum data /details required in various drawings.In the absence of any suchinformation in the purchase orderdocuments, vendor shall follow thestandard good engineering practicesin detailing the drawing.

6.0.0. CONDITIONS OF FEDO

REVIEW

6.1.0. FEDO and / or its client reserve theright to review the vendor documents.FEDOs REVIEW WITH OR WITHOUT

COMMENTS OF THE VENDOR

DOCUMENTS SHALL NOT RELIEVETHE VENDOR OF RESPONSIBILITY TO

COMPLY WITH ALL PURCHASE ORDER

TERMS AND CONDITIONS, includingall implied requirements relating tofitness for service and goodengineering practices. Approval oracceptance does not imply or inferany determination relating tocompliance by the vendor with its full


19/94



PAGE 4 OF 4


responsibilities under the purchaseorder.

6.2.0. FEDOs comments are limited toidentifying requirements within the

scope of the purchase order or failureby the vendor to comply with therequirements of purchase order, asrevealed by the limited review.Oversights in the above limitedreview cannot be taken as approvalfor the vendor to deviate from the

purchase order conditions. FEDOreserve the right to point out any suchdeviations at any stage of the orderexecution. The vendor shall comply

with all such requirements withoutany price / delivery implications.

6.3.0. FEDO review will be authorized byan official stamp as given below,

properly filled and signed by theconcerned. Comments if any will beindicated in red ink or clouded in thecase of copies of commenteddrawings.

Appropriate comment in thecomments column and status of

review column will be marked.

Comment Status of ReviewAs noted Revise and resubmit

for reviewNocomments

Proceed as noted andsubmit revised docs.For records

Notreviewed

No further reviewrequired

Forward final docs.As per P.O.

6.4.0. All documents received in FEDOshall be dispatched after reviewwithin 15 days from the date ofreceipt. Vendor shall notify FEDO ofnon-receipt of reviewed documents intime immediately, to take correctiveactions.

6.5.0. The delivery of the equipment shall inno case be linked with the review ofthe vendor drawings and data byFEDO. It is the sole responsibility ofthe vendor to execute the job as perthe purchase order conditions. Ifrequired the vendor shall depute histechnical personnel to FEDO after

submission of documents for timelyfinalisation of documents.

***********************


20/94


SPECIFICATIONTUBULAR HEAT EXCHANGER

PAGE 1 OF 14

PRPD.BY:- MVS CHKD.BY:- JR APPRD. BY:- KKR ISSUED ON:- Mar94


CONTENTS

1.0.0 GENERAL

1.1.0 Scope

1.2.0 References

1.3.0 Exclusions

2.0.0 DESIGN

2.1.0 Thermal Design

2.2.0 Mechanical Design General

2.3.0 Shell side design

2.4.0 Tube side design

2.5.0 Supports

2.6.0 Flow induced vibration2.7.0 Alloy lined tube sheets

2.8.0 Guide pins/pulling eyes

2.9.0 Nozzles and flanges

2.10.0 Kettle type re-boilers

3.0.0 MATERIALS

3.1.0 General

3.2.0 Tubing

3.3.0 Bolting and gaskets

4.0.0 FABRICATION

4.1.0 Welding

4.2.0 Post weld heat treatment

4.3.0 Tolerance

4.4.0 Painting

4.5.0 Identification

4.6.0 Earthing boss

4.7.0 Insulation clips

5.0.0 TESTING AND INSPECTION

5.1.0 Pressure testing

5.2.0 Inspection

5.3.0 Protection

6.0.0 GUARANTEE

7.0.0 SPARES

8.0.0 DOCUMENTS AND DRAWINGS


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PAGE 2 OF 14


1.0.0 GENERAL

1.1.0 SCOPE

1.0.1 This specification covers the requirements

for design, materials and fabrication ofunfired Tubular Heat Exchangers of shelland tube type.

1.1.2 The intent of this specification is tosupplement, the reference codes andstandards. However code requirements shallbe fully complied with, even if thisspecification/data sheet/setting plan does notspecifically mention the requirements.

1.1.3 All design, materials, fabrication, inspectionand testing requirements detailed inFEDO engineering specification forpressure vessel shall be complied with,

wherever applicable.1.1.4 FEDO means FACT ENGINEERING AND

DESIGN ORGANISATION, their client orrepresentative.

1.1.5 No variations from Equipment Specifica-tion/data sheet/setting plan and thisspecif ication are permitted unless approvedby FEDO.

1.1.6 Conflic ts, if any, among the exchangerdata sheets, setting plans, this specification,applicable standards, codes and purchaseorder shall be referred to FEDO forclarification prior to the manufacture,

changes in price and delivery due to theconflict is considered nil by the suppl ier. If,due to conflict, a price/ delivery change couldoccur, the conflict must be resolved prior tothe acceptance of quotation bypurchaser, If a conflict is not cleared,FEDO reserves the r ight to mandate theclarification or interpretation and any priceincrease will be absorbed by the successfulbidder/supplier and shall meet the deliveryschedule of the Purchase Order.

1.1.7 The issue of applicable codes andstandards shall be the latest edition or as

specified in this purchasing specification orequipment specification / setting plan.

1.2.0 REFERENCES

1.2.1 FEDO engineering specification 02ES025for pressure vessel.

1.2.2 TEMA, standards of Tubular ExchangerManufacturers Association (class will bespecified in the eqpt. data sheet/Eqpt.specification/setting plan).

1.2.3 ASTM specifications / IS specifications asspecified in the data sheet/setting plan.

1.2.4 ASME Section VIII-Division 1/Division 2.

1.2.5 AWS-ASME Specifications for welding elec-trodes.

1.2.6 BS 5500 - for analys is of local stress onshell due to Saddle supports/otherattachments.

1.2.7 Standards of Expansion JointManufacturers Association (EJMA)

1.2.8 ANSI B16.5 for steel pipe flanges andflanged fittings and B 1 6 . 1 1 for forgedsteel fittings, socket welded and threaded.

1.2.9 ASME SECTION II - Material specification.

1.2.10 ASME SECTION IX - Welding specification.

1.2.11 IBR (wherever applicable).

1.2.12 National, State and local codes.

1.2.13 Other standards/specifications mentionedelsewhere in this specification.

1.3.0 EXCLUSIONS

1.3.1 Unless stated otherwise in datasheet/Equipment specification/setting plan,anchor bol ts, gaskets and bolts for externalpiping, insulation with cladding and slidingplate shall not be supplied by the supplier.

2.0.0 DESIGN

2.1.0 THERMAL DESIGN

2.1.1 When thermal design is specified in thescope of the vendor, the dimensions shownin the data sheet / equipment specification /setting plan are the minimum requirementsonly. Thermal design. Calculations shall befurnished by the vendor for FEDO review.

2.1.2 Where thermal design is included invendor's scope, he shall provide a

satisfactory design, for which he shall befully responsible.

