EPCM services for INDAdeptG unit at Guwahati Refinery

HEAT EXCHANGER CS/LAS+SS CLAD

(Document No : A457-057-EE-MR-6981)

Page 1 of 121

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

Table of ContentsDocument Number Rev. Document Title Page

NumberA457-057-EE-MR-6981

A HEAT EXCHANGER CS/LAS+SS CLAD 4

A457-057-16-46-DS-4016

0 DESIG 8

A457-057-16-46-DS-4016_02

0 DESIG 9

A457-057-16-46-DS-4016_03

0 DESIG 10

A457-057-05-45-4001

1 DESIG 11

A457-057-16-46-DS-4019_rev.1

1 DESIG 12

A457-057-16-46-DS-401902_rev.1

1 DESIG 13

A457-057-05-45-4004

0 DESIG 14

A457-057-16-46-SK-0003

0 DESIG 15

A457-057-16-46-SK-0004

0 DESIG 16

A457-057-16-46-SK-0005

0 DESIG 17

A457-057-16-46-SK-0006

0 DESIG 18

A457-80-41-SP-6981 A MR JOB SPECIFICATION 19A457-80-41-SS-6981 A SCOPE OF WORK AND SUPPLY 26A457-80-41-TL-6981 A GUIDELINES TO VENDOR FOR TUBE LAYOUT 28A457-80-41-TR-6981 A INSTRUCTIONS TO VENDOR/ TECHNICAL REQUIREMENTS 31A457-057-80-41-VDR-6981

A VDR FOR VDR COMPILATION 33

6-15-0001 4 General specification for heat exchangers. 366-15-0003 4 Standard specification for welded tube to tubesheet joints. 556-15-0091 3 Standard specification for hardness requirement of static

equipments (pressure vessels, heat exchanger).64

6-78-0001 1 Specification for quality management system requirements frombidders

69

6-78-0003 1 Specification for documentation requirement from suppliers 766-81-0001 2 Standard specification for Positive Material Identification (PMI) at

Supplier's Works85

6-81-0009 3 ITP for heat exchangers 937-15-0001 4 Part details (shell & tube exchangers). 1007-15-0002 4 Types of non standard gaskets (shell & tube exchangers) 1027-15-0005 4 Support for horizontal stack units (shell & tube exchangers) 1057-15-0006 4 Tube hole preparation and roller expanding (shell & tube

exchangers & air cooled heat exchangers)107

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

108

7-15-0008 4 Eye bolt detail (shell & tube exchangers) 1097-15-0009 4 Method of fastening nuts to the tie rods (shell & tube exchangers) 1107-15-0010 4 Jack screw tapping and arrangement (shell & tube exchangers) 1117-15-0011 4 Fixing detail of dowel pins (shell & tube exchangers) 1127-15-0013 4 Lifting lug detail (shell & tube exchangers) 1137-15-0014 4 Davit for shell & channel cover (shell & tube exchangers) 1147-15-0016 4 Earthig Lug (Shell & Tube Exchangers) 117

Page 2 of 121

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

Table of ContentsDocument Number Rev. Document Title Page

Number7-15-0017 4 Name plate (shell & tube exchangers) 1187-15-0019 4 Tolerances (shell & tube exchangers) 119

Page 3 of 121

ENGINEERS INDIA LIMITED

KOLKATA Client: IOCL

Project: INDADEPT G

File Name: U:\6891.pdf

Thi

s dr

awin

g, d

esig

n an

d de

tails

giv

en o

n th

is f

orm

at a

re th

e pr

oper

ty o

f E

NG

INE

ER

S IN

DIA

LIM

ITE

D. T

hey

are

mer

ely

loan

ed o

n th

e bo

rrow

er's

exp

ress

agr

eem

ent t

hat t

hey

will

not

be

repr

oduc

ed, c

opie

d, e

xhib

ited

or u

sed,

exc

ept i

n th

e lim

ited

way

per

mitt

ed b

y a

wri

tten

cons

ent g

iven

by

the

lend

er to

the

borr

ower

for

the

inte

nded

use

. EIL

-164

1-51

5 R

ev.1

A4-

210x

297.

Sheet 1 of 4

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

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

MR CATEGORY: I DELIVERY PERIOD: As per Commercial Documents

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

11/09/2015 80

JOB NO. UNIT/ AREA

MAINCOST

CENTRE

DOC.CODE

SR. NO. REV. DATE

41

DIVN. DEPT.

ORIGINATOR

NOTES :12

3

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

REV. DATE BY CHK. APPD. DETAILS

A 11/09/2015 ISSUED FOR BIDSRR PB PB

MATERIAL REQUISITION (TOP SHEET)

057 EE MR 6981 AA457

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

Page 4 of 121

ENGINEERS INDIA LIMITED

KOLKATA Client: IOCL

Project: INDADEPT G

File Name: U:\6891.pdf

Thi

s dr

awin

g, d

esig

n an

d de

tails

giv

en o

n th

is f

orm

at a

re th

e pr

oper

ty o

f E

NG

INE

ER

S IN

DIA

LIM

ITE

D. T

hey

are

mer

ely

loan

ed o

n th

e bo

rrow

er's

exp

ress

agr

eem

ent t

hat t

hey

will

not

be

repr

oduc

ed, c

opie

d, e

xhib

ited

or u

sed,

exc

ept i

n th

e lim

ited

way

per

mitt

ed b

y a

wri

tten

cons

ent g

iven

by

the

lend

er to

the

borr

ower

for

the

inte

nded

use

. EIL

-164

1-51

5 R

ev.1

A4-

210x

297.

Sheet 2 of 4

REQUISITION NO. REV.

AA457-057-EE-MR-6981

SR. NO.TAG NO/

ITEM CODE/ [ ID. NO. ] DESCRIPTION QUANTITY

01.00

02.0003.00

04.0005.00

06.00

07.0008.0009.00

Code compliance to residual design,procurement & supply of materials andbought out components, weld preparation,fabrication, assembly at shop, NDT,sacrificial anode cathodic protection,surafce preparation and application ofprimer, inspection including inspectionbyTPIA, testing at manufacture's works,packing (sea worthy, if imported), supplyof mandatory spares, supply ofaccessories like test ring, test flangeetc. and documentation as per theenclosed EIL standrad specifications,instruction to vendors, jobspecification, data sheet etc. and othercodes and standrads attached or referred.

<< DELETED >>Transportation from Vendors work/ shoptosite for the following as pertheenclosed EIL standardspecifications,instructions to vendors,jobspecification, data sheets etc.

<< DELETED >>Supply of Two Years OperationandMaintenance Spares, as per enclosedscopeof work and supply.Unit Rates

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

Lot

Lot

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

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

01.0101.02

03.0103.02

06.01

06.02

57-E-01A-F57-E-04A-D

{03}57-E-01A-F{03}57-E-04A-D

REACTOR FEED / EFFLUENT EXCHANGERCOMBUSTION GAS / EFFLUENT EXCHANGER

For Sr. No. 01.01For Sr. No. 01.02

Unit Rates of items for addition/deletionpurpose, as per the enclosedscope of workand supply.Unit Rates for Specific tests as per theenclosed instructions to vendor.

6 Nos4 Nos

6 Nos4 Nos

1

1

Page 5 of 121

ENGINEERS INDIA LIMITED

KOLKATA Client: IOCL

Project: INDADEPT G

File Name: U:\6891.pdf

Thi

s dr

awin

g, d

esig

n an

d de

tails

giv

en o

n th

is f

orm

at a

re th

e pr

oper

ty o

f E

NG

INE

ER

S IN

DIA

LIM

ITE

D. T

hey

are

mer

ely

loan

ed o

n th

e bo

rrow

er's

exp

ress

agr

eem

ent t

hat t

hey

will

not

be

repr

oduc

ed, c

opie

d, e

xhib

ited

or u

sed,

exc

ept i

n th

e lim

ited

way

per

mitt

ed b

y a

wri

tten

cons

ent g

iven

by

the

lend

er to

the

borr

ower

for

the

inte

nded

use

. EIL

-164

1-51

5 R

ev.1

A4-

210x

297.

Sheet 3 of 4

REQUISITION NO. REV.

AA457-057-EE-MR-6981

LIST OF ATTACHMENTS

SL.No. DOCUMENT TITLE DOCUMENT NO.

REVISION

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

Setting Plan / Section drawingfor Heat Exchanger item no.:57-E-01 (No. of sheets 3)Tube Layout for Heat Exchangeritem no.: 57-E-01 (No. ofsheets 1)Setting Plan / Section drawingfor Heat Exchanger item no.:57-E-04 (No. of sheets 2)Tube Layout for Heat Exchangeritem no.: 57-E-04 (No. ofsheets 1)Details of weld deposit onchannel flange and flange andpass partition plateDetail of insertion piece forpulling eye bolt in clad tubesheetSketch for lipped floatinghead flangeDetail of weld deposit onnozzle for claded exchanger

Job Specification for Shell &Tube Heat Exchangers (No ofsheets 7)Scope of work & supply forShell & Tube Heat Exchangers(No of sheets 7)Guide line to Vendor regardingTube Layout Preparation (Noof sheets 3 ) Instructions for submittingoffers for Shell & Tube HeatExchangers (No of sheets 2)

Vendor Data Requirements (Noof sheets 3)

General Specification for HeatExchangers (No of sheets 19)Standard specification forwelded tube to tubesheetjoints (No of sheets 9)Specification for qualitymanagement system requirementsfrom bidders (No of sheets7+2)Specification fordocumentation requirementsfrom suppliers (No of sheets8+1+1+1+1)

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

A457-057-16-46-DS-4016

A457-57-05-45-4001

A457-057-16-46-DS-4019

A457-57-05-45-4004

A457-057-16-46-SK-0003

A457-057-16-46-SK-0004

A457-057-16-46-SK-0005

A457-057-16-46-SK-0006

A457-80-41-SP-6981

A457-80-41-SS-6981

A457-80-41-TL-6981

A457-80-41-TR-6981

A457-057-80-41-VDR-6981

6-15-0001

6-15-0003

6-78-0001

6-78-0003

0 A B D

1

1 A B D

0

0

0

0

0

A

A

A

A

A

4

4

0

0

DRAWINGS

JOB SPECIFICATION

VENDOR DATA REQUIREMENTS

STANDARD SPECIFICATIONS

Page 6 of 121

ENGINEERS INDIA LIMITED

KOLKATA Client: IOCL

Project: INDADEPT G

Sheet 4 of 4

File Name: U:\6891.pdf

Thi

s dr

awin

g, d

esig

n an

d de

tails

giv

en o

n th

is f

orm

at a

re th

e pr

oper

ty o

f E

NG

INE

ER

S IN

DIA

LIM

ITE

D. T

hey

are

mer

ely

loan

ed o

n th

e bo

rrow

er's

exp

ress

agr

eem

ent t

hat t

hey

will

not

be

repr

oduc

ed, c

opie

d, e

xhib

ited

or u

sed,

exc

ept i

n th

e lim

ited

way

per

mitt

ed b

y a

wri

tten

cons

ent g

iven

by

the

lend

er to

the

borr

ower

for

the

inte

nded

use

. EIL

-164

1-51

5 R

ev.1

A4-

210x

297.

REQUISITION NO. REV.

AA457-057-EE-MR-6981

LIST OF ATTACHMENTS

SL.No. DOCUMENT TITLE DOCUMENT NO.

REVISION

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

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

GENERAL NOTES:

Standard Specification forPositive MaterialIdentification at Vendor'sWorks (No of sheets 8)Standard specification forhardness requirement (No. ofsheet 5)

Inspection and test plan forheat exchangers (No. ofsheets 8)

Part details (No. of sheets2)Type of Non-standard gaskets(No. of sheets 3)Support for horizontal stackunit (No. of sheets 2)Tube hole preparation androller expanding (No. ofsheets 1)Sliding/deflector strips totubesheet welding details(No. of sheets 1)Eye bolt detail (No. ofsheets 1)Method of fastening nuts totie rods (No. of sheets 1)Jack screw tapping arrangement (No. of sheets 1)Fixing detail of dowel pin(No. of sheets 1)Lifting lug detail (No. ofsheets 1)Davit for heat exchanger(shell & tube exchangers)(No. of sheets 3)Earthing Lug (No. of sheets1)Name plate for shell & tubeexchangers (No. of sheets 1)Tolerances (shell & tubeexchangers) (No. of sheets 3)

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

6-81-0001

6-15-0091

6-81-0009

7-15-0001

7-15-0002

7-15-0005

7-15-0006

7-15-0007

7-15-0008

7-15-0009

7-15-0010

7-15-0011

7-15-0013

7-15-0014

7-15-0016

7-15-0017

7-15-0019

2

2

2

4

4

4

4

4

4

4

4

4

4

4

4

4

4

STANDARD SPECIFICATIONS

STANDARD INSPECTION TEST PLAN

STANDARDS

Page 7 of 121

Pag

e 8

of

121

Pag

e 9

of

121

Pag

e 10

of

121

1-1641-0504 REV.0 A4-210x297

The

draw

ing,

des

ign

and

deta

ils g

iven

on

this

form

at a

re th

e pr

oper

ty o

f EN

GIN

EE

RS

IND

IA L

IMIT

ED

. The

y ar

e m

erel

y lo

aned

on

the

borr

ower

's e

xpre

ss a

gree

men

t tha

t the

yw

ill n

ot b

e re

prod

uced

, cop

ied,

exh

ibite

d or

use

d, e

xcep

t in

the

limite

d w

ay p

erm

itted

by

a w

ritte

n co

nsen

t giv

en b

y th

e le

nder

to th

e b

orro

wer

for t

he i

nten

ded

use

.

NEW DELHIENGINEERS INDIA LIMITED

REV.DRAWING NO.

APPD.APPD.CHECKEDBYREVISIONDATEREV.CLIENT: IOCL-GAUWAHATI

PROJECT:INDADEPT G

TUBE LAYOUTFOR

ITEM NO: 57-E-01 A/B/CA457-57-05-45-4001 1

SSJSKVKISSUED FOR ENGINEERING13.05.20130SSJSKKMBREISSUED FOR ENGINEERING14.06.20131

Pag

e 11

of

121

Pag

e 12

of

121

Pag

e 13

of

121

The

draw

ing,

des

ign

and

deta

ils g

iven

on

this

form

at a

re th

e pr

oper

ty o

f EN

GIN

EE

RS

IND

IA L

IMIT

ED

. The

y ar

e m

erel

y lo

aned

on

the

borr

ower

's e

xpre

ss a

gree

men

t tha

t the

yw

ill n

ot b

e re

prod

uced

, cop

ied,

exh

ibite

d or

use

d, e

xcep

t in

the

limite

d w

ay p

erm

itted

by

a w

ritte

n co

nsen

t giv

en b

y th

e le

nder

to th

e b

orro

wer

for t

he i

nten

ded

use

.