2.1.3 Effective surface is calculated as outsidesurface based on length of tubes measuredbetween inner faces of tube sheets. For U-Tube bundles the exposed surface at U-Bend portion is admissible, provided-shellnozzle location is beyond U-Bends andvelocity of flowing fluid makes this surfaceeffective.


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2.1.4 When alternate operating conditions arespecified, the exchanger unit shall bedesigned to handle either conditionswithout exceeding the allowable pressuredrop and the estimated pressure drop shall

be stated by the vendor for allalternatives.

2.1.5 Fouling factors are net. Tube side valuesshall be increased by ratio of outside toinside surfaces.

2.1.6 Bidders shall consider pressure drops toinclude entrance and exit losses also.

2.1.7 When viscosity values are omitted, it shall bethe responsibility of the bidder to establishproper values for their calculations.

2.1.8 Unless otherwise specified on theexchanger data sheet. Split ring floating

head construct ion shall not be used when:

a. Tube side design pressureexceeds 42 kg/cm2g.

b. When nominal shell diameter exceeds635 mm.

2.1.9 For vertical type thermosyphon re-boilersthe allowable boiling side pressure dropincludes friction, acceleration, static head,and nozzle inlet and outlet losses. Suppliershall guarantee the allowable boiling sidepressure drop.

2.1.10 Minimum tube side velocity for cooling

water shall be 1.5 m/sec. at meantemperature. If this requirement conflictswith the allowable pressure drop, analternate proposa l shall indicate pressuredrop necessary to satisfy this requirement.When oil is used as the reboiler-heatingmedium, the minimum velocity is 1 m/sec,at mean temperature.

2.1.11 Maximum tube side velocity shall be 2.5m/sec. when water carries solids, and shallnot exceed 3 m/sec. when water is clean andwithout solids.

2.1.12 Parts subjected to both shell and tube side

fluids shall be designed to withstand thepressure on shell side only and tube sideonly, and the most severe combination ofthe pressure unless FEDO drawingsexplicitly require other design conditions.

2.1.13 Where slated, tube bundles may bedesigned for the differential pressure givenin Equipment specification. Vendor shallprovide visible warning plate adjacent to, oras a part of, nameplate outlining testpressure regulations, when differentialpressure design is used.

2.1.14 Tube sheets, for economic or otherjustif iable reason, may be provided as cladand faced type, with the concurrence fromFEDO.

2.1.15 Use of integral low fin tubing per ASTM A

498 (ferrous) or B 359 (non-ferrous) ispermitted provided the fluid filmcoefficients, when corrected for fouling,show the shell side controlling by a ratio of 2:1or more. Low fin tubing may also be usedwhen it permits use of increased MTDvalues due to film temperature limitation ofshell side medium, such as Sulfolane.

2.2.0 MECHANICAL DESIGN - GENERAL

2.2.1 TEMA class R shall be followed unlessspecified otherwise.

2.2.2 Mechanical design of the equipment is inthe scope of vendor. The dimensions shownin the data sheet/equipmentspecification/setting plan are the minimumrequirements only. Mechanical designcalculations shall be forwarded toFEDO forreview.

2.2.3 Materia ls selected for the design of theequipment shall be as specified in theequipment Specification. Materials of partsnot specified in the equipment datasheet/drawing shall be decided by the fabricatorand shall be shown on his fabricationdrawing for FEDO approval. Cast iron shallnot be used.

2.2.4 Designer of exchanger unit shall beresponsible for furnishing equipment thatis free of over-stressing for any loadinglisted below in addition to the designconditions specified in the eqpt. Datasheet / spec.

a. Wind loads or seismic loads.

b. Loads of internals and inside fluid.

c. Weights of piping, platform and otherattachment.

d. Loads due to vibration.e. Reactions from piping system.f. Loads during transportation and

erection.

2.2.5 Vendor's strength calculation shall coverthe following: (All calculations shall be donein MKS / SI units)

a. All pressure holding parts.b. Nozzle reinforcements.

c. Lifting lugsd. Supports


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e. Local stress on shell due to supports.

f. Local stress on shell due to externalloading or nozzles from connectedpiping. The loads/ moments acting onthe nozzle will be specified along with

the Purchase Order/ during detailedengineering. Loads normally allowedfor various nozzle sizes are indicated inengg. spec. for pressure vessels.

g. Calculations to check the necessity ofexpansion bellows.

h. Design of expansion bellows, if any.i. Calculations for channel, Pass

partition plates for tube side pressuredrop.

J. Bearing stress calculation of heat barrierin case or low temp, heat exchangers.

k. Flow induced vibration of tube bundle.2.2.6 Wherever it is practical, exchanger shall

be designed for maximum inter-changeability of parts.

2.2.7 For units greater than the limits specifiedin TEMA, the recommended good practices(RGP section) of TEMAshall be mandatory.

2.2.8 The fol l owing points shal l be note dwh ile designing the tube sheets of fixedtube sheet type heat exchangers:

a. Calculations shall be done for bothcorroded and new conditions.

b. Consideration must be given to thestresses induced at operating, alternateoperat ing, start-up, shutdown and otherupset conditions.

2.2.9 When shells are stacked, removablebundles shall be made symmetric for inter-changeability. For stacked units 2 sets ofcarbon steel shims of sizes 1,2,3,4 &5 mmeach shall be provided with each section.The vendor shall supply for intermediatesupports the shims, serv ice bolts, nuts andwashers for each pair/set. The stacked units

shall be set up in the shop and checked fornozzle match. In no case shall the gasketfaces of mating flanges be out of parallel bymore than 0.8 mm. Bolts between connectingnozzles shall be removable without movingthe exchangers. Gaskets, bolts, nuts andwashers for intermediate nozzles shall be invendor's scope.

2.2.10 Lifting lugs made of killed carbon steel shallbe provided on the shell, shell cover,channel , channel cover, floating head andtube sheet of removable tube bundles. The

lifting lugs on shel l shall be designed to takethe weight of complete unit with full of water.

2.2.11 Corrosion allowance

Corrosion allowance shall be as specified inthe datasheet / equipment specification /setting plan In the case of TEMA - class 'B'or class 'C heat exchangers when thespecified corrosion allowance for carbonand low-alloy steel shell and channel isgreater than that specified in TEMAStandards (i.e. 1.5 mm), the minimumthickness of shell and channel shall becomputed by adding the excess corrosionallowance (i.e. the difference between thespecif ied corrosion allowance and 1.5 mm)to the mini mum thickness given in TEMA.

2.3.0 SHELL SIDE DESIGN2.3.1 If type is not specified in data sheet,

preferred type shall be horizontal singlepass shell with conventional floating headtube bundle having rolled in tubes andarranged with two or more tube passes pershell.