NEW DELHIENGINEERS INDIA LIMITED

REV.DRAWING NO.

APPD.APPD.CHECKEDBYREVISIONDATEREV.CLIENT:- IOCL GAUHATI

PROJECT:- INDA DEPT-G

TUBE LAYOUTFOR

ITEM NO: 57-E-04A457-57-05-45-4004 0

SS0 13.05.13 ISSUED FOR ENGG. VK JSK

Pag

e 14

of

121

bZ-vkbZ-,y

Pag

e 15

of

121

bZ-vkbZ-,y

Pag

e 16

of

121

Pag

e 17

of

121

Page 18 of 121

A 11.09.2015 ISSUED FOR BIDS RR PB PB

Rev. No Date Purpose Prepared by Checked by Approved by

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

SPECIFICATION NO. A457-80-41-SP-6981

Rev.A Page 1 of 7

JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

(INDAdept-G PROJECT)

JOB SPECIFICATION

FOR

SHELL & TUBE TYPE HEAT EXCHANGERS

Page 19 of 121

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

SPECIFICATION NO. A457-80-41-SP-6981

Rev.A Page 2 of 7

JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

(INDAdept-G PROJECT)

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

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

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

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

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

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

iii) Design data and materials of construction.

iv) Critical details like tube to tubesheet joint detail.

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

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

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

Sl. No. Item Nos.

1. 57-E-01A, 57-E-01B, 57-E-01C, 57-E-01D, 57-E-01E & 57-E-01F

2. 57-E-04 A, 57-E-04 B, 57-E-04 C & 57-E-04 D

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

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

Individual test rings/test flanges as listed against the items (refer sht 2 of spec # A457-80-41-SS-6981).

o Common test rings/test flanges for following items:

Sl. No. Item Nos.

1. -

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

Page 20 of 121

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

SPECIFICATION NO. A457-80-41-SP-6981

Rev.A Page 3 of 7

JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

(INDAdept-G PROJECT)

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

Sl.No. Item Nos.

1. -

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

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

o Based on enclosed tube layouts.

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

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

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

11. ACCEPTABLE ALTERNATIVES:

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

a) Shell side only

57-E-04 A/B/C/D

b) Tube side only

57-E-01 A/B/C/D/E/F

Both Shell & Tube sides

-

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

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

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

a) Tubes shall be procured in cold drawn condition.

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

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

Sl. No. Item Nos.

1 XX-E-XXX A/B

Page 21 of 121

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

SPECIFICATION NO. A457-80-41-SP-6981

Rev.A Page 4 of 7

JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

(INDAdept-G PROJECT)

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

FLANGES GASKET

MATERIAL HARDNESS (BHN) MATERIAL HARDNESS

(BHN)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

24. The heat exchangers should have free movement at sliding end on the supports to avoid any restriction during thermal expansion. The saddle of the exchanger should be at centre of the foundation bolt slot during erection. Only SS shims shall be used for equipment alignment.

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

Page 22 of 121

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

SPECIFICATION NO. A457-80-41-SP-6981

Rev.A Page 5 of 7

JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

(INDAdept-G PROJECT)

26. Nozzle schedule/thickness indicated on the drawings are minimum required. It shall be fabricator’s responsibility to select the nozzle schedule so that shrinkage or warping occurs during weld overlay.

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

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

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

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

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

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

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

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

34. For CS/LAS equipment only:

All production welding shall be examined by RT. In case vendor want to perform UT by TOFD technique in lieu of RT the same is acceptable subject to the following:

a) Thickness of plate is greater than 38mm.

b) With Code Case 2235, Automated UT incorporating TOFD and pulse echo probes or TOFD and Phased Array mounted on the same chassis that automatically traverses along the joints to be inspected and displaying both results simultaneously on a single screen may be considered in lieu of RT.

c) Calibration block of similar material/thickness shall be used. Calibration block shall have suitable notches to simulate longitudinal as well as transverse cracks on outside and inside surface. Setup should be capable of detecting defects on outside as well as inside while scanning from one surface only.

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

Page 23 of 121

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

SPECIFICATION NO. A457-80-41-SP-6981

Rev.A Page 6 of 7

JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

(INDAdept-G PROJECT)

representative. Based on which, the approval of the parties and their AUT system shall be given.

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

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

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

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

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

37. When spot radiography is specified the extent of radiography defined in Clause 5.3 of EIL specification 6-15-0001 shall be replaced as follows:

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

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

39. INSPECTION

Inspection requirements are as mentioned hereunder.

All materials including those used for internals shall be procured with stage-wise inspection. Stage wise and final inspection of equipments and its components shall be carried out by Third Party Inspection Agency. Quoted price shall include for the same.

For acceptable third party inspection agencies (TPIA), refer commercial documents.

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

Page 24 of 121

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

SPECIFICATION NO. A457-80-41-SP-6981

Rev.A Page 7 of 7

JOB SPECIFICATION FOR SHELL & TUBE HEAT EXCHANGERS

(INDAdept-G PROJECT)

40. TECHNICAL DOCUMENTATION REQUIRED WITH BID

The technical part of the bid document shall contain following:

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

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

o Any other documents as required in the MR.

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

Items quoted Refer Scope of work & supply Spec. No A457-80-41-SS-6981

Name of third party inspection agency.

INDICATES APPLICABILITY.

Page 25 of 121

A 11.09.2015 ISSUED FOR BIDS RR PB PB

Rev. No Date Purpose Prepared by Checked by Approved by

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

SPECIFICATION NO. A457-80-41-SS-6981 Rev.A

Page 1 of 2 SCOPE OF WORK & SUPPLY

FOR SHELL & TUBE HEATEXCHANGERS (INDAdept-G PROJECT)

SCOPE OF WORK & SUPPLY FOR

SHELL & TUBE HEAT EXCHANGERS

Page 26 of 121

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

SPECIFICATION NO. A457-80-41-SS-6981 Rev.A

Page 2 of 2 SCOPE OF WORK & SUPPLY

FOR SHELL & TUBE HEATEXCHANGERS (INDAdept-G PROJECT)

SCOPE OF WORK AND SUPPLY

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

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

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

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

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

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

11. Vendor to carry out design calculation and mention maximum allowable working pressure for shell side and tube side in vendor drawings.

EQUIPMENT SCHEDULE

SL NO

ITEM NO.

QUANTITY

NO. OF UNITS SHELLS PER

UNIT NO. OF TEST

RINGS NO. OF TEST

FLANGES NO. OF DUMMY

SHELLS

1 57-E-01 A/B/C/D/E/F

ONE SIX SIX - -

2 57-E-04 A/B/C/D ONE FOUR FOUR - -

(B) 2 years operation and maintenance Spares – Vendor shall quote the separate itemized price for this along with bid. Price for this shall not be considered for evaluation.

5% of fasteners (min 1 no.) for each size of installed fasteners and 15% of gasket (min. one set) for each installed gaskets.

NOTES:

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

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

Vendor’s Name :

Vendor’s Signature

With Seal/ Stamp :

Date :

Page 27 of 121

A 11.09.2015 ISSUED AS JOB SPECIFICATION RR PB PB

Rev. No Date Purpose Prepared by Checked by Approved by

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

SPECIFICATION NO. A457-80-41-TL-6981

Rev.A Page 1 of 3

GUIDE LINE TO VENDOR REGARDING TUBE LAYOUT PREPARATION

(INDAdept-G PROJECT)

GUIDE LINE TO VENDOR

REGARDING TUBE LAYOUT PREPARATION

Page 28 of 121

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

SPECIFICATION NO. A457-80-41-TL-6981

Rev.0 Page 2 of 3

GUIDE LINE TO VENDOR REGARDING TUBE LAYOUT PREPARATION

(INDAdept-G PROJECT)

SCOPE

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

GUIDELINES

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

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

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

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

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

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

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

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

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

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

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

Page 29 of 121

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

SPECIFICATION NO. A457-80-41-TL-6981

Rev.0 Page 3 of 3

GUIDE LINE TO VENDOR REGARDING TUBE LAYOUT PREPARATION

(INDAdept-G PROJECT)

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

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

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

Shell ID (mm) Notch width (mm)

Less than 300 : 6

300 to 600 : 10

Greater than 600 : 12

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

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

TABLE - 1 MINIMUM SIZE OF SLIDING STRIPS

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

Less than 432 -- --

433 to 812 50 16

813 to 1092 60 18

1093 to 1524 70 20

1525 & above 100 25

Page 30 of 121

A 11.09.2015 ISSUED FOR BIDS RR PB PB

Rev. No Date Purpose Prepared by Checked by Approved by

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

SPECIFICATION NO. A457-80-41-TR-6981 Rev. A

Page 1 of 2

INSTRUCTIONS FOR SUBMITTING OFFERS FOR S & T HEAT EXCHANGERS

(INDAdept-G PROJECT)

INSTRUCTIONS FOR

SUBMITTING OFFERS FOR

SHELL & TUBE TYPE HEAT EXCHANGERS

Page 31 of 121

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

SPECIFICATION NO. A457-80-41-TR-6981 Rev. A

Page 2 of 2

INSTRUCTIONS FOR SUBMITTING OFFERS FOR S & T HEAT EXCHANGERS

(INDAdept-G PROJECT)

GUIDE LINES TO BIDDER FOR SUBMITTING OFFER

A) BIDDING INSTRUCTION (CATEGORY-I)

1. Bidder to note that no correspondence whatsoever shall be entered in to or entertained after the bid submission.

2. Bidder to furnish quotations only for those items, which he is approved by EIL and which he can supply strictly as per MR specifications.

3. No technical details of any nature shall be included in the offer. If the offer contains any technical deviations or clarifications or stipulates any technical specifications (even if in line with MR requirements), the offer is liable for rejection.

4. The submission of prices by bidder shall be construed to mean that he has confirmed compliances with all technical specification of corresponding item(s).

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

Page 32 of 121

VENDOR DATA REQUIREMENTS

FOR

HEAT EXCHANGER

A 11-SEP-2015 ISSUED FOR BIDS RR PB PB

Rev.No.

Date Purpose Prepared by Checked by Approved by

VENDOR DATA REQUIREMENTSFOR

HEAT EXCHANGER of 3

Document No.A457-057-80-41-VDR-6981

Rev. A

Page 1

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

Page 33 of 121

VENDOR DATA REQUIREMENTS

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

HEAT EXCHANGERS

S.NO.

DESCRIPTION WITHBID

POST ORDERREMARKSFOR

REVIEWFOR

RECORD

WITHDATABOOK

(FINAL)

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

Duration ofsubmission: 4 weeksafter LOI

2. TUBE BUNDLE DETAILS Duration ofsubmission: 4 weeksafter LOI

3. DETAIL OF NOZZLES AND EXCHANGERSUPPORT

Duration ofsubmission: 4 weeksafter LOI

4. DETAILS OF GASKETS Duration ofsubmission: 4 weeksafter LOI

5. LIST OF SPARE PARTS WITH DETAILS Duration ofsubmission: 4 weeksafter LOI

6. MANUFACTURER'S DATA REPORT

7. HEAT EXCHANGER DETAILED DRAWINGSAND PARTS LIST

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

9. INSPECTION AND TESTING PLAN @ Duration ofsubmission: 4 weeksafter LOI

10. WELDING PROCEDURES ANDQUALIFICATION TEST REPORTS @

Duration ofsubmission: 4 weeksafter LOI

11. DESTRUCTIVE AND NON-DESTRUCTIVETEST REPORTS @

12. MATERIAL TEST CERTIFICATES @ Duration ofsubmission: 4 weeksafter LOI

13. RADIOGRAPHIC EXAMINATION REPORTSWITH FILMS @

14. HEAT TREATMENT PROCEDURE AND TIMETEMPERATURE CHARTS @

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

16. PACKING AND FORWARDINGINSTRUCTIONS @

17. AS BUILT S. NO.: 1-5

VENDOR DATA REQUIREMENTSFOR

HEAT EXCHANGER of 3

Document No.A457-057-80-41-VDR-6981

Rev. A

Page 2

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

Page 34 of 121

Notes :

1. "TICK" denotes applicability.

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

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

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

submission through EIL eDMS.

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

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

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

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

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

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

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

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

VENDOR DATA REQUIREMENTSFOR

HEAT EXCHANGER of 3

Document No.A457-057-80-41-VDR-6981

Rev. A

Page 3

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

Page 35 of 121

Page 36 of 121

Page 37 of 121

Page 38 of 121

Page 39 of 121

Page 40 of 121

Page 41 of 121

Page 42 of 121

Page 43 of 121

Page 44 of 121

Page 45 of 121

Page 46 of 121

Page 47 of 121

Page 48 of 121

Page 49 of 121

Page 50 of 121

Page 51 of 121

Page 52 of 121

Page 53 of 121

Page 54 of 121

STANDARD SPECFICATION ENGINEERS FOR WELDED INDIA LIMITED

) IA Govt of India UndenakIng) TUBE TO TUBESHEET JOINTS

STANDARD SPECIFICATION No.

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

(Q ,1611 ZaTeZ •71) {CPR TrriW 'WU

STANDARD SPECIFICATION FOR WELDED

TUBE TO TUBESHEET JOINTS

4 07.06.13 REAFFIRMED AND REISSUED AS STANDARD SPECIFICATION

3 28.01.08 REAFFIRMED AND REISSUED AS STANDARD SPECIFICATION

REVISED AND REISSUED AS STANDARD 2 01.09.99 HN PK SPECIFICATION

RKT/SC DM

AKM

RKA AS

KA PK

VC

1 04.05.89 ISSUED AS STANDARD SPECIFICATION RKA BSG VKM RNS

Rev. No. Date Purpose Prepared Checked

by by

Standards Standards Committee Bureau Convenor Chairman

Approved by

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

Copyright EIL — All rights reserved Page 55 of 121

ENGINEERS STANDARD SPECFICATION STANDARD SPECIFICATION No.

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

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

0ll6iel Ogee

Abbreviations:

API ASME AWS OD TEMA TIG

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

Static Equipment Standards Committee

Convenor :

Members:

Mr. R K Trivedi

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

Copyright EIL — All rights reserved Format No. 8-00-0001-F1 Rev. 0 Page 56 of 121

ENGINEERS STANDARD SPECFICATION Igar 22egWv INDIA LIMITED FOR WELDED

IA Govt of InOta Undertaking) TUBE TO TUBESHEET JOINTS

STANDARD SPECIFICATION No.

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

CONTENTS

1.0 SCOPE 4

2.0 APPLICABLE CODES AND STANDARDS 4

3.0 WELDING PROCESS AND JOINT DETAIL 4

4.0 WELDING PROCEDURE QUALIFICATION 4

5.0 WELDERS QUALIFICATION 6

6.0 PREPARATION OF TUBES AND TUBESHEET 6

7.0 WELDING 6

8.0 EXAMINATION OF JOINTS 7

9.0 TUBE EXPANDING 7

10.0 REPAIRS 7

11.0 TEST AND REPAIR REPORTS 7

APPENDIX-1 - JOINT DETAILS

APPENDIX-2 - DETAILS OF TEST SPECIMENS

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

Copyright EIL — All rights reserved Page 57 of 121

ENGINEERS STANDARD SPECFICATION STANDARD SPECIFICATION No.

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

1.0 SCOPE

1.1

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

2.0 APPLICABLE CODES AND STANDARDS

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

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

3.0 WELDING PROCESS AND JOINT DETAIL

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

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

4.0 WELDING PROCEDURE QUALIFICATION

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

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

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

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

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

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

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

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

Copyright EIL — All rights reserved Page 58 of 121

STANDARD SPECIFICATION No.

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

ei ENGINEERS STANDARD SPECFICATION ligar Offleu INDIA LIMITED FOR WELDED

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Copyright EIL — All rights reserved Format No. 8-00-0001-F1 Rev. 0 Page 59 of 121

" ENGINEERS STANDARD SPECFICATION kiVeGVIW' INDIA LIMITED FOR WELDED

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

STANDARD SPECIFICATION No.

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

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

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

5.0 WELDERS QUALIFICATION

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

6.0 PREPARATION OF TUBES AND TUBESHEET

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

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

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

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

7.0 WELDING

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

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

Copyright EIL — All rights reserved

Page 60 of 121

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

Govt of Indo Undertaking) TUBE TO TUBESHEET JOINTS

STANDARD SPECIFICATION No.

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

8.0 EXAMINATION OF JOINTS

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

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

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

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

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

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

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

9.0 TUBE EXPANDING

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

10.0 REPAIRS

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

11.0 TEST AND REPAIR REPORTS

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

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

Copyright EIL — All rights reserved Page 61 of 121

FIG-2

D = 1.6t TO 2t

FIG-6

W= t R = t

D = t FOR t<3 AND

= 0.6t FOR t >3

APPENDIX 1 - JOINT DETAILS

w i t

FIG-1

W t

FIG-3

FIG-5

FIG-7

FIG-4

t or 3 WHICHEVER IS MORE

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

STANDARD SPECIFICATION No.

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

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

Page 62 of 121

30 30 * *

I I

O

It

It

O

FIG-12

STANDARD SPECIFICATION No.

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

el 5igat Rift

1***clecrnetv3*,,,*)

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

APPENDIX 2 - DETAILS OF TEST SPECIMENS

* - - EDOG O+W+ * Act

FIG-11

* 1

NOTE:-

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

*

*

BUNDLE SIDE

FIG-13 FOR PLUG TYPE AIRCOOLERS

I I I

FIG-14 FIG-15

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

Copyright EIL — All rights reserved Format No. 8-00-0001-F1 Rev. 0 Page 63 of 121

1 26.03.04 REAFFIRMED AND REISSUED AS

STANDARD SPECIFICATION

Rev. No

Date Purpose

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

VB RKG AKM N.DUARI

NSK PK SSA SKG

RV SSA RKA AS

Prepared by

Checked by

Standards Committee Convenor

Standards Bureau

Chairman

Approved by

3 05.11.14 REVISED & REISSUED AS STD. SPEC.

2 29.06.09 REAFFIRMED & REISSUED AS STD. SPEC.

0 15.03.96 ISSUED AS STANDARD SPECIFICATION

l511

£;12e5 man ,roxt asTararr,

STANDARD SPECIFICATION STANDARD SPECIFICATION No. ENGINEERS

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

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

if[R4

r(N-R 4-11-ich

STANDARD SPECIFICATION FOR

HARDNESS REQUIREMENT OF

STATIC EQUIPMENTS (PRESSURE VESSELS, HEAT EXCHANGER)

Page 64 of 121

STANDARD SPECIFICATION STANDARD SPECIFICATION No.

Og—a[ f&if51 2.12ErreM1.3.7..11

Page 2 of 5

Abbreviations:

ASTM

BHN

HAZ

PWHT

American Society for Testing & Materials

Brinell Hardness Number

Heat Affected Zone

Post Weld Heat Treatment

Static Equipment

Convenor : Mr.

Standards Committee

R.K. Trivedi

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

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

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

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

Page 65 of 121

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

Page 3 of 5

CONTENTS

1.0 SCOPE 4

2.0 HARDNESS REQUIREMENTS 4

3.0 WELDING QUALIFICATION TEST 4

4.0 PRODUCTION TEST 4

5.0 APPROVAL 5

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

Page 66 of 121

441, rs'enl L151,7,77.1

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

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

1.0 SCOPE

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

2.0 HARDNESS REQUIREMENTS

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

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

3.0 WELDING QUALIFICATION TEST

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

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

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

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

4.0 PRODUCTION TEST

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

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

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

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

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

Page 67 of 121

ON CROSS SECTION (TYP)

HEAT AFFECTED ZONE

HEAT AFFECTED ZONE (TYP)

"I‘

3(TYP)

VICKERS HARDNESS TEST

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

Page 5 of 5

5.0 APPROVAL

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

BRINELL HARDNESS TEST

FIG.1- HARDNESS REQUIREMENT ON TEST COUPONS

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

Page 68 of 121

QMSStandardsCommittee

1 12.03.15 General Revision

QMS

QMS0 04.06.09 Issued as Standard Specification

Standards

Standards SCT

NDCommittee

Committee

Rev.No Date Purpose Prepared by Checked

by

StandardsCommitteeConvener

StandardsBureau

Chairman

QMSStandardsCommittee

MPJ

SC

ENGINEERSlakgINDIA LIMITED

(A Gavt at India Undertaking)

SPECIFICATION FOR QUALITYMANAGEMENT SYSTEMREQUIREMENTS FROM

BIDDERS

STANDARD SPECIFICATION No.

6-78-0001 Rev. 1Page 1 of 7

mren ewaire mjvam)

64)(11 Chrlf qu i ciall -51-04ffu tea aliikrrat t ?drift'

SPECIFICATION FOR QUALITYMANAGEMENT SYSTEM

REQUIREMENTS FROM BIDDERS

Approved by

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

Copyright EIL — All rights reservedPage 69 of 121

ENGINEERS SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.

INDIA LIMITED SYSTEM 6-78-0001 Rev. 1lft2 (AG'"ind'Undelt6ung) REQUIREMENTS FROM BIDDERS Page 2 of 7

Abbreviations:

CV Curriculum Vitae

ISO International Organization for Standardization

MR Material Requisition

PO Purchase Order

PR Purchase Requisition

QA Quality Assurance

QMS Quality Management System

QMS Standards Committee

Convener: Mr. M.P. Jain

Members: Mr. A.K. Chaudhary (Insp.)Mr. S.K. Kaul (C&P)Mr. R.K. Trivedi (Engg.)Mr. Ravindra Kumar (Const.)Mr. Tilak Raj (Projects)Mr. Vinod Kumar (CQA)

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

Page 70 of 121

ENGINEERS SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.

INDIA LIMITED SYSTEM 6-78-0001 Rev.'A

Govt At ' nth' Und"k"V) REQUIREMENTS FROM BIDDERS Page 3 of 7Igar llks

Oiren

CONTENTS

Clause Title Page

No.

1.0 SCOPE 4

2.0 DEFINITIONS 4

3.0 REFERENCE DOCUMENTS 4

4.0 QUALITY MANAGEMENT SYSTEM — GENERAL 4

5.0 QUALITY SYSTEM REQUIREMENTS 4

6.0 AUDITS 7

7.0 DOCUMENTATION REQUIREMENTS 7

Copyright EIL — All rights reservedFormat No. 8-00-0001-F1 Rev. 0Page 71 of 121

el ENGINEERS SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.

$1g-zg faReg INDIA LIMITED MANAGEMENT SYSTEM 6-78-0001 Rev. 1

own 120.2 .I J40.9) IA GOVt of India Undertaking) REQUIREMENTS FROM BIDDERS Page 4 of 7

1.0 SCOPE

This specification establishes the Quality Management System requirements to bemet by BIDDER for following purpose:

• QMS requirements to be met by suppliers/contractors after award of work/during contract execution.

2.0 DEFINITIONS

2.1 Bidder

For the purpose of this specification, the word "BIDDER" means the person(s), firm,company or organization who is under the process of being contracted by EIL /Owner for delivery of some products (including service). The word is consideredsynonymous to supplier, contractor or vendor.

2.2 Project Quality Plan

Document tailored from Standard Quality Management System Manual of BIDDER,specifying how the quality requirements of the project will be met.

2.3 Owner

Owner means the owner of the project for which services / products are beingpurchased and includes their representatives, successors and assignees.

3.0 REFERENCE DOCUMENTS

6-78-0002

Specification for Documentation Requirements fromContractors

6-78-0003

Specification for Documentation Requirements from Suppliers

4.0 QUALITY MANAGEMENT SYSTEM — GENERAL

Unless otherwise agreed with EIL / Owner, the BIDDER proposed quality systemshall fully satisfy all relevant requirements of ISO 9001 "Quality ManagementSystems — Requirements." Evidence of compliance shall be current certificate ofquality system registration to ISO 9001 or a recent compliance audit recommendingregistration from a certification agency. The quality system shall provide theplanned and systematic control of all quality related activities for execution ofcontract. Implementation of the system shall be in accordance with BIDDER'SQuality Manual and PROJECT specific Quality Plan.

5.0 QUALITY SYSTEM REQUIREMENTS

5.1 BIDDER shall prepare and submit for review / record, Project Quality Plan / QualityAssurance Plan for contracted scope / job. The BIDDER'S Quality Plan shalladdress all of the applicable elements of ISO 9001, identify responsible partieswithin BIDDER'S organization, for the implementation / control of each area,reference the applicable procedures used to control / assure each area, and verifythe documents produced for each area. The Project Quality Plan shall necessarilydefine control or make reference to the relevant procedures, for design andengineering, purchase, documentation, record control, bid evaluation, inspection,production/manufacturing, preservation, packaging and storage, quality control at

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

Copyright EIL — All rights reservedPage 72 of 121

ENGINEERS SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.

INDIA LIMITED MANAGEMENT SYSTEM 6-78-0001 Rev. 1(A Gavt of India undertaking' REQUIREMENTS FROM BIDDERS Page 5 of 7

construction site, pre-commissioning, commissioning and handing over (asapplicable) in line with contract requirement and scope of work.

5.2 BIDDER shall identify all specified or implied statutory and regulatory requirementsand communicate the same to all concerned in his organization and his subcontractor's organization for compliance.

5.3 BIDDER shall deploy competent and trained personnel for various activities forfulfillment of PO / contract. BIDDER shall arrange adequate infrastructure and workenvironment to ensure that the specification and quality of the deliverable aremaintained.

5.4 BIDDER shall do the quality planning for all activities involved in delivery of order.The quality planning shall cover as minimum the following:

ResourcesProduct / deliverable characteristics to be controlled.Process characteristics to ensure the identified product characteristics are

realizedIdentification of any measurement requirements, acceptance criteriaRecords to be generatedNeed for any documented procedure

The quality planning shall result into the quality assurance plan, inspection and testplans (ITPs) and job procedures for the project activities in the scope of bidder.These documents shall be submitted to EIL/Owner for review/approval, beforecommencement of work.

5.5 Requirements for sub-contracting / purchasing of services specified in contract /tender shall be adhered to. In general all outsourced items will be from approvedvendors of EIL. Wherever requirements are not specified, or approved sub vendorsdo not exist, the sub-contractor shall establish and maintain a system for purchasing/ sub-contracting to ensure that purchased product / service conforms to specifiedrequirements. Criteria for selection of sub-contractor, evaluation, re-evaluation,maintenance of purchasing data and verification of purchased product (sub-contractor services), constitute important components of this requirement.

5.6 BIDDER shall plan and carry production and service provision under controlledconditions. Controlled conditions shall include, as applicable

the availability of information that describes the characteristics of the productthe availability of work instructionsthe use of suitable equipmentthe availability and use of monitoring and measuring devicesthe implementation of monitoring and measurementthe implementation of release, delivery and post-delivery activities

5.7 BIDDER shall validate any processes for production and service provision whereresulting output cannot be verified by subsequent monitoring and measurement.This includes any process where deficiencies become apparent only after theproduct is in use or service has been delivered.

5.8 BIDDER shall establish a system for identification and traceability of product /deliverable throughout product realization. Product status with respect to inspectionand testing requirements shall be identified.

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

Page 73 of 121

ei ENGINEERS SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.

lge.ji id5fez INDIA LIMITED MANAGEMENT SYSTEM 6-78-0001 Rev. 1IA Govt of India undettaking) REQUIREMENTS FROM BIDDERS Page 6 of 7

Oren erRRIZ .71.1.113,70

5.9 BIDDER shall identify, verify, protect and safeguard EIL / Owner property (material /document) provided for use or incorporation into the product. If any Owner / EILproperty is lost, damaged or otherwise found to be unsuitable for use, this shall bereported to the EIL / Owner.

5.10 BIDDER shall ensure the conformity of product / deliverable during internalprocessing and delivery to the intended destination. Requirements mentioned in thetender shall be adhered to.

5.11 BIDDER shall establish system to ensure that inspection and testing activities arecarried out in line with requirements. Where necessary, measuring equipmentsshall be calibrated at specified frequency, against national or internationalmeasurement standards; where no such standard exists, the basis used forcalibration shall be recorded. The measuring equipments shall be protected fromdamage during handling, maintenance and storage.

5.12 BIDDER shall ensure effective monitoring, using suitable methods, of the processesinvolved in production and other related processes for delivery of the scope ofcontract.

5.13 BIDDER shall monitor and measure the characteristics of the product/deliverable toverify that product requirement has been met. The inspection (stage as well asfinal) by BIDDER and EIL / Owner personnel shall be carried out strictly as per theITPs forming part of the contract. Product release or service delivery shall notproceed until the planned arrangements have been satisfactorily completed, unlessotherwise approved by relevant authority and where applicable by Owner / EIL.

5.14 BIDDER shall establish and maintain a documented procedure to ensure that theproduct which does not conform to requirements is identified and controlled toprevent its unintended use or delivery

5.15 All non-conformities (NCs) / deficiencies found by the BIDDER'S inspection /surveillance staff shall be duly recorded, including their disposal action shall berecorded and resolved suitably. Effective corrective and preventive action shall beimplemented by the BIDDER so that similar NCs including deficiencies do not recur.