2.3.2 When U-tube bundle or kettle type re-boilershell (TEMA "K") is used, the shell covershall be integral with shell.

2.3.3 The use of removable longitudinal shell baffleis not permitted except as follows:

a. For TEMA shells. Type "G or "H"when applied to low-pressure drop (0.14Kg/cm2 max.) Re-boiler or condensingoperations.

b. For TEMA shell, type "F", when appliedpressure drop does not exceed 0.335kg / cm2. Limit shell side differential to135C.

c. Seal strips shall be of replaceable typeand be securely attached to longitudinalsides of baffle plate adjacent to shell wall.They shall be Multiflex of an alloyappropriate for the service, or Neoprene

rubber or equal, subject to design temp:limit recommended for the material beingused. When metal seals. Are used,fabricator shall provide three copies ofinstructions to FEDO that outlines propersteps for folding seal strips inward so thatedges do not rub unduly against inside offlange when tube bundle is inserted intoshel l .

2.3.4 Impingement baffles shall be provided,wherever required by TEMA / equipmentspecification. When impingement baffles


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are welded to tie rod or spacers, they shallbe supported by at least two tie rods orspacers. Minimum thickness of impingementbaffles shall be 6 mm for carbon and low-alloy steel and 3 mm for high-alloy steel and

non-ferrous.2.3.5 Impingement baffles shall be no closer to

the inlet nozzle than is required for escapeheight and flow area.

a. They shall be of sufficient size so thatthe distance from the projected insideof the nozzle to the edge of the plate, inany direction, is at least equal to thedistance of the plate from the nozzleopening.

b. Perforated baffles are not permitted,unless otherwise specified in the

equipment data sheet / dwg.2.3.6 Tube bundle baffles shall be of segmental

cross-flow type, unless otherwise specified.

2.3.7 When longitudinal baffles are welded tothe shell, the weld seams shall not be closeto the longitudinal weld seams of the shell.The fixed tube sheets shall be providedwith the gasket grooves for the baffles.

2.3.8 De-burr and ream all tube holes inbaffles / support plates to eliminate all sharpedges. Also deburr edges on cut for bafflewindow.

2.3.9 Sealing strips shall be provided whereverthe same is required as per the equipmentspecif ication/data sheet. Minimum thicknessof sealing strips shall be 6 mm for carbonand low-al loy steel and 3 mm for high-alloysteel and non- ferrous. The width of sealingstrips shall be such that the clearancebetween the strip and the nearesttube/spacer O/D does not exceed thenominal clearance between tubes.

2.3.10 Fixed tube sheet exchangers shall beanalysed to find any necessity forexpansion joints and setting plan. The

following requirements of expansion jointsshall be satisfied:

a. Design of expansion joint shall be inaccordance with EJMA - Standards ofExpansion Joint Manufacturer

Association.b. Minimum number of cycles to be used

for fatigue analysis shall be 7000 unlessother wise specified.

c. Expansion bellows shall be of thesame material as the shell of the

exchanger, as far as possible, to avoiddissimilar weld joints. If supplier intendsto use any other mater ial, prior approvalfrom FEDO / FEDO shall be obtained.

d. The expansion bellow shall be designed

for both new and corroded conditions.

e. Stress relieving shall be done afterforming of bellows. If made out ofaustenitic stainless steel, solutionannealing shall be done.

f. The thickness variation after formingshall be inspected.

g. Suitable venting and drainingconnections shall be provided.

h. Fabrication and s tress re lievingprocedure shall be submitted for FEDOapproval.

2.3.11 Guide rails shall be provided for all types ofexchangers with a removable tube bundleweighing 10 tons and over.

2.4.0 TUBESIDE DESIGN

2.4.1 On heat exchangers of 400 mm diameterand above, a fitting allowance shall beprovided on pass partition plates to enable theclearances in the tube plate grove to bemaintained as speci fied in the code. 6 mmdia weep holes shall be provided on partitionplates for proper venting and draining.

2.4.2 Pass partition groves shall be machined torectify any distortion, which may be causedby the tube fixing. The minimum designtube plate thickness shall be maintained.

2.4.3 Pass partit ion grove corners shall bemachined to chamfer of to clear the filletwelds of the channel partition.

2.4.4 Pass partition plates shall be designed fortube side pressure drop if specified in theequipment specification / data sheet / settingplan, but not to be thinner than the minimumthickness specified in TEMA Standards.

2.4.5 Single pass tube bundle exchangers, havinga bellows type expansion joint betweenfloating head and shell covers, are permitted.Such de signs shall include provisions (guidedevice) that allows quick and easy mating ofexpansion jo int and flange to its companionflange on the inside face of shell cover.Expansion joint shall be the hydraulicallyformed type and it shall also permitreplacement in the field


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2.4.6 Single pass tube bundle with floating headand having packed gland in shell cover isacceptable only for water tube flue gas heatrecovery exchanger units.

2.4.7 U-tube bundle construction is permitted

when tube side medium is clean; i.e. steam,boiler feed water , heat stable re-boileringoils, reactor effluent streams containinghydrogen gas (P lat f orming, Unibon, etc.)and / or i t is desirable for process reasons,to minimize the number of joint closures.Stress investigations shall be con ductedwhenever temperature differentials of 110deg. C or greater, are assigned over bothlegs of any U-tube. When steam is in U-tubes and process is controlled by lowcontrol o f condensate, U- tube shall be in ahorizontal plane.

2.4.8 The stationary head for the U-tubeconstruct ion outlined above shall be TEMAtype "B" or "C" for all applications exceptwhen tube side medium is water or tubeside design pressure is higher than 140Kg/cm2. Above 140 Kg/cm2 use the TEMAType "C" head with internal pass partition toassure against inter-pass leak age. When"8' head is used, the tube sheet shall be fulldiameter type with threaded holes thatpermits testing or shell side when thestationary head is removed, or, if fulldiameter tube sheet is not provided, a test

ring shall be furnished with the exchanger.2.4.9 All tube sheet holes and the grooving in

them shall conform to TEMA and the followingsupplements. Grooves shall be squareedged and concentric. When heattreatment of tube sheet is required, finaltube ho le sizing shall be attained byreaming after heat treatment.

2.4.10 When aus teni tic tubes are roll ed intotube sheets (or any tube material tubes areto have welded tube to tube sheet joints],the special close fit tolerances stated inTEMA shall be used.

2.4.11 The type of tube-to-tube sheet joint shallbe as specified in the equipment datasheet /setting plan. If not specified, it shallbe considered as expansion with doublegrooves with seal welds.

2.4.12 When welded tube-to-tube sheet joints arespecified in the equipment data sheet/setting plan, supplier shall submit completewelding and testing procedures.

2.4.13 The reduction ratio of the tube thickness dueto the expanding of tube-to-tube sheet joints,shall be with in the range listed below.

T u b e M a t e r i a l P R ( % )

Carbon steel 5 - 10

Low alloy steel 5 - 10

High alloy steel 5 -10

Copper alloy 4 -8

PR = (d2-d1) (D-do)

(do-d1)Where:

X 100

PR = Percentage reduction in tube thk. (%)

d1 = inside dia of tube before expansion (min.)

d2 = inside dia of tube after expansion (mm)

D = inside dia of tube hole of tube sheet.

do = outside dia of tube before expansion (mm)

2.4.14 Tube thickness specified is the requiredminimum wall thickness, unless otherwisespecified.

2.4.15 For U-tube the wall thickness specifiedapplies to the tubing before bending exceptas noted below. All tubes including U-tubes shall be formed from a continuouslength of tubing free on girth welds.