5.16 All deficiencies noticed and reported by EIL / Owner shall be analyzed by theBIDDER and appropriate corrective and preventive actions shall be implemented.BIDDER shall intimate EIL / Owner of all such corrective and preventive actionimplemented by him.

5.17 BIDDER should follow the standards, specifications and approved drawings.Concessions/Deviations shall be allowed only in case of unavoidable circumstances.In such situations Concession/deviation request must be made by the BIDDERthrough online system of EIL eDMS. URL of EIL eDMS ishttp://edocx.eil . co . in/vportal.

5.18 BIDDER shall have documented procedure for control of documents.

5.19 All project records shall be carefully kept, maintained and protected for any damageor loss until the project completion, then handed over to EIL / Owner as per contractrequirement (Refer Specification Nos. 6-78-0002 - Specification for DocumentationRequirements from Contractors and 6-78-0003 - Specification for DocumentationRequirements from Suppliers), or disposed as per relevant project procedure.

Copyright EIL—All rights reservedFormat No. 8-00-0001-F1 Rev. 0Page 74 of 121

ENGINEERS SPECIFICATION FOR QUALITY STANDARD SPECIFICATION No.

INDIA LIMITED MANAGEMENT SYSTEM 6-78-0001 Rev. 1(A Goof of India UndertakIngi REQUIREMENTS FROM BIDDERS Page 7 of 7

eiJrIft kif51ft.wirer riraxem3Tmil

6.0 AUDITS

BIDDER shall plan and carry out the QMS audit for the job. Quality audit programmeshall cover design, procurement, construction management and commissioning asapplicable including activities carried out by sub-vendors and sub-contractors. Thisshall be additional to the certification body surveillance audits carried out underBIDDER'S own ISO 9001 certification scheme.

The audit programmes and audit reports shall be available with bidder for scrutinyby EIL / Owner. EIL or Owner's representative reserves the right to attend, as awitness, any audit conducted during the execution of the WORKS.

In addition to above EIL, Owner and third party appointed by EIL/Owner may alsoperform Quality and Technical compliance audits. BIDDER shall provide assistanceand access to their systems and sub-contractor / vendor systems as required for thispurpose. Any deficiencies noted shall be immediately rectified by BIDDER.

7.0 DOCUMENTATION REQUIREMENTS

BIDDER shall submit following QMS documents immediately after award of work(Within one week) for record / review by EIL / Owner.

Organization chart (for complete organization structure and for the project)Project Quality Plan/Quality Assurance PlanJob specific Inspection Test Plans, if not attached with PRJob ProceduresInspection/Test Formats

In addition to above QMS documents, following documentation shall be maintainedby the BIDDER for submission to EIL / Owner on demand at any point of time duringexecution of the project.

Quality ManualCertificate of approval for compliance to ISO: 9001 standardProcedure for Control of Non-conforming ProductProcedure for Control of DocumentsSample audit report of the QMS internal and external audits conducted duringlast one yearCustomer satisfaction reports from at least 2 customers, during the last oneyearProject QMS audit reportTechnical audit reports for the projectCorrective action report on the audits

Documents as specified above are minimum requirements. BIDDER shall submitany other document/data required for completion of the job as per EIL/Ownerinstructions.

Copyright EIL—All rights reservedFormat No. 8-00-0001-F1 Rev. 0Page 75 of 121

1 12.03.15 General Revision

C)(415----2QMS QMS

Standards StandardsCommittee Committee

SC

∎31 ENGINEERSligar lafgesW INDIA LIMITED

(411W1 292,51V MIJ‘10571) Govt o India Undertalongj

SPECIFICATION FORDOCUMENTATION

REQUIREMENTS FROMSUPPLIERS

STANDARD SPECIFICATION No.

6-78-0003 Rev. 1Page 1 of 8

affrirewufat 74ER

*mat t feituSPECIFICATION FOR

DOCUMENTATION REQUIREMENTSFROM SUPPLIERS

QMS QMS0 04.06.09 Issued as Standard Specification

Standards Standards SCT NDCommittee Committee

Rev.No Date Purpose Prepared Checked

by by

Standards StandardsComm ifte BureauConvener Chairman

Approved by

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reservedPage 76 of 121

STANDARD SPECIFICATIONNo.

6-78-0003 Rev. 1Page 2 of 8

(t,ft. ENGINEERS1i laWGNIIY INDIA LIMITEDogire, efiTIWAnowAl (A Govt of Into Undertaking(

SPECIFICATION FORDOCUMENTATION

REQUIREMENTS FROMSUPPLIERS

Abbreviations:

DCI - Document Control Index

eDMS - Electronic Document Management System

FOA Fax of Acceptance

HOD Head of Division / Department

IC Inspection Certificate

IRN Inspection Release Note

ITP Inspection and Test Plan

LOA Letter of Acceptance

MOU Memorandum of Understanding

MR Material Requisition

PO Purchase Order

PR Purchase Requisition

PVC Polyvinyl Chloride

QMS Quality Management System

TPIA Third Party Inspection Agency

URL Universal Resource Locator

QMS Standards Committee

Convener: Mr. M.P. Jain

Members: Mr. A.K. Chaudhary (Insp.)Mr. S.K. Kaul (C&P)Mr. R.K. Trivedi (Engg.)Mr. Ravindra Kumar (Const.)Mr. Tilak Raj (Projects)Mr. Vinod Kumar (CQA)

Copyright EIL — All rights reservedFormat No. 8-00-0001-F1 Rev. 0Page 77 of 121

SPECIFICATION FORDOCUMENTATION

REQUIREMENTS FROMSUPPLIERS

STANDARD SPECIFICATIONNo.

6-78-0003 Rev. 1Page 3 of 8

ei ENGINEERSOaez idiWIeg INDIA LIMITED

011E71 ewaxedaagem) (A Govt of India Undertaking)

CONTENTS

Clause Title PageNo.

1.0 SCOPE 42.0 DEFINITIONS 43.0 REFERENCE DOCUMENTS 44.0 DOCUMENTATION REQUIREMENTS 4

Attachments

Format for completeness of Final Documentation Format No. 3-78-0004

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

Copyright EIL — All rights reservedPage 78 of 121

ENGINEERSINDIA LIMITED(A Govt of Intha Undertakongt

SPECIFICATION FORDOCUMENTATION

REQUIREMENTS FROM

STANDARD SPECIFICATIONNo.

6-78-0003 Rev. 1dol

5'gzir tlf5ltuI.VOM

SUPPLIERS Page 4 of 8

1.0 SCOPE

This specification establishes the Documentation Requirements from Suppliers.

All documents/data against the PO / PR / MR shall be developed and submitted toEIL/Owner by the suppliers for review / records, in line with this specification.

2.0 DEFINITIONS

2.1 Supplier

For the purpose of this specification, the word "SUPPLIER" means the person(s),firm, company or organization who is under the process of being contracted by EIL /Owner for delivery of some products (including service). The word is consideredsynonymous to bidder, contractor or vendor.

2.2 Owner

Owner means the owner of the project for which services / products are beingpurchased and includes their representatives, successors and assignees.

3.0 REFERENCE DOCUMENTS

6-78-0001 Specification for Quality Management System Requirementsfrom Bidders

4.0 DOCUMENTATION REQUIREMENTS

4.1 Documents/Data to be Submitted by the Supplier

4.1.1 The Supplier shall submit the documents and data against the PO/PR/MR as per thelist given in respective PO/PR/MR.

4.1.2 Review of the supplier drawings by EIL would be only to review the compatibility withbasic designs and concepts and in no way absolve the supplier of hisresponsibility/contractual obligation to comply with PR requirements, applicablecodes, specifications and statutory rules/regulations. Any error/deficiency noticedduring any stage of manufacturing/execution/installation shall be promptly correctedby the supplier without any time and cost implications, irrespective of comments onthe same were received from EIL during the drawing review stage or not.

4.1.3 Unless otherwise specified, submission of documents for Review/Records shallcommence as follows from the date of Fax of Intent / Letter of Intent/ Fax ofAcceptance (FOA)/ Letter of Acceptance (LOA):

QMS - 1 weekDrawing/Document Control Index - 2 weeksOther Documents/Drawings - As per approved Drawing/Document Control

Index/Schedule

4.1.4 Documents as specified in PO/PR/MR are minimum requirements. Supplier shallsubmit any other document/data required for completion of the job as per EIL/Ownerinstructions.

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

Copyright EIL — All rights reservedPage 79 of 121

'7f 11I OfiTt cYeawlnn

ENGINEERSINDIA LIMITED(A Govt of India UndenakIngi

SPECIFICATION FORDOCUMENTATION

REQUIREMENTS FROMSUPPLIERS

STANDARD SPECIFICATIONNo.

6-78-0003 Rev. 1Page 5 of 8

4.2 Style and Formatting

4.2.1 All Documents shall be in ENGLISH language and in M.K.S System of units.

4.2.2 Before forwarding the drawings and documents, contractor shall ensure that thefollowing information are properly mentioned in each drawing:

Purchase Requisition NumberName of Equipment / PackageEquipment / Package Tag No.Name of ProjectClientDrawing / Document TitleDrawing / Document No.Drawing / Document Revision No. and Date

43 Review and Approval of Documents by Supplier

4.3.1 The Drawing/Documents shall be reviewed, checked, approved and dulysigned/stamped by supplier before submission. Revision number shall be changedduring submission of the revised supplier documents and all revisions shall behighlighted by clouds. Whenever the supplier require any sub-supplier drawings to bereviewed by EIL, the same shall be submitted by the supplier after duly reviewed,approved and stamped by the supplier. Direct submission of sub-supplier's drawingswithout contractor's approval shall not be entertained.

4.4 Document Category

4.4.1 Review Category

Following review codes shall be used for review of supplier Drawings/Documents:

Review Code 1 No comments. Proceed with manufacture/fabrication as per the document.

Review Code 2 Proceed with manufacture/fabrication as percommented document. Revised documentrequired.

Review Code 3 Document does not conform to basicrequirements as marked. Resubmit for review

R Document is retained for Records. Proceedwith manufacture/fabrication.

V Void

4.5 Methodology for Submission of Documents to EIL/Owner

4.5.1 Document Control Index (DCI)

Supplier shall create and submit Document Control Index (DCI) for review based onPO/PR/MR along with schedule date of submission of each drawing/document on EILeDMS. The DCI shall be specific with regard to drawing/document no. and the exacttitle. Proper sequencing of the drawings/documents should be ensured in scheduledate of submission.

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

Page 80 of 121

r1.7-14 ENGINEERS51g-a feff5leg INDIA LIMITED

1.17,124ifflsrefloJOORI1 IA GUN. of India Undertaking,

SPECIFICATION FORDOCUMENTATION

REQUIREMENTS FROMSUPPLIERS

STANDARD SPECIFICATIONNo.

6-78-0003 Rev. 1Page 6 of 8

4.5.2 Submission of Drawings/Documents

Drawings/documents and data shall be uploaded on the EIL eDMS Portal as per DCI.The detail guidelines for uploading documents on EIL eDMS Portal are available onfollowing URL

http://edocx.eil.co.in/vportal

4.5.3 Statutory Approvals

Wherever approval by any statutory body is required to be taken by Supplier, theSupplier shall submit copy of approval by the authority to EIL.

4.5.4 Details of Contact Persons of Supplier

After placement of order supplier shall assign a Project Manager for that order. Thedetails are to be filled online through the portal. The details include e-mail address,mailing address, telephone nos., fax nos. and name of Project Manager. All the systemgenerated emails pertaining to that order shall be sent to the assigned ProjectManager.

4.5.5 Schedule and Progress Reporting

Supplier shall submit monthly progress report and updated procurement, engineeringand manufacturing status (schedule vs. actual) every month, beginning within 2 weeksfrom FOA/LOA. In case of exigencies, EIL/Owner can ask for report submission asrequired on weekly/fortnightly/adhoc basis depending upon supply status and suppliershall furnish such reports promptly without any price implication. Format for progressreport shall be submitted by the Supplier during kick off meeting or within one week ofreceiving FOA/LOA, whichever is earlier.

4.5.6 Quality Assurance Plan/Inspection and Test Plan

Inspection and test plans (ITP) attached if any, to the MR/PR are to be followed.However for cases wherein ITPs have not been attached with MR/PR, Supplier shallsubmit within one week of receiving FOA/LOA, the Quality Assurance Plan formanufacturing, covering quality control of critical bought out items/materials,inspection & testing at various stages of production, quality control records and siteassembly & testing as may be applicable to the specific order and obtain approvalfrom concerned Regional procurement Office of EIL/third party inspection agency, asapplicable.

For Package equipment contracts, the supplier shall prepare a list of items/equipments and their inspection categorization plan for all items included in the scopeof supply immediately after receipt of order and obtains approval for the same fromEIL. The items shall be categorized into different categories depending upon theircriticality for the scope of inspection of TPIA and/or EIL.

4.5.7 Inspection Release Note (IRN)/ Inspection Certificate (IC)

IRN/ IC shall be issued by EIL Inspector/ third party inspection agency on the basis ofsuccessful inspection, review of certificates as per specifications & agreed quality plan(as applicable) and only after all the drawings/documents as per DCI are submittedand are accepted under review code-1 or code R. Supplier shall ensure that necessarydocuments/manufacturing and test certificates are made available to EIL/TPIA as andwhen desired.

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

Page 81 of 121

ENGINEERSOgell 0151jeg INDIA LIMITED

IA Govt of India Unclettalong)1.127, owtore o43frosso

SPECIFICATION FORDOCUMENTATION

REQUIREMENTS FROMSUPPLIERS

STANDARD SPECIFICATIONNo.

6-78-0003 Rev. 1Page 7 of 8

Note: Non fulfilling above requirement shall result into appropriate penalty or with-holding of payment as per conditions of PO/PR/MR.

4.5.8 Transportation Plan

Transportation Plan for Over Dimensional Consignments (ODC), if any, shall besubmitted within 2 weeks of receiving FOA/LOA, for approval. Consignment withparameters greater than following shall be considered as over dimensional.

Dimensions: 4 meters width x 4 meters height x 20 meters length

Weight : 32 MT

4.6 Final Documentation

4.6.1 As Built Drawings

Shop changes made by Supplier after approval of drawings under `Code 1' by EIL anddeviations granted through online system , if any, shall be marked in hard copies ofdrawings which shall then be stamped 'As-built' by the supplier. These 'As-built'drawings shall be reviewed and stamped by EIL Inspector/ TPIA also. Supplier shallprepare scanned images files of all marked — up 'As — built' drawings. SimultaneouslySupplier shall incorporate the shop changes in the native soft files of the drawingsalso.

4.6.2 As Built Final Documents

As built final documents shall be submitted as listed in PO/PR/MR.

4.6.3 Packing/Presentation of Final Documents

Final Documents shall be legible photocopies in A4, A3 size only. Drawings will beinserted in plastic pockets (both sides transparent, sheet thickness minimum 0.1 mm)with an extra strip of 12 mm wide for punching so that drawings are well placed.

Final Documentation shall be bound in Hard board Plastic folder(s) of size 265 mm x315 mm (10 1 /2 inch x 12 1 /2 inch) and shall not be more that 75 mm thick. It may be ofseveral volumes and each volume shall have a volume number, index of volumes andindex of contents of that particular volume. Where number of volumes are more,90mm thickness can be used. Each volume shall have top PVC sheet of minimum0.15 mm thick duly fixed and pressed on folder cover and will have 2 lever clip. Incase of imported items documents, 4 lever clip shall also be accepted. All four cornersof folders shall be properly metal clamped. Indexing of contents with page numberingmust be incorporated by supplier. Spiral/Spico bound documents shall not beacceptable. As mentioned above, books should be in hard board plastic folders withsheets punched and having 2/4 lever clips arrangement.

Each volume shall contain on cover a Title Block indicating package Equipment TagNo. & Name, PO/Purchase Requisition No., Name of Project and Name of Customer.Each volume will have hard front cover and a reinforced spine to fit thickness of book.These spines will also have the title printed on them. Title shall include also volumenumber (say 11 of 15) etc.

4.6.4 Submission of Soft Copies

Supplier shall submit to EIL, the scanned images files as well as the native files ofdrawings/documents, along with proper index.

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

Page 82 of 121

SPECIFICATION FORDOCUMENTATION

REQUIREMENTS FROMSUPPLIERS

STANDARD SPECIFICATIONNo.

6-78-0003 Rev. 1Page 8 of 8

C,'(L:ED'D ENGINEERSINDIA UMITEDIA Govt of India Undertaking)

ligar idf5lesI MT riernfO7IJOCFAI

In addition to hard copies, Supplier shall submit electronic file (CD-ROM) covering softcopies of all the final drawings and documents, all text documents prepared oncomputer, scanned images of all important documents (not available as soft files), allrelevant catalogues, manuals available as soft files (editable copies of drawings/textdocuments, while for catalogues/manuals/proprietary information and data, PDF filescan be furnished).

All the above documents shall also be uploaded on the EIL eDMS portal.

4.6.5 Completeness of Final Documentation

Supplier shall get the completeness of final documentation verified by EIUTPIA andattach the Format for Completeness of Final Documentation (Format No. 3-78-0004)duly signed by EIL Inspector or TPIA as applicable to the document folder.

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

Page 83 of 121

$afg7:11 tel5legMen eRali• 4,30.0

ENGINEERS COMPLETENESS OF FINAL

INDIA LIMITED DOCUMENTATION(A Gort of hula Undertakog)

fEr)

COMPLETENESS OF FINAL DOCUMENTATION

Name of Supplier/Contractor

Customer

Project

EIL's Job No.

Purchase Order No./Contract No.

Purchase Requisition No./Tender No. Rev. No. :

Name of the Work/Equipment

Tag. No.

Supplier's/ Contractor'sWorks Order No.

Certified that the Engineering Documents/ Manufacturing & Test Certificates submitted by thesupplier are complete in accordance with the Vendor Data Requirements of PurchaseRequisition.

Signature

Date

Name

Designation

Department

Signature

Date

Name

Designation

Department

Supplier/Contractor EIL/TPIA

arTilittl/APPROVED

gTffTeR/ Sig eilegiltktvi .

4/ Name: ......... .. . ......................

f4-41--/ Date: ..... ••••••• .... ........................

Copyright EIL — All rights reservedFormat No. 3-78-0004, Rev. 1/ 12.03.2015Page 84 of 121

151fRiseAstigat efaleg

ENGINEERSINI NA LIMITED/A “nul Ina. Lnden.,),

STANDARD SPECIFICATIONFOR POSITIVE MATERIALIDENTIFICATION (PMI) AT

SUPPLIER'S WORKS

STANDARD SPECIFICATION No.

6 -81 -0001 Rev. 2Page I of 8

c 1T covingii 4,flcomoict) TIPTth LI 111

f'6g itta-vr

STANDARD SPECIFICATION

FORPOSITIVE MATERIAL

IDENTIFICATION(PMI)

AT SUPPLIER'S WORKS

40D., 15,

2 20.10.11 REVISED AND RE-ISSUED AKC DM

1 15.07.08 REVISED AND RE-ISSUED NKR SSL SKP VC

0 07.12.00 ISSUED AS STANDARD SPECIFICATION AKC AKB AKB MI

Standards StandardsRev.No Date Purpose Prepared

byChecked

byCommitteeConvenor

BureauChairman

Approved by

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

Page 85 of 121

151M-ae? le. ' ENGINEERSimegver INDIA LIMITEDyin eRaWanJelwill Govl of India Undertakno

STANDARD SPECIFICATIONFOR POSITIVE MATERIALIDENTIFICATION (PM I) AT

SUPPLIER'S WORKS

STANDARD SPECIFICATION No.6-81-0001 Rev. 2

Page 2 of 8

Abbreviations:

API American Petroleum InstituteAS Alloy SteelLSTK Lump Sum Turn KeyPMI Positive Material IdentificationSch ScheduleSS Stainless SteelTPI or TPIA Third Party Inspection Agency

Inspection Standards Committee

Convenor: Mr.AK Chaudhary

Members: Mr. SS LotayMr. SC GuptaMr. RK SinghMr. Rajeev KumarMr. Anoop GoelMr. G SureshMr. G Poornachandra RaoMr. MP Jain (Projects)

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

Page 86 of 121

STANDARD SPECIFICATIONFOR POSITIVE MATERIALIDENTIFICATION (PMI) AT

SUPPLIER'S WORKS

151M4-e?fte ENGINEERSOgrir tfigtegW INDIA LIMITED

Gorl of India undertaking}

STANDARD SPECIFICATION No.

6-81-0001 Rev. 2Page 3 of 8

CONTENTS

1.0 SCOPE 4

2.0 REFERENCE DOCUMENTS 4

3.0 DEFINITIONS 4

4.0 PMI EXAMINATION 5

5.0 ACCEPTABLE METHODS FOR PMI 5

6.0 EXTENT OF PMI EXAMINATION 6

7.0 RECORDING AND DOCUMENTATION 7

8.0 MARKING 7

Copyright EIL —All rights reservedFormat No. 8-00-0001-F1 Rev. 0Page 87 of 121

STANDARD SPECIFICATIONFOR POSITIVE MATERIALIDENTIFICATION (PMT) AT

SUPPLIER'S WORKS

/ft ENCJNEERSbeire,altateg '-‘60- 1 INDIA LIMITED

STANDARD SPECIFICATION No.

6-81-0001 Rev. 2Page 4 of 8

1.0 SCOPE

1.1 This specification applies to the requirements for Positive Material Identification (PMI) to beperformed at the Supplier's works on Metallic Materials procured either directly by theOwner/EIL/ LSTK contractor or indirectly through the sub-Suppliers.

1.2 Any post order deviation from this specification must be approved by Owner/EIL in theDeviation/ Waiver Permit format (No. 5-0000-0180-F1) enclosed with Material Requisition.

1.3 This specification covers the procedures and methodology to be adopted to assure that thechemical composition of the material is consistent with the material specifications as specifiedin purchase documents using 'Alloy Analyzer' at the time of final inspection before dispatch.

1.4 The scope of this specification shall include but shall not be limited to Positive MaterialIdentification (PMI) to be performed on Materials listed below:

1.4.1 For alloy Steel materials as below:Alloy Steel Pipes including Clad PipesAlloy Steel Flanges & ForgingsAlloy Steel Fittings including Clad FittingsAlloy Steel FastenersAlloy Cast & Forged steel valvesAlloy Steel Instrumentation Items (Control Valves, Safety Valves etc.)Longitudinal Pipe & Fittings Welds.Gaskets (for Ring Type Joints)

1.4.2 For Carbon Steel materials as below:All Carbon Steel Piping items under NACE or HIC or H2Carbon Steel flanges and valves (Rating 900# and above)Carbon Steel Pipes & fittings for following thicknesses:Size 1"- 2" NB : Sch 160 & aboveSize 3" NB : Sch XS & aboveSize 4" - 12" NB : Sch 120 & above

Following items shall be excluded from scope of PMI examination.

Gaskets other than for Ring Type JointsInternal Components of Valves

1.5 All grades of material supplies including Stainless Steels shall be liable for PMI test at site. Incase of any defective materials being found at site, the Supplier shall be responsible to effectreplacement of such defective materials at project site without any delays to the satisfaction ofEIL site RCM (Resident Construction Manager).

2.0 REFERENCE DOCUMENTS

2.1 API Recommended Practice 578 (First Edition, May 1999) - Material Verification Program forNew and Existing Alloy Piping Systems.

3.0 DEFINITIONS

3.1 Supplier: Any Supplier or Manufacturer on whom an order is placed for the supply of referreditems. This definition shall also include any sub-Supplier or manufacturer on whom a sub-orderis placed by the Supplier.

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

Page 88 of 121

STANDARD SPECIFICATIONFOR POSITIVE MATERIALIDENTIFICATION (PM I) AT

SUPPLIER'S WORKS

SaIRCIELM—; ENGINEERSPar taiReZ VW INDIA LIMITED

STANDARD SPECIFICATION No.

6-81-0001 Rev. 2Page 5 of 8

3.2 Inspection Lot: A group of items offered for inspection covered under same size, Heat andHeat treatment lot.

3.3 Alloy Material: Any metallic material (including welding filler materials) that containsalloying elements such as chromium, nickel, molybdenum or vanadium, which are intentionallyadded to enhance mechanical or physical properties and/or corrosion resistance.

4.0 PMI EXAMINATION

4.1 The Supplier shall submit a procedure of PMI to comply with the requirements of thisSpecification Approval of PMI Procedure shall be obtained from Owner/EIL/TPIA prior tocommencing manufacture/ inspection of product.

4.2 PMI examination of materials is independent of any certification, markings or colour codingthat may exist and is aimed at verifying that the alloy used are as per specified grades.

4.3 The Supplier shall identify all incoming alloy materials and maintain full traceability of all alloymaterials, including all off-cuts. Transfer of identification marks shall be undertaken prior tocutting to ensure maintenance of identification on off-cuts.

4.4 The Supplier shall ensure that all alloy materials are segregated and stored in separatelyidentified locations to prevent the mix up of materials of different alloy specifications or alloymaterial with carbon steel. Non ferro-magnetic materials shall be segregated at all times fromferro-magnetic materials.

4.5 PMI examination is subject to surveillance inspection by Owner/EIL/TPIA.

5.0 ACCEPTABLE METHODS FOR PMI

5.1 The method used for PMI examination shall provide a quantitative determination of the alloyingelements like chromium, nickel, molybdenum or vanadium in Alloy Steel items.

5.2 Instruments or methods used for PMI examination shall be able to provide quantitative,recordable, elemental composition results for positive identification of alloying elementspresent.

5.3 The acceptable instruments for alloy analyzer shall be either "Portable X-Ray fluorescence" or"Optical Emission" type each capable of verifying the percentage of alloy elements withinspecified range.

5.4 Chemical spot testing, magnets, alloy sorters and other methods using eddy current ortriboelectric testing methods are not acceptable for PMI examination.

5.5 The PMI instrument used shall have the sensitivity to detect the alloying elements in thespecified range.

5.6 All PMI instruments shall have been serviced within a 6 month period of the time of use toverify the suitability of batteries, sources etc., and the data of the last service shall be stated onthe PMI Report Form (Sample enclosed).

5.7 Each analyzer must be calibrated according to the manufacturer's specification at the beginningand end of each shift. Instrument must be checked against known standard for each alloy typeto be inspected during the shift.

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

Page 89 of 121

STANDARD SPECIFICATIONFOR POSITIVE MATERIALIDENTIFICATION (PMI) AT

SUPPLIER'S WORKS

ISillaZreqe ENGINEERSs'Ig7e2eg W INDIA UMITED

Govt a Inaa Undenakingi

STANDARD SPECIFICATION No.

6-81-0001 Rev. 2Page 6 of 8

5.8 Certified samples, with full traceability, of a known alloy materials shall be available for use asa random spot check on the instrument calibration.

5.9 The surfaces to be examined shall be prepared by light grinding or abrasive paper and solventcleaner. Evidence of Arc burn resulting from examination shall be removed by light grinding orabrasive paper. No permanent marks, which are injurious to the usage of product in service, areacceptable.

5.10 Alloy Steel ring type joint Gaskets shall be inspected by using portable X-Ray fluorescenceinstrument.

5.11 Testing shall be done as per the procedures outlined by the manufactures of alloy analyzerbeing used. Modification of these procedures if any must be approved by Owner/EIL.

5.12 The persons performing PMI shall demonstrate their capabilities to the satisfaction ofOwner/EIL/TPIA visiting engineer. If the Supplier has qualified operator on their rolls, he mayperform the examination. Otherwise PMI examination shall be sub-contracted to an independenttesting agency approved by EIL.

5.13 Whenever material is identified as not meeting requirements by the visiting engineer a rejectionnote shall be issued.

6.0 EXTENT OF PMI EXAMINATION

Following sampling plans shall be applicable for PMI examination of various items.

Flanges, Fittings 100%Valves, RTJ Gaskets

Pipes 100% (for pipes procured from traders).

2 random samples drawn from eachSize/Heat/Lot (for pipes procured directly from mills)

C. Fasteners

Lot Size Sample Size

Upto 100 2% (Min 2)101 to 500 1% (Min 3)501 and above 0.5% (Min 5)

Note:

For Welded Pipes and Fittings, PMI shall be performed on Base Metal as well asweldments.

Whenever any sample drawn to PMI test on the basis of percentage selection in B & Cabove, fails to meet specification requirements, 100% of items of lot shall be tested forPMI.

Copyright EIL — All rights reservedFormat No. 8-00-0001-F1 Rev. 0Page 90 of 121

STANDARD SPECIFICATIONFOR POSITIVE MATERIALIDENTIFICATION (PMI) AT

SUPPLIER'S WORKS

i.311-aelti. ENGINEERS

ogrir EiRtegi INDIA LIMITEDIA Go' at India Undertaking)

STANDARD SPECIFICATION No.6-81-0001 Rev. 2

Page 7 of 8

7.0 RECORDING AND DOCUMENTATION

The results of PMI examination shall be recorded in a Report Format as enclosed with thisspecification.