2.4.16 The minimum mean radius of U-bends shallbe 1-1/2 times the O.D. of the tube.Flattening at the bends shall not exceed10% nominal O.D of straight portion tube.Proposal shall be based on the use of heavierwall tubing for short radius U-bends whendes ign pressure demands thicker tube walls.

2.4.17 Thickness reduction after bending of U-tubes shall be inspected by suitable meanssuch as ultrasonic thickness gauge

2.5.0 EXCHANGER SUPPORTS2.5.1 Equipment specification / setting plan shall

be referred for the type and number ofsupports. If the support details are to begenerated by the vendor, then the sameshall be suitably designed by him. Baseplate and anchor bolt details indicated in theeqpt. data sheet shal l be accommodated bythe vendor, to the extend possible, orientationof the support and anchor bolt locations shallbe finalised in consultation with FEDO.


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2.5.2 Saddle supports for Horizontal exchangersshall comply with the Standard Drawingattached or as shown in the equipmentdrawing. When it is important, FEDO willindicate which support shall be fixed and

which support shall be sliding; otherwise thevendor shall indicate this on his proposaldrg. Supports welded to the heat ex-changers shall not interfere with inspectionof heat exchanger circumferential seams.

2.5.3 Saddle supports must withstand a tubebundle pulling force equal to the weight ofthe removable bundle.

2.5.4 Foundation bolt details , if specified inEquipment specification shall be checkedand approved by supplier, and shall bemodified only after agreement in writingwith FEDO. Bolts shall have a minimum

nominal diameter of 20 mm.

2.5.5 Exchangers designed for low temperatureservice shall be provided with a woodenheat barrier under the saddle supports.

2.6.0 FLOW INDUCED VIBRATION

2.6.1 Thevibration analysis of the exchanger isincluded in the scope of supplier.

2.6.2 For Exchanger Units subject to vibration,the tube bundles shall be designed asfollows:

a Maximum baffle spacing shall be450mm when process stream is eitherall vapour, or two phase, or 750mmwhen it is all liquid.

b Consider split flow segment type bafflesto obtain minimum span betweenadjacent baffles. Irregular baffle spacingis permitted.

C For baffles spaced less than 300 mmapart tube hole diameter shall notexceed the O.D. of the tube plus 0.5mm.For baffles and tube support platesspaced 300 mm or more apart the tubehole diameter shall not exceed theO.D. of the tube plus 0.3 mm.

d Minimum baffle thickness shall be 10mm. Otherwise follow TEMA.

e Provide full periphery distributionbel t at shel l inlet or providead eq ua te in te rn al dome space andimpingement protection In either case.Limit PV2into bundle to 500.

2.7.0 ALLOY LINED TUBE SHEETS

2.7.1 When tube sheets are specified to be alloylined type, the same may be achieved bycladding or weld deposit over lay with thefollowing restrictions:

a Cladding shall be integrally and

continuously bonded to the base metal.

b L in ing sha ll no t be accounted for t he Strength it adds to the tube sheet.

c When other parts in contact with thesame fluid are specified as killed steel,the base metal of the clad or faced tubesheet shall also be killed steel.

d Minimum thickness of lining/weldoverlay shall be 8 mm after machining.

e. Silver soldered or brazed bondedliners shall not be used.

2.7.2 Linings shall be either integrally bondedclad ding conforming to ASTM A263, A 264,

A255 or weld deposit overlay by a qualif iedwelding procedure and properly machined,also refer engg. Spec for pressure vessel02ES25.

2.7.3 Clad tube sheets that have grooved tubeholes, shall have one full groove in thecladding and at least one groove in thebase materia l. Alternatively, seal weldingshall be provided for the tube-lo-tube sheet

joint. Shell side claddings on tube sheetsare not acceptable.

2.8.0 GUIDE PINS/PULLING EYES

2.8.1 Guide pins shall be placed in tube sheetsto facilitate assembly and to keep tubesheets (or channels with integral tubesheets) from dropping out of position whenthe bundle is to be withdrawn from theshell.

a. Provide three guide pins approximately120 deg. apart with one located on top ofvertical centreline of a horizontal unit,the outside edges are to be 0.75 mm

clear of the shell I.D. and are to be thesame material as the tie rods.

2.8.2 Guide pins are not required when thelubes sheets are held in position by:

a. Tube sheets with tapped holes forstud bolts, nuts at both ends.

b. Tube sheets having drilled holes whenadjoining flanges are tapped for studs.

c. When the distance from the tube sheetto the second segment cut baffle is450mm or l ess, or when the tube bundle


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is made up of baffles spaced 225 mmcenter to center or less, regardless ofthe distance f rom the tube sheet to thefirst baffle.

2.8.3 Alignment marks shall be provided to

prevent misassembly of channelco ve rs , ch an ne l flanges, shell flanges,shell cover flanges and floating heads.

2.8.4 For removable tube bundles, the tube sheetshall be provided with 4 Nos. tapped holesand pulling eye bolts, and plugs for closingthe holes while the exchanger is inoperation, as per the standard drawingattached.

2.8.5 2 Nos. lapped holes and eyebolts shallbe provided on the outer periphery of tubesheets of removable bundles and floating

head cover flanges, for lifting.

2.9.0 NOZZLES AND FLANGES

2.9.1 The minimum nominal pipe size ofthreaded connect ions shall be 20 NB pipesize. Couplings sha ll be rat ed as perTEM A req uir em ent s. Threads shall beNPT conforming to ANSI B 2.1.

2.9.2 PI/TI connections shall be provided onnozzles, if required by TEMA/ Equipmentspecification/data sheet/ setting plan.

2.9.3 A vent and drain connections shall be

provided at the high and low points ofexchanger respectively when theex ch an ge r is no t ve nt ed or drained bynozzles.

2.9.4 For total condensing service, a flanged 25NB vent nozzle shall be provided on the topof shell at end opposite to shell inlet. Forstacked units provide vent and drain ineach shell. Rating, flange facing etc. shallbe equal to that provided for main shellside/channel side nozzles.

2.9.5 Standard confined joint construct ion shallbe used for flanged girth joints. All Girth

flanges for exchanger proper shall be of thethrough bolted type with stud bolts,threaded full length with a removable nuton each end, unless otherwise specified.The minimum permissible bolt size for girthflanges shall be as follows:

Shell ID (mm) Bolt size

Up to 550 M20

600-1400 M22

1500 2000 M24

2100 and over M30

2.9.6 The facing of intermediate nozzlesbetween stacked units shall be FF or RFtype.

2.9.7 Ring flanges for interna l floating coversshall have:

a. Counter bored facing with nubbin.

b. Bolt hole max. clearance 1.5 mm largerthan the bolts.

c. Corrosion allowance added to allexposed surfaces.

d. Solid metal or jacketed gaskets only.

2.9.8 Main girth type flanges shall be machinedafter welding or stress relieving.

2.9.9 T h e minimum thickness of flat gasketsfo r flanged girth joints shall be 3 mm.

2.9.10 All joints shall be easily accessible forreplacement of gaskets.

2.9.11 All bolt holes in nozzle and manholeflanges shall straddle the principal vertical

and horizontal center lines of theequipment, unless other wise specified.

2.9.12 One set of jack screws shall be fitted inthe flanges of all removable parts as perthe standard drawing attached.

2.9.13 Davits for removal of manholecovers/channel covers shall be providedas per standard drg. attached.

2.9.14 When appurtenances of carbon steelsuch as external clips, sup ports, bracketsetc. are to be connected to alloy steel parts,a pad plate of min 5 mm thick of the same

alloy shall be placed on the part to bewelded.

2.10.0 KETTLE TYPE REBOILERS

2.10.1 Shell shall be TEMA Type "K" with weirplate directly behind tube bundle. Weirsh al l be welded rightly to shell, containno drain holes and have sufficient heightto flood top of top tubes with a minimum or50 mm of process fluid, for normaloperation.


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2.10.2 Provide sliding rails (or tracks) that are fullyseal welded to shell sides to support andguide tube bundle. Also, provide a "hold"angle iron above tube bundle to keepbundle in place during shipment and

handling. It is to be located directly above andclose to the floating head flanges [TEMAType "T") or the 16 mm thick [minimum) fulldiameter support plate when u-tubeconstruction is used.

2.10.3 General arrangement and connections shallbe as shown on Standard Drawing attached.

2.10.4 If Kettle type Re-boiler is used as a steamgenerator, the general arrangement similarto Std. Drg. shall be followed except:

a. A weir is not required and minimisedimension "L".

b. Steam outlet shall employ a steamseparating device, the lowest part ofwhi ch is 500mm above the normalwater level.

c. A clearance of 50 mm (Minimum) shallbe provided between the outside layer oftubes and shell.

d. If thermal design is under the scopeof vendor, he shall guarantee that theunit will produce steam or 99.5%(minimum) quality when operated at125% of design capacity.

2.10.5 The angle of conical sect ion of ket t letype re-boilers shall be 30 deg. unlessotherwise specified in the equipment datasheet.

3.0.0 MATERIALS

3.1.0 GENERAL

3.1.1 Heat Exchangers shall be constructed fromthe materials specified on the Data Sheet, orequivalent materials approved in writing byFEDO.

3.1.2 Where a heat exchanger has la be linedinternally with corrosion resistant material,vendor shall get approval from FEDO en themethod of application of the lining. Specialattention shall be given to the joints oredges of the lining to ensure that the basemetal is fully protected, and that the efficiencyof the lining is not impaired by contaminationfrom the base metal. The supplier shall notifyFEDO of his intentio n to use integrally cladplates when the vessel design takes accountof the strength of the liner, and shall

obtain FEDO approval in writing beforeproceeding.

3.1.3 Materials specified for heat exchangersuppor ts are suitable for the temperaturesexpected during operation, bearing in mind

thatfor insulted heat exchangers the pointof contact with the shell will be insulatedtogether with the heat exchanger. Supportsmade from two different materials may beused if justified economically by the supplierand approved by FEDO in writing.

3.1.4 If material of any part is not mentioned inthe datasheet / equipment specification /setting plan supplier is at liberty to choosesuitable material. He will then be fullyresponsible for the suitability of materials forthe conditions and duties speci fi ed in theequipment specification / data sheet /

setting plan.

3.2.0 TUBING

3.2.1 All nonferrous U-bends shall be stress reliefannealed after bending. Austenitic alloysteel exchanger U-tube bundles sha ll beheat t reated to relieve the stress caused bycold bending the tubes. For tubes of type304 L, 3 1 6 L, 321 or 347, heat treatmentshall consist of furnace heating to 871 to899 deg. C and holding for 10 minutesminimum. Heat Treatment shall be applied to

the whole length of the bent tubes beforeinstallation in the tube sheet or to a portionassembled bundle which includes the tubebends and a minimum of 300 mm of thestraight tangents. Alternate solutionannealing at 1066 plus or minus-14 deg. Cfol lowed by rapid air cooling may be applied.

A sample shall be submitted to show thesurface condition after heat treatment andcleaning.

3.2.2 Tubing shall be in the fully heat treatedconditions as received from the mill. Heattreatment may be annealing, normalizing, or

normalizing and tempering per the ASTMspecification used.

3.2.3 Seamless cold drawn tubes shall be used forall exchangers unless otherwise specified.

3.2.4 When welded stainless steel tubes arespecified in equipment data sheet/dwg. shallbe in accordance with ASME SA 249.

3.2.5 Welded austenitic stainless steel tubes shallbe cold drawn to a minimum reduction of15% in wall thickness prior to a final fullsolution annealing.


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3.2.6 All welded tubing shall pass a non-destructive electric test per ASTM A 450.When the enti re cross-section of the tubesmeets the requirements of this test, thehydrostatic test may be-waived.

3.2.7 Integral low tin tubing shall conform to ASTMA 498 (ferrous) or B 359 (non ferrous).

3.2.8 Non-ferrous tubing shall be supplied in thetemper per B 359.

3.3.0 BOLTING AND GASKETS

3.3.1 Bolting for channel and girth flanges shallconsist of continuously threaded bollsconforming to ASTM A193-B7 with nuts inaccordance with ASTM A 194-2H unlessotherwise specified.

a. Vendor shall guarantee lightness andcompatibility of their closure designs.This, especially, pertains to closureswhere designer amalgamatescomponents having different thermalexpansion properties.

b. When diameter of bolting exceeds 40mm, the bolting design shall provideclearance dimensions that permit useof a stud and bolt tensioner device. Itmay be, the hydraulic type, the springtension resilient washer type or theelectric stud heater type. Installer of

exchanger unit shall control nozzle orien-tation and support saddle locations thatassures clearance for adaptation of thechosen tensioner.

3.3.2 Floating heads shall be through bolted type.

3.3.3 The gaskets for intermediate flanges ofstacked units and to manholes andnozzles with blind flanges shall besupplied by the supplier along with bolt,nuts and washers.

3.3.4 All gaskets shall be made in onecontinuous piece all around including thepass partition ribs nd therefore must be cut

from one sheet.

4.0.0 FABRICATION

4.1.0 WELDING

4.1.1 Girth, longitudinal and nozzle attachmentwelds in exchanger shall be full penetrationweld.

4.1.2 For units requiring strength welding of tubesto tube sheets, the proposed method offabrication including complete sequential jointpreparation, cleaning, assembly, welding,

testing etc. and the inspection procedurestogether with a representative sample of thetube to tube sheet weld shall be furnished toFEDO inspector for review and commentsbefore commencing fabrication.

4.1.3 For expanded and welded tube to tubesheet joints:

a. Expansion to be done first, followedby welding.

b. Graphite or water-soluble lubricant shallbe used for expansion tool to avoid welddefect caused by oil.