8.0 MARKING

8.1 All alloy materials tested by PMI shall be identified using either of the following methods byindicating "PMI OK"

Bar Code/Hologram StickerA low stress stamp marking

Copyright EIL — All rights reservedFormat No. 8-00-0001-F1 Rev. 0Page 91 of 121

STANDARD SPECIFICATIONFOR POSITIVE MATERIALIDENTIFICATION (PMI) AT

SUPPLIER'S WORKS

012-ael ie ENGINEERSst",ar &Reg W INDIALIMTED

GOA Of India undertakng)

STANDARD SPECIFICATION No.6-81-0001 Rev. 2

Page 8 of 8

POSITIVE MATERIAL IDENTIFICATION REPORTBULK MATERIALS

Page of

Project: Client Job No.

PMI Report No. Supplier/Sub-Supplier

Purchase Order No. Testing Agency

PurchaseRequisition No:

PMI Location

Bulk Item Type (as per Requisition)

Material Specification/Grade

Number of items in Lot

Requisition Item No./ Description Major content, Weight Percent RemarksAccept/Reject

Element Cr Mo Ni V

Specified Range

Actual observations

Instrument Type / ID

Last Service Date Inspection Agency Witnessed By

Copyright EIL — All rights reservedFormat No. 8-00-0001-F1 Rev. 0Page 92 of 121

ENGINEERS INSPECTION AND TEST PLAN

STANDARD SPECIFICATION No.

$1=g-ZIE fa5le'S.

INDIA LIMITED

FOR

6-81-0009 Rev. 3 IA Govt of India Undertaking)

HEAT EXCHANGERS Page 1 of 7

c 1-1

fiteTur trtuur EW-9-r

INSPECTION AND TEST PLAN FOR

HEAT EXCHANGERS

Cbt -Y-L-

3 09.09.2013 REVISED AND RE-ISSUED TKK G DM

2 15.07.2011 REVISED AND RE-ISSUED HP SCG AKC DM

1 25.10.2005 GENERAL REVISION TSSR PRV SY VC

0 01.11.02 ISSUED FOR IMPLEMENTATION NKN SPS AKB GRR

Rev. No. Date Purpose Prepared

by Checked

by

Standards Committee Convenor

Standards Bureau Chairman

Approved by

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved

Page 93 of 121

$1g-ez 051-eg ,4-17R rieoxecrINCI5.0

ENGINEERS INDIA LIMITED IA Goof of India Undertaking)

INSPECTION AND TEST PLAN FOR

HEAT EXCHANGERS

STANDARD SPECIFICATION No.

6-81-0009 Rev. 3

Page 2 of 7

Abbreviations:

CEIL Certification Engineers International Limited MRT Mechanical Run Test CIMFR Central Institute of Mining & Fuel Research NDT Non Destructive Testing CE Carbon Equivalent NPSH Net Positive Suction Head DFT Dry Film Thickness PO Purchase Order DPT Dye Penetrant Testing PESO Petroleum Explosive Safety Organization DHT De-hydrogen Heat Treatment PQR Procedure Qualification Record ERTL Electronics Regional Test Laboratory PR Purchase Requisition FCRI Fluid Control Research Institute PMI Positive Material Identification HT Heat Treatment RT Radiography Testing HIC Hydrogen Induced Cracking SSCC Sulphide Stress Corrosion Cracking ITP Inspection and Test Plan TC Test Certificate IP Ingress Protection TPI or TPIA Third Party Inspection Agency IHT Intermediate Heat Treatment UT Ultrasonic Testing IC Inspection Certificate VDR Vendor Data Requirement IGC Inter Granular Corrosion WPS Welding Procedure Specification MPT/MT Magnetic Particle Testing WPQ Welders Performance Qualification MTC Material Test Certificate

Inspection Standards Committee

Convenor : Mr. S C Gupta

Members:

Mr. R.K. Singh

Mr. Rajeev Kumar Mr. Himangshu Pal Mr.Neeraj Mathur

Mr. T Kamalakannan Mr. Deepak Gupta (Project) Mr. Mayank Jain

Format No. 8-00-0001-F7 Rev. 0

Copyright EIL — All rights reserved

Page 94 of 121

k_71 ENGINEERS INSPECTION AND TEST PLAN

STANDARD SPECIFICATION No.

tiff INDIA LIMITED

FOR

6-81-0009 Rev. 3 IA Govt of India Undertaking)

HEAT EXCHANGERS

Page 3 of 7

1.0 SCOPE

This Inspection and test plan covers the minimum testing requirements of Heat exchanger

2.0 REFERENCE DOCUMENTS

PO/PR/ Standards referred there in/ Job specifications /approved documents.

3.0 INSPECTION AND TEST REQUIREMENTS

SL NO.

STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK

RECORD SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER EIL/TPIA

1.0 Procedures

1.1 Hydro test ,heat treatment, NDT, hot forming and other Procedures Documented procedures. 100%

Procedure documents

- H R

1.2 WPS/ PQR /WPQ/Mock up Documented procedures. 100% Procedure documents

- H R-Existing

W-New

2.0 Materials inspection

2.1

Plates, pipes, Forgings, Expansion Bellows, Anodes, Fittings, Fasteners,

Gaskets, etc (As applicable) As per PR/Purchase

Specification 100% Mill TC H H R

2.2

Tube sheets, Tubes & Non standard flanges

(Supplier / sub supplier to arrange TPIA Certification)

As per PR/Purchase Specification

100% Mill TC / TPIA'S

IRN H H R

3.0 In process inspection

Format No. 8-00-0001-F7 Rev. 0

Copyright EIL — All rights reserved

Page 95 of 121

ei ENGINEERS INDIA LIMITED

• I el eage Z1,1 IA Govt of India Undertaking)

STANDARD SPECIFICATION No.

6-81-0009 Rev. 3

Page 4 of 7

INSPECTION AND TEST PLAN FOR

HEAT EXCHANGERS

SL NO.

STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK

RECORD SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER EIL/TPIA

3.1 Materials identification of pressure parts

Review of test certificates, markings visual & dimensional inspection, identity correlation & transfer of

identity

100% Material clearance

record - H H

3.2 Non Pressure Parts

Review of test certificates 100% Material

test certificate

W R R

3.3 Inspection of formed components

NDT of weld seam as applicable 100% NDT

Reports / RT Films

H H R

DPT on knuckle portion (both inside and out side) and weld overlay as

applicable

100% Inspection report

H H R

HT chart review as applicable 100% HT Chart W W R

Test coupon as applicable 100% Inspection

report W W W

Visual & dimensional (min. thickness, profile, ovality etc )

inspection

100% report

Inspection H H W

UT for lack of bond (after final heat treatment if any) formed from clad

plates as applicable 100%

report

Inspection H H R

3.4 Welding consumable Chemical , mechanical properties &

IGC as applicable 100% Batch test

certificates H H R

Format No. 8-00-0001-F7 Rev. 0

Copyright EIL —All rights reserved

Page 96 of 121

rwart ..3mcn.o

STANDARD SPECIFICATION No.

6-81-0009 Rev. 3

Page 5 of 7

4oi ENGINEERS 51gar 25:leg INDIA LIMITED

IA Govt of India Undertaking)

INSPECTION AND TEST PLAN FOR

HEAT EXCHANGERS

SL NO.

STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK

RECORD SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER EIL/TPIA

3.5 Weld edge preparation & Set up of

pressure Parts

Visual & dimensional inspection, weld edge, root gap, offset, alignment, cleanliness etc.

100% Insp Inspection check list

- W

NDT of weld edges as applicable 100% Inspection Insp check list

- W -

3.6 Intermediate Inspection of Welding Visual / inter pass temperature /DPT

as applicable 100 % Inspection

report - W -

Heat treatment as applicable 100% HT chart H R

3.7 Inspection of tube sheet Hole diameter, drift, layout, groove depth, ligament, tube hole surface

finish etc 100%

report

Inspection H H H

3.8 Inspection of Baffles Hole diameter, drift, layout, etc 100% Inspection Insp

report W W -

3.9 Skeleton of tube bundle before tube

insertion Visual / Completeness of assembly 100% Insp Report - H -

3.10 Tube bundle assembly Visual / Completeness of assembly 100% Insp Report - H H

3.11 Floating head assembly (As applicable) Visual / Dimension 100% Insp Report - H R

3.12 Pull through test of shell Passing of Gauge 100% Insp Report - H R

3.13 Tube to tube sheet joint ( welding/expansion)

% thining, Length of expansion, weld visual and DP as applicable

100% Insp. report

- H RW

3.14 Pneumatic Test of RF Pads & Tube to Tube sheet joints Leak Test 100%

Inspection Report

H H R

4.0 Final inspection

Format No. 8-00-0001-F7 Rev. 0

Copyright EIL — All rights reserved

Page 97 of 121

ENGINEERS INSPECTION AND TEST PLAN

STANDARD SPECIFICATION No.

ligaroot,cg w INDIA LIMITED

FOR

6-81-0009 Rev. 3 1.11VM el,M1.1151,PRISTI1

IA Govt 01 Ind. Undertaking)

HEAT EXCHANGERS Page 6 of 7

SL NO.

STAGE/ ACTIVITY CHARACTERISTICS QUANTUM OF CHECK

RECORD SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER EIL/TPIA

4.1

Visual and dimensional inspection (internals & externals) including welds of shell, channel shell, shell cover shell

etc. (before PWHT as applicable)

Visual/ dimensions, completeness of assembly and weld visual for

reinforcement, undercuts, Surface defects, etc.

100% Inspection

report - H H

4.2 PMI as applicable Chemical check Each

component and weld

Inspection report

- H R

4.3 Inspection of completed welds

PWHT as applicable 100% HT chart H R

NDT as applicable Spot/100% NDT report / RT films

- H R

Production test coupon testing as applicable

as per specification /

drawing

Inspection report

- H H

Weld chemical for undiluted chemistry as applicable

Each component

for each welding process.

Inspection report

- H R

Hardness for weld /HAZ as applicable

As per spec. Inspection

report H RW

4.4 Hydrostatic test (As applicable) Leak check 100% Inspection

report - H H

4.5 Drying and nitrogen filling Visual/ gas pressure 100% Inspection

report - W -

Format No. 8-00-0001-F7 Rev. 0

Copyright EIL — All rights reserved

Page 98 of 121

ENGINEERS INSPECTION AND TEST PLAN

STANDARD SPECIFICATION No.

$1g-af faiteg INDIA LIMITED

FOR

6-81-0009 Rev. 3 erterr,

IA Gcnit of India Undertaking)

HEAT EXCHANGERS

Page 7 of 7

SL NO. STAGE/ ACTIVITY CHARACTERISTICS

QUANTUM OF CHECK

RECORD SCOPE OF INSPECTION

SUB SUPPLIER SUPPLIER EIL/TPIA

5.0 Painting

5.1 Final painting (As applicable)

Visual inspection (after surface preparation and final painting for workmanship, uniformity) DFT

check

100% Inspection

report - H

6.0 Documentation and IC

6.1 Final stamping, review of inspection documents and issue of IC

Verifying stamping details and review of inspection documents

100% IC /

Inspection reports

- H H

6.2 Final documents as per PR Verification & compilation of inspection & test records for

submission to customer 100%

Final dossier

- H H

Legend: H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or 10% ( min.1 no. of each size and type of Bulk item)), R-Review, W-Witness (Give due notice, work may proceed after scheduled date).

NOTES (As applicable► :

1. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be applicable. (Unless otherwise agreed upon)

2. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred there in /Job Specification /Approved Documents.

Format No. 8-00-0001-F7 Rev. 0

Copyright EIL — All rights reserved

Page 99 of 121

Olgz=ENGINEERS NDIA LIMITED (A Govt. of Indle Undortoking)

PART DETAILS

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0001 Rev. 4

Page 1 of 2

+2 -0 T

+1.5 -o.o 6 T1

CX45• 1.,) +

N + 0 *** 0

0 m

— — —

< (...) CD

+ 0 Z.-5

0 1--

„,

±1

DETAIL-2

BC

D

r.r) 1:trl o

+0.8 -0.0 TO SUIT toc/

+ ?? ,IG! no . —o +1.< 6X45' --\ T (21 o 7

m

r, ci, nj ?cl'' '?

7 ** ..,

0+ m

>2 ‹ z ' 5 0 > < (,)

11111 11 ■ 21 :. < o

m o

DETAIL-3 DETAIL-1

T2

•X4 • T 6X45• T G1 T 6X45• T1 r•-, + o

--------\ ** ,o + o

** •,) + o + o

I m m m m

- — - .

< a (.) m : AP.... . < c, o -- ci < (..., ***

m m co 0)

m

CD r> 0 MIIIIIIMIII

m

DETAIL- 6

+ o * ---

DETAIL-4 o

H m

...

DETAIL-

H

5

m

DETAIL- 7 r.,) + 1---- --1

** y) + C)

F ** ** r --1

** r- \

1>-- 411

/-1)

L4 TUBE

03 x :,* -:, i- _i w _ m SIDE SIDE *** ***

o a

o com

***

- ■■ R2 r)

l

<-) m r) i m 0

T3 tn i m T3

T3 T3 m

DETAIL-11 DETAIL-1Q DETAIL-9 DETAIL- 8

---1

REQD A1/A2

alb kiA> 4

"1,111/

ill». ___ _ 11:1111111111111111 „1,01

lirily 111311) ■

DETAIL-13

SUPPORT PL REF. T/SHT OR CH. COVER

— J 20 25

ii 3

1 L

0 r..) m

I

**1

T3

r"

1.) mI

1 ii E. • ,

1-1 C--- DEFLECTOR T

L ,:f 1 STRIPS

.511121LIQL.I2EELFSIQE STRIPS END DETAII,

PGARRZIPDFEUTLC T2 =Ti +3

DETAIL- 15 DETAIL-1 2 DETAIL-14

KT

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM VC

4 06.05.14 REVISED AND REISSUED AS STANDARD k"Ni"---GCP

Rev. No. Date Purpose

Prepared Checked

by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Format No. 8-00-0001-F4 Rev.O

Copyright EIL - All rights reserved

Page 100 of 121

mi

-r T3

**

ci—zsi/ SC 4 06.05.14 REVISED AND REISSUED AS STANDARD GCP

Iffiteid ENSNEERS Ogat18 INDI 11ffieu A LIMIT1ED

Govt. of Inctla Undortoking) (SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0001 Rev. 4

Page 2 of 2

PART DETAILS

DETAIL-21

DETAIL-1 9 ED

X4

5

DETAIL-23 DETAIL-22

DETAIL-24

DEPOSIT

DETAIL-28 DETAIL-29

T3 ro

DETAIL-25

DETAIL-30

DETAIL– 27

***

CHANNEL SIDE

mI

DETAIL-31

NOTES: –

1. FOR CHANNEL COVER & TUBE SHEET A, BCD & D ETC. SHALL BE SAME AS FOR MATING FLANGES.

2. IF SPIRAL WOUND GASKET IS USED FOR A JOINT:– a) DIAMETER OF TUBE SHEET & CHANNEL COVER

'D' SHALL BE GASKET OD + 8 mm. b) DIAMETER OF FLANGE RECESS FOR GASKET SHALL BE

GASKET OD + 11 mm. 3. (9 WELD DEPOSIT OR CLADDING SHALL BE AS SPECIFIED ON

EQUIPMENT DRAWING. 4. FOR ASTERISK MARKS REF R TABLE-1. 5. WHERE EVER 'R' IS SPECIFI D, IT INDICATES TO BE RADIUSED.

6. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

TABLE NO.– 1

DIMENSIONS * ** *** FOR IJA & NON ASBESTOS 5 6 5 / EIASTOMER GASKET. FOR 4.5 mm SPWD GASKET 6 7 6

FOR 6.35 mm SPWD GASKET 8 9 7

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM VC

Prepared Checked by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Copyright EIL - All rights reserved

Purpose Rev.

No. Date

Format No. 8-00-0001-F4 Rev.O

Page 101 of 121

STANDARD No.

7-15-0002 Rev. 4

Page 1 of 3

TYPES OF NON STANDARD

GASKETS

(SHELL & TUBE EXCHANGERS) $14= IENG~S

INDIA UMITED 14111,1111•111M~ (A Govt. of India Undortoking)

TYPE-1

TYP E— 4

TYPE-7

TYPE-1 0

TYP E— 2

TYPE-5

TYPE— 8

TYPE-11 06.05.14 REVISED AND REISSUED AS STANDARD

RKG AKM VC

Checked Stds. Committee Stds. Bureau

b Convenor Chairman

y Approved by

Copyright EIL - All rights reserved

27.01.09 REAFFIRMED AND REISSUED AS STANDARD 3

Rev.

No. Date

Purpose

TYPE— 3

TYPE— 6

TYPE— 9

on

TYPE-12 SC

Format No. 8-00-0001-F4 Rev.O

VPR

Prepared

by

Page 102 of 121

TYPE-1 3 TYPE-1 4

Ognr ENGINEERS egOINDIA LIMITED

4~1111•111~111110 (A Govt. of Indlo Undortoking)

TYPES OF NON STANDARD

GASKETS

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0002 Rev. 4

Page 2 of 3

TYPE-1 5

TYPE-1 6

TYPE-1 7 TYP E-1 8

TYPE-1 9 TYPE-20

TYP E- 21

4 06.05.14 REVISED AND REISSUED AS STANDARD S&CP 3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR

Xet

VC

T

RKG AKM

Rev.

No. Date Purpose Prepared Checked

by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Format No. 8-00-0001-F4 Rev.O

Copyright EIL - All rights reserved

Page 103 of 121

ENGNEIERS INDIA LIMITED (A Govt. of Indlo Undortoking)

TYPES OF NON STANDARD GASKETS

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0002 Rev. 4

Page 3 of 3

PERMISSIBLE TOLERANCES PASS PARTITION PLATE THIS SIDE

FILLER TYPICAL SECTION OF METAL

JACKETTED GASKETS

D + 8

4 WIDE NOSE

GASKFT WIDTH

METAL WINDINGS METAL WINDINGS WITH FILLER

TYPICAL DETAIL OF SPIRAL WOUND GASKET

GENERAL NOTES: —

1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

2. THE HARDNESS OF THE METAL FOR SOLID OR CLAD GASKETS SHALL BE MINIMUM 15 BHN LOWER THAN

THAT OF THE MATERIAL OF THE FLANGE GASKET SEATING SURFACE AND IN ANY CASE NOT TO EXCEED

THE FOLLOWING.

(a) LOW CARBON STEEL / LAS — 110 BHN

(b) 5 Cr. 1/2 Mo. — 130 BHN

(c) STAINLESS STEEL — 160 BHN

(d) 11 — 13 Cr. — 170 BHN

(e) MONEL — 130 BHN

(f) SOFT IRON 90 BHN

(g) COPPER, BRASS 50 BHN

(h) ALUMINIUM 30 BHN

3. FILLER IN METAL JACKETTED GASKETS SHALL NOT BE OF COMPRESSED TYPE. 4. ALL GASKETS SHALL BE MADE IN ONE CONTINUOUS PIECE ALL AROUND INCLUDING THE PASS PARTITION

RIBS AND THEREFORE MUST BE CUT FROM ONE SHEET. 5. THE CORNER RADII OF ALL GASKETS TO BE 10 mm. 6. SOLID FLAT METAL GASKET SHALL BE 2 mm. THK. 7. FOR SPIRAL WOUND GASKETS:—

a) THE PASS PARTITION RIB SHALL BE OF METAL JACKETTED WELDED TO CENTRING RING. b) CENTRING RING THK. SHALL BE SAME AS NOSE THK. c) GASKET THK. SHALL BE AS SPECIFIED IN EQUIPMENT DRAWINGS. IT SHALL BE MIN. 4.5 FOR

SHALL DIA UP TO 1000 & MIN. 6.35 FOR SHALL DIA MORE THEN 1000, IF NOT SPECIFIED. 8. 'm' AND 'y' VALUES SHALL BE AS PER ASME SEC. Vlll DIV. I. 9. GASKET PLAN IS VIEWED FROM DIRECTION 'X' .

10. FILLER SHALL BE ARAMIDE FIBRE UNLESS SPECIFIED OTHERWISE IN DRAWINGS & ASBESTOS NOT TO BE USED.

4 06.05.14 REVISED AND REISSUED AS STANDARD

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD

VPR

RKG

Rev.

No. Date

Format No. 8-00-0001-F4 Rev.O

Purpose Prepared Checked

by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Copyright EIL - All rights reserved

NO

SE

THK

. mm1le111111111111111111111111111111

CENTRING RING

GASKET O.D. (D)

CENTRING RING THK

AKM

SC

VC

Page 104 of 121

1-10 0 VENT HOLE

o_ >-

10

2 10 0 VENT HOLES

IN WRAPPER PLATE

10(r(P.)

2-10 0 VENT HOLES

013:MENGINEERS

ONDIA UMITED 11~1~11113•••0 (A Govt. of Indlo Und«toking)

SUPPORTS FOR HORIZONTAL STACK UNITS

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0005 Rev. 4

Page 1 of 2

2 10 0 VENT HOLES

* >

o_ } 15(TYP.)

IN WRAPPER PLATE

*14 FOR S.S

m

O(TYP.) .L 20(TYP.) 1

2-30 0 HOLES

4-33 0 HOLES

FOR M-24 BOLTS

2-30 X 65 SLOTTED HOLES FOR M-24 BOLTS 1351

FOR M-27 BOLTS

/<

t \

4-33 X 68 SLOTTED 1 HOLES FOR M-27 BOLTS

1351

**

FOR TYPE I AND II SADDLES FOR TYPE III AND IV SADDLES

REFER SETTING PLAN.

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD CP

AKM vc 3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG

Rev.

No. Date Purpose

Prepared

by

Checked

by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by

Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

Page 105 of 121

RKG

AKM

VC

Prepared Checked

by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Copyright EIL - All rights reserved

Rev. No. Date Purpose

Format No. 8-00-0001-F4 Rev.O

51XOENGNEERS NDIA UMITED (A Govt. of Indla Undortokh,g)

SUPPORT FOR HORIZONTAL STACK UNITS

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0005 Rev. 4

Page 2 of 2

SL. NO. UNIT SIZE O.D. mm.

A B C D NO. OF RIBS

TYPE—I TYPE—Il

1 219.1 400 230 130 — 1 3

2 273 460 260 160 — 1 3

3 323.8 510 270 190 — 1 3

4 355.6 540 280 200 — 1 3

5 406.4 590 310 220 — 1 3

6 457.2 640 330 250 80 2 4

7 500 680 350 270 103 3 5

8 550 730 380 290 105 3 5

9 600 780 400 320 120 3 5

10 650 830 430 340 135 3 5

11 700 880 450 370 160 3 5

12 750 930 480 390 165 3 5

13 800 980 500 410 180 3 5

14 850 1030 530 430 195 3 5

15 900 1080 550 460 220 3 5

16 950 1130 580 480 235 3 5

TYPE—III / IV

17 1000 1190 650 510 180 AS SHOWN

18 1050 1240 675 530 200

19 1100 1290 700 560 220

20 1150 1340 725 580 230

21 1200 1390 750 610 250

22 1250 1440 775 630 270

23 1300 1490 800 660 280

24 1350 1540 825 680 280

25 1400 1590 850 710 300

26 1450 1640 875 730 320

27 1500 1690 900 760 340

28 1600 1790 950 810 350

29 1700 1890 1000 860 380

30 1800 1990 1050 910 420

31 1900 2090 1100 960 450

32 2000 2190 1150 1010 480

33 2100 2290 1200 1060 500

34 2200 2390 1250 1110 530

35 2300 2490 1300 1160 550

36 2400 2590 1350 1210 580

NOTES: — 1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD iSkCP

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR

Page 106 of 121

3 (NOTE-2) 6 3 3 3 3 3+CORROSION ALLOWANCE

(NOTE-4)

TU

BE

SH

EET

TU

BE

SH

EET

TU

BE

SH

EE

T

TU

BE

SH

EE

T

0.4

DE

PT

H O

F G

RO

OV

E

0.4

DE

PTH

OF

GR

OO

VE

u_ O

c.) 07

0 O

c.)

CLADDING

EXPANDED LE

FIG.-2

4 06.05.14 REVISED AND REISSUED AS STANDARD CP

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD

VPR

SC

VC RKG AKM

TUBE HOLE PREPARATION BVGNEQZS

OfazIM INDIA LIMITED AND ROLLER EXPANDING

(A Govt. of Indla Undortoking) (SHELL & TUBE EXCHANGERS & AIR COOLED HEAT EXCHANGERS)

STANDARD No.

7-15-0006 Rev. 4

Page 1 of 1

EXPANDED LENGTH

FIG.-1

NOTES : - 1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

2. FOR TUBESHEET THICKNESS WHERE THE GAP BETWEEN 2ND GROOVE & BACK OF TUBE SHEET IS LOWER THAN 6 mm DELETE 2ND GROOVE.

3. FOLLOW SPECIAL CLOSE FIT AS PER TEMA / API 661 UNLESS SPECIFIED OTHERWISE.

4. FOR CORROSION ALLOWANCE LESS THAN 4 mm., INCREASE THIS DIMENSION TO TUBE SHEET THICKNESS

MINUS 18 mm. BUT NOT TO EXCEED 7 mm.

*5. CHAMFER (1X45') OR RADIUS (R=1).

Rev. No.

Date

Format No. 8-00-0001-F4 Rev.O

Purpose Prepared Checked

by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Copyright EIL - All rights reserved

Page 107 of 121

SLIDING STRIP STATIONARY TUBE SHEET

SECTION—AA

TYPE - 1

STATIONARY TUBE SHEET

SLIDING STRIP

M-12 STUD 22 LG. THREADED

SECTION—BB

TYPE - 2

TYPE - 3

M-12 STUD 22 LG. THREADED

STATIONARY TUBE SHEET

SLIDING STRIP

AKM VC 3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG

Rev. No. Date Purpose

Prepared Checked by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD GCP KA SC

0148MENGINMS

ONDIALIMITED (A Govt. of Indlo Undortoking)

SLIDING & DEFLECTOR STRIPS TO TUBE SHEET

WELDING DETAILS

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0007 Rev. 4

Page 1 of 1

NOTES: —

1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

2. USE TYPE-1 WHEN SLIDING STRIP & TUBE SHEET MATERIAL IS DIFFERENT & W ?, 25

3. USE TYPE-2 WHEN SLIDING STRIP & TUBE SHEET MATERIAL IS DIFFERENT & W < 25

4. USE TYPE-3 WHEN SLIDING STRIP & TUBE SHEET MATERIAL IS SAME

5. FOR DIMENSIONS 'T' AND W' REFER GUIDE LINES FOR TUBE LAYOUT.

6. FOR DEFLECTOR STRIPS UNLESS SPECIFIED OTHERWISE USE DETAILS AS ABOVE.

Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved Page 108 of 121

Rev. No. Date Purpose

Prepared Checked by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Copyright EIL - All rights reserved Format No. 8-00-0001-F4 Rev.O

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD %,\CP KA

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM

SC

VC

0048~ENGMBZS NDLek UMITID (A Govt. of Indlo Undortokklg)

EYE BOLT DETAIL

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0008 Rev. 4

Page 1 of 1

NOM. BOLT DIA A

THREAD LENGTH L

STOCK B

I. DIA. C

0. DIA. D

SAFE LOAD IN kg

mi 0 20 32 26 42 600

M12 24 38 30 52 1000

M16 32 45 35 64 1800

M20 40 50 38 72 2700

M22 44 58 44 84 3000

M24 48 64 46 92 3300

M27 54 70 50 102 4200

M33 66 76 56 114 6800

M39 78 90 64 132 8100

M45 90 96 74 154 9900

M48 96 102 84 162 11400

M56 112 127 102 168 14200

NOTES: —

1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

2. EYE BOLT SHALL BE MADE OF FORGING.

3. MATERIAL OF CONSTRUCTION CARBON STEEL HAVING U.T.S OF 42 kg/mm2 MIN.

4. UPTO M22 COARSE THREAD SERIES, M24 & ABOVE SHALL HAVE 3 mm PITCH.

Page 109 of 121

CHISEL TIE—ROD SPACER

13■IGNEERS INDIA UMIT133 (A Govt. of lodla Undortoking)

METHOD OF FASTENING NUTS TO THE TIE RODS

STANDARD No.

7-15-0009 Rev. 4

(SHELL & TUBE EXCHANGERS) Page 1 of 1

STEEL TIE—ROD

TIE—ROD SPACER

NOTES: —

1. ALL DIMENSIONS ARE IN mm. UNLESS STATED OTHERWISE.

2. WELD 1st NUT TO SUPPORT PLATE

3. WELD 2nd NUT TO TIE—ROD

4. WELD BOTH NUTS TOGETHER

5. ALL WELDS TO EXTEND THE LENGTH OF ONE FLAT OF NUT.

LAST SUPPORT PLATE OR BAFFLE

NON FERROUS TIE—ROD

LAST SUPPORT PLATE OR BAFFLE NOTE: —

*BREAK THREAD OF TIE—ROD IN TWO PLACES NEAR LAST NUT

WITH BLUNT CHISEL TO LOCK TIE—ROD NUTS IN PLACE.