4.2.0 POST WELD HEAT TREATMENT

4.2.1 Requirement of post weld heat treatmentof equipments shall be as specified in theeqpt. Data sheet/setting plan andapplicable codes. Also refer relevantclauses in FEDO engg. spec. for pressurevessel.

4.3.0 TOLERANCE

4.3.1 Unless otherwise specified, tolerancesshall conform to the applicable code andTEMA standards.

4.3.2 The dimensions, weights and permissibletolerances of U-bend steel heal exchangertubes shall conform to the requirements of

ASME SB395

4.4.0 PAINTING

4.4.1 Exchanger shall be shop painted inaccordance with the standard specificationfor painting worn for equipment, steelstructure and piping and. Datasheet/Equipment specification/settingplan.

4.4.2 Machined gasket surfaces and Earthingclip shall not be painted.

4.5.0 IDENTIFICATION

4.5.1 The code stamp ( if applicable) and otheridentification marks shall be so located as tobe accessible after installation.

4.5.2 The nameplate and nameplate bracket shallbe as per FEDO design standard.

4.6.0 EARTHING BOSS

4.6.1 Earthing boss as per FEDO designstandard shall be provided on the support ofheat exchanger.


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4.6.2 All heat exchangers shall be provided withtwo earthing bosses, (one in each support).

4.6.3 If the support is not welded to shell or onlytack welded, the earthing boss shall beprovided on the shell.

4.6.4 In the case of stacked heat exchangersshells -of, which are bolted together,they shall be treated separate units as faras earthing Boss is concerned.

4.7.0 INSULATION CLIPS

4.7.1 When insulation is specified on the heatexchanger data sheet/drawing, insulationclips shall be provided on theshell/channel/head por tions as per FEDOdesign standards.

5.0.0 TESTING AND INSPECTION

Refer FEDO Engg. spec for Inspection andTesting and engg. spec, for pressure vesselfor minimum requirement on shopinspection, NDT, heat treatment etc.

5.1.0 PRESSURE TESTING

5.1.1 Heat exchangers shall be hydraulicallytested in accordance with applicable code oras specified in the data sheet/equipment

specification/setting plan.5.1.2 The test pressure shall be maintained for at

least half an hour.

5.1.3 When exchanger is tested for thedifferential pressure, testing shall be doneto each side simultaneously with finalraising of shell to top pressure with tubes attop pressure or tube to top pressure withshell at top pressure, as the case may be.Supplier shall provide a conspicuouslyvisible caution plate near to or as a part ofthe nameplate, indicating that the internals ofthe exchanger have been designed for

dif ferential pressure and that any operatingconditions of testing conditions must not beallowed to exceed this differential.

5.1.4 Exchangers which are to be stacked inservice shall be stacked in the shop andpressure tested as a combined equipment.

5.1.5 Test rings/flanges shall be supplied for allheat exchangers except for fixed tube sheettype. Dummy shell shall be supplied for stab-in type heat exchangers. Material used forfabricating these shall be of tested quality.

Prices for the above items are indicated inthe purchase order separately.Drgs/calculations for these items shall besubmitted for approval.

5.1.6 Pneumatic test shall be carried out for the

following:

a. In order to check the leak tightness oftube-to-tube sheet joint, pneumatic testshall be conducted from shell side.Test pressure shall be 6kq/cm g orshell side design pressure, whicheveris less, unless otherwise specified.

b. Reinforcement pads, slip -on flangesand linings at a pressure of 2-kg /cm2 g.

5.1.7 If any of the pressure part is found to bedamaged after a successful test, theexchanger shall be retested after repairs.

5.1.8 When integral finned tubes are used theyshall meet the requirements of ASTM A 498after f inning or shall be hydro-tested afterfinning.

5.2.0 INSPECTION

5.2.1 Exchangers shall be subject to inspectionby FEDO.

5.2.2 Prior lo the final inspection of exchangers,ail slag, loose scale, dirt, grit, weld spatter,

paint, oil and other foreign matter are to bethoroughly removed in order that theinspection can be conducted to the bestadvantage.

5.2.3 The approval of the work by FEDOinspector and/or his release of theexchangers for shipment shall in no, wayrelieve the supplier of, any responsibility fromcarrying out all the provisions of the purchaseorder specifications.

5.2.4 If exchanger is covered under IBR thesame shall be designed, fabricated,inspected and tested as per the

requi rements of the regulation. Necessaryapproval from IBR of drawings/designcalculations shall be obtained by supplier.The supplier shall provide all technicaldocuments/supports needed for the same.Responsibility of FEDO with respect to theBoiler In spectorate is limited to paying the.Registra tion fees only. All other fees andexpenses in connection with IBR approvalsshall be borne by the supplier.

5.2.5 Supplier shall also arrange ail otherstatutory inspections, approvals /


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documentation if required, in addition tothe IBR requirement.

5.3.0 PROTECTION

5.3.1. After completion of all testing and inspectionthe inside of complete equipment shall bethoroughly drained and dried out by blowinghot air for sufficient time until no furtherincrease in-relative humidity of outgoingair is observed. Drying-out shall be donesimultaneously on both shell and tube sides.

All spare tubes, if supplied, shall be protectedwith caps on both ends of the tubes, packedseparately with a tag indicating item no.,make, material and marked "SPARES.

5.3.2 Also refer FEDO engg. spec, for pressurevessels engg. spec for packing, marking andforwarding.

6.0.0 GUARANTEE

6.1.0 Vendor must guarantee that all materialsused for the equipment have been submittedto regular acceptance procedure and freefrom any defect regarding quality, form andappearance.

6.2 .0 Equipment must be guaranteed for design,materials, workmanship, and performance (ifthermal design is included in scope) for aperiod as specified-in the commercial

conditions of the Purchase Order.6.3.0 Any equipment, or its part not having been

submitted^ to wrong operating service orfaulty manipulation and found defectiveduring test after installation or duringoperat ion, shal l be replaced and reinstalledby vendor without delay and free of costwithin the guarantee period.

6.4.0 In case of detective equipment, FEDOshall have the option lo replace theequipment after intimating to the vendor, inorder to avoid time delay. In such an event,FEDO shall be ent itled to recover the cost of

such replacement from the vendor.

7.0.0 SPARES

7.1.0 Supplier shall supply spares as specified inthe Purchase Order. If not specified theminimum requirement of spares shall bre asmentioned in FEDO engg. spec, for pressurevessel.

8.0.0 DOCUMENTS / DRAWINGS

8.1.0 Vendor shall submit the documents listed inthe enclosed 'Vendor Data Requirements'form in accordance with the "Vendor DataSubmission Procedure'. Each category ofvendor data shall contain the followinginformation as a minimum requirement:

8.1.1 Dimensioned outline drawings

These drawings shall include:

a. Exchanger outline showing alldimensions, size, location, projection andorientation of every connection; locationsof the supports to the Processconnections and the ir projections; thesize and locations of the anchor boltholes and slots; base plate and slidingplate thickness: clearances for removal

of bundle and shell cover bonnets (whenapplicable).

b. Arrangement drawings of platforms andladders (i f applicable).

c. Arrangement of clips and insulationsupport rings (If applicable), lifting lugs,name plate with bracket and earthingboss.

d. Approximate shipping weight andtotal weight of equipment when full ofwater.

e. The design and test conditions,

corrosion allowances, working fluids,nozzle and connection summary and billof materials.

8.1.2 Foundat ion loading diagrams.These drawings shall show:

a. The Empty weight, Operating weight(including all dead and live loads) andweight full of water of the equipment.

b. Forces and moments due toearthquake and wind loads (ifapplicable).

c. Dimensions of base plate and sliding

plate (if applicable) complete withdiameter, number and location of holddown bolts or- anchors and thicknessof metal through which bolts mustpass.

8.1.3 Schematics or flow diagrams

a. Where a vendor supplies equipmentwhich includes, any instrumentation,instrument connections, valves, safetydevices, or control schemes, thesecomponents shall be shown on aschematic diagram identifying vendor


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and type and listing respectiveoperating conditions or settings.

8.1.4 Detail drawingsThese drawings shall include:

a. Weld details.b. Details of appurtenances including

nozzles and reinforcement plates.

c. Details of platforms ladders etc. (asapplicable)

d. Details of clips and insulation supportrings (if applicable)

e. A non-dimensioned scaled tube holelayout showing: the shell inside diameterand the maximum outer tube limit, allbaff le cuts and ears, all support plate cuts,all pass parti tion lanes, all tie rod and seal

strip locations, all impact plates andtheir supports or their equivalent, thelong baffle section for "F" type shells,all vent and drain notches, any handlingdevice holes or any other constructiondetails that affect the flow and/or bypassof the shell side fluid, all peripheral tubesof each tube pass, all of the above,when applicable, shall be superimposedon a large enough layout so that it is readilyand easily interpreted^ In addition to theabove, a sketch showing the passarrangement and the numerical tubecount in each pass (including one pass)shall be furnished

f. Drg. shall show the location of allparts which are to be stress relieved,gasket sketches for all internal andexternal joints, the method of holdinggaskets in place during assembly when

joints are not of the confined type,fabrication details of any speciallyconstructed parts and of parts con-structed of alloy materials, and otherfabrication details when required bythe purchase order.

8.1.5 Erection / assembly Drawingsa Drawings or diagrams showing all mark

numbers, sequence of assembly orerection, and any notes necessary toensure satisfactory assembly,preparation for ship ment and erection.

b. For steel work, include materialsummaries and placement list andindication of material weights

c. For items part shop and part fieldfabricated, drawings shall indicate extentof shop and field fabrication.

8.1.6 Calculations

a. Detailed thermal design of theexchanger shall be furnished (ifapplicable).

b. Detailed Mechanical calculations shallbe furnished in accordance with coderequirement and this specification.

8.1.7 Predicted performance curves

Required only if requested on 'VendorData Requirements' form.

8.I .8 Manufacturer's data reportsa. Heat Treatment Charts.b. Documentation of non-destructive

testingc. Impact test results.e. Mill test and material test

certificate.f. Hydro test certificates.

8.1.9 Performance Test Reports

Required only when specified on 'VendorData Requirements' form.

8.1.10 Installation, maintenance & operatinginstructions

When specified on 'Vendor DataRequirements' form the instructions shall bein a completely self-contained manual

including the following as a minimum.

a. Equipment description with outline,cross section and details.

b. Full installation instructions.

c. Full pre-comissioning check list:

d. Details of routine maintenance andrepair procedure.

8.1.11 Governmental or third party requirements

a. All local authority or third party data suchas des ign calculations, test certificatesand performance data.

8.1.12 Recommended spare parts lists.

a. Unless otherwise specified, the vendorshal l provide priced recommended sparepar ts list including all items of equipmentwithin his scope of supply. Quantitiesshall be sufficient forTWOyear's operation.


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8.2.0 Certified Equipment Data Report8.2.1 Contents of data shall be as given below:

IndexManufacturer's Data report (for specified

code)WPSPQR

Inspection specifications including weld-mapfor radiography.Material test results / mill test certificates.Radiographic examination record sheetsAny o ther NDT recordsHydraulic/Pneumatic test certificates

Stress relieving charts/procedure.Rubbing of Name plate.Rubbing of hard stamping onequipment.

Final certified 'As Built drawings.

8.2.2 The data must be fastened into folder titledCertified Equipment Data Report. Thefollowing information shall be printed on

the cover of theFolder.Name of vendor

Project reference

Project No.

Equipment No.

P.O. No.

Supplier's shop/Job No

***********************


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02 ES 019/ 94ENGINEERINGSPECIFICATION

INSPECTION AND TESTING OF VESSELSAND HEAT EXCHANGERS PAGE 1 OF 18

PRPD.BY:- PSK CHKD.BY:- GPN APPRD. BY:- KKR ISSUED ON:- Oct `94


CONTENTS1.0.0. SCOPE

2.0.0. BASE DOCUMENTS

3.0.0. WITNESSING

4.0.0. INSPECTION AND TEST RECORDS

5.0.0. INSPECTION AND TEST ITEMS

6.0.0. MATERIAL TEST

7.0.0. WELDING INSPECTION

8.0.0. VISUAL INSPECTION

9.0.0. POST WELD HEAT TREATMENT

10.00. HYDROSTATIC AND PNEUMATIC TEST

11.0.0. RADIOIGRAPHIC EXAMINATION

12.0.0 ULTRASONIC EXAMINATION OF WELDED JOINTS

13.0.0. MAGNETIC PARTICLE OR LIQUID PENETRANT EXAMINATION

14.0.0. MOCK-UP TEST

INSPECTION AND TEST REQUIREMENT FOR:

CLASS - A1CLASS B1CLASS A2 & B2CLASS C1CLASS C2CLASS D

CLASS SCLASS SCCLASS MCLASS - T


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02 ES 019/ 94ENGINEERING

SPECIFICATION

INSPECTION AND TESTING OF VESSELSAND HEATEXCHANGERS PAGE 2 OF 18


1.0.0 SCOPE

1.1.0 This specification covers therequirements for the procedures ofinspection and tests to be carr ied out

by Vendor, and the acceptancestandards of FEDO to such procedure.

1.2.0 This specification shall apply to shopinspection arid tests of tanks, pressurevessels, shell-and-tube type heatexchangers, etc. (hereinafter referred toas vessel) fabricated in accordance withthe FEDO Engineering Specificationsand specified codes. The requirementsspecified in this spec, shall supplementthe requirements specified in thedesign and fabrication codes or otherstipulations mentioned elsewhere inthe enquiry/p.o spec.

1.3.0 SPECIAL REQUIREMENTS

1.3.1 Special requirements, if any specifiedalong with the eqpt. spec or theenquiry / P.O shall be supplementedto this specification.

1.4.0 VENDOR'S RESPONSIBILITY

1.4.1 Vendor shall carry out all inspectionand tests specified in this specification,and shall prepare the records for eachitem to show that the vessels having

been constructed in accordance withthe purchase order specifications.

1.5.0 All reference to FEDO shall meanFACT ENGINEERING ANDDESIGN ORGANISATION, theirclient, authorised representative,

third party inspector or statutoryauthority like IBR.

1.6.0 Any reference to vendor shall alsoinclude their sub-vendor, if any, asapplicable.

2.0.0 BASE DOCUMENTS

2.1.0 CODE AND STANDARDS

2.1.1 The codes and standards mentioned in theeqpt. data sheet / dwg. shall also bereferred.

2.2.0 SPECIFICATIONS AND DRAWINGS

2.2.1 Inspection and tests shall be carried outbased an FEDO specifications, andvendor drawings. Such specifications anddrawings shall be of the latest.

2.2.3 Where there are conflicts, at the time ofinspection and tests, between thespecifications and the drawings, FEDOshall be promptly notified.

2.3.0 VENDOR'S INSPECTIONPROCEDURE

2.3.1 Where application of any item in thisspecification is considered impractical,Vendor shall. prior to it to FEDO forapproval.

2.3.2 Vendor shall submit to FEDO his ownstandard inspection procedure (forspecial items) when so requested byFEDO.

3.0.0 WITNESSING

3.1.0 Witness inspection shall, as a rule, becarried out at Vendor's shop.

3.2.0 Witness (here in after referred to asFEDO inspector} shall, mean inspectorsof FEDO, his designated representative,customers and / or a third party.

3.3.0 At any time during manufacturing,FEDO inspector shall have free access toany of vendor1 shop concerned withmanufacture of the vessels.

3.4.0 Vendor shall provide all facilitiesreasonably necessary to satisfy FEDOinspector that the vessels are beingfurnished in accordance with thespecifications.

3.5.0 Inspections shall be witnessed by way ofstage inspection, and final inspection,depending on the design, fabricationmethods, and service Condition of thevessels.


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3.6.0 In general, items to be witnessed shallbe, prior to fabrication of the vessels,mutually agreed between Vendor andFEDO. Vendor shall submit to FEDO

a written request for witnessinginspection sufficiently in advance ofthe inspection operation to permitFEDO inspector to arrive at Vendor'sshop.

3.7.0 Vendor shall, at the time of inspection,submit to FEDO inspector one copy ofthe records of his own prior inspectionand tests. This copy shall be inaddition to the number specified in theVDR.

3.8.0 Witnessing by the FEDO Engineershall in no way relieve Vendor of hisresponsibility to meet thespecification.

4.0.0 INSPECTION AND TESTRECORDS

4.1.0 Vendor shall submit to FEDO thefollowing records of each vessel.

a. Material mill test certificate

b. Hydrostatic and pneumatic testc. Dimensional inspection

d. Non- destructive examination

e. Post weld heat treatment

f. Welding procedures andqualification

g. Production weld test

h. Other inspection and test, wherespecified

4.2.0 Vendor shall provide the followinginformation in the first part of all therecords of inspection and tests

a. Name of the client (end user)

b. Job No: Item No: and name of thevessel

c. Name of the manufacturer

d. Date of manufacture and inspection

e. Short specification of the vessel

5.0.0 INSPECTION AND TEST ITEMS

5.1.1 CLASSIFICATION OF VESSELS

Unless otherwise specified in the FEDOpurchase order spec. or drawings, theapplication of the inspection and tests for

each vessel shall be as shown in the Inspection and Test requirements forvarious classes (class A to T) as listed

below. The tables for various classes areattached at the end of this specification.However this list shall not limit / dilutethe code requirements.

ClassificationDesign Pressure

Material and serviceUp to 50

kg/cm2

g

50 kg/cm2

g and

above

Low alloy steel for high

temp service Mo, Cr-Mo,Mn-Mo, Mn-Mo-Ni

A1 A2

Carbon steels for high and

medium temp service

C, C-Si, Si-Mn (Designtemp>= -10

oC)

B1 B2

Carbon steels for low temp

service

(Design temp, -50oC to -

11oC)

C1 C2

Low alloy steels for low

temp service 2.5 Ni,3.5 Ni, (Design temp, -

105oC to -51

oC

D

Austenitic Stainless steel SAustenitic Stainless steelclad vessel

SC

Multi layer cylindrical vessel MStorage tank T

5.1.2 Where the application of any item in thelist is considered impractical. Vendorshall submit a suggested alternative in

detail to FEDO for approval.

5.1.3 Inspection and test items specified in thecodes and standards shall govern whereapplicable.

5.2.0 WELD JOINT LOCATIONS ANDCATEGORIESThe categories of the weld joints indicatedin the attached Inspection and TestRequirement tables are illustrated asfollows:


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5.2.1 Solid Single Wall Vessel : Refer fig.-15.2.2 Multi-Layer Wall Vessel : Refer fig. 2

A: Pressure retaining joint to besubjected to full load

B: Pressure retaining joint to besubjected to a half load

C: Fillet nozzle-to-flange welds

D: Shell-to-nozzle weldsE: Attachment welds

F: Butt welded joint of inner shellG: Longitudinal welded joint of shell

layer

H: Circumferential welded joint of fullthickness shell layer'

I: Circumferential shell layer-to-solid wall welds

J: Shell layer-to-nozzle weldsK: Fillet weld of shell layer wound

endT: Tube-to-tube plate welds

6.0.0 MATERIAL TEST

6.1.0 Vendor shall submit the mill testcertificates for the following:

a. Shell, Head, Nozzle

b. Tube plate, Channel cover, Flange

c. Tube, Tray made of alloy steel(Including high and low alloysteel such as C-Mo, Cr-Mo 3.S

Ni Steel,etc.)

d. Pressure retaining bolt and nut,and alloy steel (Including highand low alloy steel such as C-Mo, Cr-Mo 3.5 Ni Steel, etc.) boltand nut

6.2.0 Submission of mill test certificates formaterials may be exempted for any ofthe followings:

6.2.1 Materials conforming to IS-226Rolled Steel for General Structure andtheir ASTM equivalent (A 283 GR.C).

6.2.2 Stocked materials not used in pressureretaining parts. Stocked materialsused in pressure retaining parts, butnot for main parts, where their milltest certificates are not readilyobtainable. In such cases, Vendor'scertificates may be substituted forthe original mill test certificates.

6.2.3 Materials conforming with IS-1239.Carbon Steel Pipes for OrdinaryPiping or their ASTM equivalent;( A53 Type F).

6.3.0 Vendor shall, prior to fabrication ofthe vessel, check the charge numberand the following items for thematerials:

a. Chemical compositionsb. Mechanical properties

c. Heat treatmentd. Other items specified in the

applicable codes and standards.

6.4.0 Materials shall be free frominjurious defects, such as surfaceflaw and lamination, and these shall

be visually inspected.

6.5.0 Material conforming with AISI(Austenitic stainless steel containingmolybdenum) or their ASTM

equivalent not used in major parts of any


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SPECIFI

Technical Specification -LPG Heater

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