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD ')'‘CP KA

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG

AKM

VC

Rev.

No. Date Purpose Prepared Checked

by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

Page 110 of 121

GASKET SIDE EXPOSED SIDE

Fl ANGF OR CHANNFI COVFR

NCOUNTER BORE d + 2

THREAD=2d

BO

LT C

IRC

LE

DIA

ME

TE

R

d = DIAMETER OF JACK SCREW

ENGNIEIRS NDIA LIMMED (A Govi of Indki Undertaking)

JACK SCREW TAPPING AND ARRANGEMENT

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0010 Rev. 4

Page 1 of 1

/ I

"91't

2—HOLES

/ I

3:5:(

3—HOLES 4—HOLES

NO. REQD. 'd' SHELL I.D.

2 14 UPTO & INCL. 300

3 16 301 TO & INCL. 580

4 20 581 & LARGER

LOCATION OF JACK SCREW TAPPING HOLES 1. HOLES ARE TO BE LOCATED ON THE BOLT CIRCLE DIAMETER

OF FLANGE AND HALF WAY BETWEEN ADJACENT HOLES.

2. FIRST HOLE SHALL BE LOCATED BETWEEN FIRST AND

SECOND BOLT HOLE COUNTING CLOCKWISE FROM MARK 'T'.

3. HOLES SHALL BE SPACED AS FOLLOWS 2—HOLES LAYOUT 180' APART

3—HOLES LAYOUT APPROX 120' APART

4—HOLES LAYOUT 90' APART.

NOTES: — 1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE. 2. JACK SCREW SHALL BE OF STAINLESS STEEL MATERIAL.

4 06.05.14 REVISED AND REISSUED AS STANDARD IS‘')/CCP KA

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD

Rev.

No. Date

Purpose

VPR RKG AKM VC

Prepared by

Checked by

Stds. Committee Convenor

Stds. Bureau Chairman

Approved by Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

Page 111 of 121

G 0

SC

AKM VC

Rev.

No. Date Purpose

Prepared Checked

by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by

034~INDIA LINITED FIXING DETAIL OF DOWEL PINS

(A Govt. of Inao UndertakIng)

STANDARD No.

7-15-0011 Rev. 4

Page 1 of 1 (SHELL & TUBE EXCHANGERS)

FIXING DETAIL OF DOWEL PINS (AT STATIONARY TUBE SHEET)

FIXING DETAIL OF DOWEL PINS ( AT CHANNEL COVER )

SEE NOTE-9

20 20 SEE NOTE-3

(sr

NOTES: —

1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

2. DOWEL PINS TO BE PROVIDED ONLY WHEN CHANNEL CONSISTS OF PASS—PARTITION PLATE/S.

3. DOWEL PIN SHALL BE OF CARBON STEEL UNLESS SPECIFIED OTHERWISE.

4. MIN. 2 DOWEL PINS SHALL BE PROVIDED FOR EACH FLANGE & SHALL NOT BE LOCATED AT 180' APART.

5. ALL SHARP EDGES OF DOWEL PINS SHALL BE ROUNDED OFF.

6. SHALL END OF DOWEL PIN SHALL BE HELD IN POSITION BY TIGHT FIT.

7. LUG TO BE WELDED TO TUBESHEET. HOWEVER LUG FOR DOWEL PIN MAY BE THREADED AND SCREWED IN TUBE SHEET TO AVOID PWHT IN SPECIFIC CASES. MATERIAL OF LUG SHALL BE COMPATIBLE WITH TUBE SHEET MATERIAL.

8. WHEN GAP BETWEEN SHELL & CHANNEL FLANGES IS 25 MM. OR LESS, DOWEL PINS SHALL BE PROVIDED IN CHANNEL FLANGE ONLY.

9. AT THE LARGER END OF DOWEL PIN THE LENGTH CAN BE REDUCED IN CASE OF A SMALLER GAP BETWEEN SHELL AND CHANNEL FLANGES.

4 06.05.14 REVISED AND REISSUED AS STANDARD ‘CP KA

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG

Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

Page 112 of 121

Oli4=ENGINEERS NDIA LIMETED

INUI.11111111~0 (A Govt. of Indla Undortoking)

LIFTING LUG DETAIL

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0013 Rev. 4

Page 1 of 1

10 FULL FILLET WELD ALL AROUND

LIFTING LUG FOR SHELL COVER.

LIFTING LUG FOR

CHANNEL AND CHANNEL COVER

FLOATING HEAD COVER

SHELL I. D. A D R THK.

UPTO 450 65 25 28 12

451 — 1000 75 30 35 16

1001 — 1200 100 30 35 20

1201 & ABOVE CUSTOM DESIGN

NOTES: — 1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

2. MATERIAL SHALL BE COMPATIBLE WITH PART IT IS WELDED TO. (USE BOILER QUALITY FOR CARBON STEEL)

3. USE TWO LIFTING LUGS EACH FOR CHANNEL AND SHELL COVER AND ONE FOR CHANNEL COVER AND

)(4."/

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD iSkP KA RKkLi-I SC

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM VC

Rev. Prepared Checked Stds. Committee Stds. Bureau

No. Date Purpose by by

Convenor Chairman Approved by

FLOATING HEAD COVER.

Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

Page 113 of 121

CHANNEL SHELL COVER

SHELL

SHELL FLANGE

SHELL COVER FLANGE

LIFTING LUG

TOP AND BOTTOM PLATE

CHANNEL FLANGE

CHANNEL COVER

LIFTING LUG 25

25 SLIDING LINK SEE DETAIL

PLAN OF DAVIT SUPPORT ASSEMBLY OF DAVIT ON EXCHANGER

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD (')66P KA RKT

DETAIL—'A'

BOTTOM PLATE 10 o WEEP HOLE

STOPPER PLATE/

d0

5R 3

DETAIL OF SLIDING LINK 6 0 FLAT

DETAIL OF DAVIT DETAIL OF DAVIT SUP ORT

II II

SHELL/CHANNEL

FLANGE

TOP PLATE

16 THK. RIB PLATE

'A'

II

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM VC

Prepared Checked by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by Copyright EIL - All rights reserved

Purpose Rev.

No. Date

Format No. 8-00-0001-F4 Rev.O

ENGINEERS INDIA UMITED (A Govi of Indlo Undortoking)

DAVIT FOR SHELL & CHANNEL COVER

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0014 Rev. 4

Page 1 of 3

Page 114 of 121

STANDARD No.

7-15-0014 Rev. 4

Page 2 of 3

lgelEr4GMERS

4fazi INDIALJMITED

NIRVI (A Govt. of Inctio UndortokIng)

DAVIT FOR

SHELL & CHANNEL COVER

(SHELL & TUBE EXCHANGERS)

DIM

EN

SIO

N-A

0 0 0 -4- i- rl, rd N N r.r) (C11

-° .0°00 oo CO f' )̀ co dr r')

0 0 o cy rr, N N

.-- r'' .-

-° Ln °00 o CO .4- 0 CO .nd- tv)

0 up°

0 c‘i N 1.r) N N (1) (£7, (0

dr- CO 1.1"

00 0 0 ..4- r.r)

0 0 0 c \I ,- F- N 1..-) N c‘l ,,,.— s'-' ,--

CD vd- 1.0 ro ,j- r. 0 "

.- ,r) 0 0 0 csj 0 I- - ro N N

up in o Lo dr

o ro L11

o st. 0

rO

o o o c■j a) t- o iv.) CV

-oLn000 " f •- „-,'"- vtj- ID

o r.,-) o r.,

c00 00

C0

3 e _(

"0

o 0

•fl-

or 0

O if) 0 0 CO

r■ I- CO r., 0

"4- o ro •of-

o LO

o in

Lr> csj

s- ° tD°‘' 0 0 0 (Nj I- f-- (0. iv, ,- -

( ro v:F•

rO .4 . 0°OLD ro N

o 0 o o LO I- (0 r.-) ,- .- 0) N n

f- o •F

o rr.) ir) c‘r

0 0 0 o ',1- I- co ,...) ,-.

•- 00°000Ln o ,t-

o) r,-) ,.,-) c■I

-0 0 0 o o o o 0 rO I- -rl- r")

cr) •'" -

O) ro o up r0

„..) olo (..‘,

0 0 0 1,.. N t--- csi CD •-

CO r.,) O ro

o Fr)

0 N

- 0 Ln 0 0 0 r■ - -

csj 0 Ln o

o Lo ,,i,

o O rn

o 0

0 0 o h. 0 I- N 0 -

La 0 00 0 •iii-

r«.r) 00 N r.-)

o cs,i

o O 0 co CY' 1- ° N

•- o Ot

0 000000 o 1,)

Lo N r0 N

1:5 ° C3 ICID") co I- C» cd u9) o0

O r',

r9> N

,,,° ° C\I

0 2 0 LO 'O CO N

•- 0 0000 in CO

0 f'")

0 N N o N

,__0 8 ,i, • r-- cs, h. 8 rO

8 ,-

in c‘i

o "

Lo . (.0 N co s ,2 8 N •- Cs1 ..-

0 0 ir:: o r.,-) Lo N 0

co cr)

O ,,.„, Lf") c., (=> N co

1- > co ..:( - o o

c..) o _i Z -o

<

Z 0 — (I) Z L.L.1

in

0 0 ° dr i- u0 N N 0) c.‘, •ol- to ,,,t. rO (D ° NI- ° Fr)

0 0 0 r•-) I- cl- N N

ci) c.‘, rs- tr) co ,i. o u'0000

o (,) ,,j. r.,-)

o o N I- rO N N N

(-‘, c»

rO c\I .4. co „-, •- 0 r'")

•"" 0 O o o ,--- 1- N N N

C) cy, c.,r

Lö r-- N

cr) c\I .4-

o rn tr)

2 -.. .„0 ,-,

o" o o° 0 I- •- N N

O c: n c \I

( , iL r) N

0 ,d..--

0 2

o •fl-

o rO

0 0 0 CD 0

c',/ 0.) csj

-̀ °0°00 0 N .--

,- ,„1.. O ,-) ° °

0 0 0 00 1- 0/ ,- ,-

0 cn c‘i

° 1.0 ,-

0 ,- .4- 0 03 .4-

o t')

o rO

-- 0 o 0 c) r■ 1-- co c.,, (r) o

o r-- ,,, .4. Ln rO ID N

•-• 0 o 0 0 (L) I- f-, .- .--

cp CD c,i u" C \I 0

rn i■ ,..,)

o rO ,,. ° r0 Ln N

° ° 0 in /— (C)

cra CV

r-- 0, K)

Ir) .:1" Fr) N N

.- 0 ° 0 O -i- ,— Lo - --

8 N

11•3 O)

5?) o r.,)

0 r.r) r̀ )

Lr) c\J

- °

1') 1- 1̀" 0 0

o N

Lo 00

o cr) r.,-)

o co Nom) N,

co N

° ° 0 ° c\I - ''') .... ,._

0 In Cd

0 0 c0

0 0 r.,)

0 rO r.,)

0 r,"

0 N

° 0 ° 1- "

l'' 0)

N '-- ° 000

lt, r--

0 1.,)

0 ro

re9 c\IC)

- ° 0 o ° ° 1- -

o o N

tn N co

o r-- C•1

o co N

00 ro N

° 6". ° O I— 0

0 0 c.,

rr) C•J cc)

o CO N

o ro N

° °

0 ° 8 co ,— . c9r ii.ri (5) cs4

2 c.r

o 1.'"

o "

5 ,..0 8 1". - CO

0° CsI

c.,") Lr) c., L?) (., N ° N

r: o 52 -I3) 1- r‘-j

0 {.:3

0 L.)-

o R,

o ,__°.

Lo -J

o "

: : : o 9, V) I- (‘1:5

03 c°

C D ?

o C-d-

o_ u j.-

o "

co .-

0_ 0 co

00 -

(3I- 00001D LI F') , •-

N N •"'"

0 c.,, co ‘_

I- 5 < o 75

03 0 o -.1 Z -f)

_J 021

0

_J

U)

0 LL

wI

0 C.)

LIJ zz

tY0 IJ-

o

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD )6;)

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG

Rev. Prepared Checked Date Purpose

No. by by

RKT(J21..,-Av:, SC ,(04

KA

AKM

VC Stds. Committee Stds. Bureau

Convenor Chairman Approved by

Copyright EIL - All rights reserved Format No. 8-00-0001-F4 Rev.O Page 115 of 121

BNIGNEERS INDIA UMETED (A GovL of Indlo UndeflokIng)

DAVIT FOR SHELL & CHANNEL COVER

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0014 Rev. 4

Page 3 of 3

TABLE — 3

WT. X C.

(ToN) (mTR)

DIMENSIONS/SIZE OF DAVITS

N....E SCH bic F

NB SCH T R S NB SCH

UPTO 0.1 2"-160 1-1/2"-160 3 32 3"-1 60

0.11-0.3 3"-160 2"-160 3 47 4"-80

0.31-0.6 4"-160 2"-160 13 59 6"-80

0.61-1.25 6"-80 3"-160 10 86 8"-80

1.26-2.5 8"-80 3"-160 11 112 10"-60

2.6-4.0 10"-60 4"-120 8 139 12"-60

4.1-6.3 10"-120 4"-120 8 139 12"-60

6.4-7.8 10"-160 4"-120 8 139 12"-60

NOTES: —

1. ALL DIMENSIONS ARE IN mm. UNLESS OTHERWISE INDICATED.

2. WHEN DAVITS ARE REQUIRED, USE THE FOLLOWING PROCEDURE TO FIND OUT THE DIMENSIONS 2.1 IDENTIFY THE DIMENSION A, i.e. THE MAXIMUM DIAMETER OF THE COMPONENT TO BE HANDLED.

2.2 REFER TABLE-1 OR TABLE-2 (AS THE CASE MAY BE ) FOR THE DIMENSIONS AND SIZES B,C,D,L,N & d INDICATED IN THE COLUMN CORRESPONDING TO DIMENSION A.

2.3 DETERMINE WEIGHT OF THE PART TO BE HANDLED (i.e. WT. OF SHELL COVER ASSEMBLY OR CHANNEL COVER)

2.4 CALCULATE THE PRODUCT OF WEIGHT (IN TONNES) X DIMENSION C (IN METRES)

2.5 REFER TABLE-3 & OBTAIN DIMENSION AND SIZES E,F,T,S & R INDICATED IN THE ROW AGAINST THE PRODUCT CALCULATED AT 2.4 ABOVE.

3. MATERIALS OF CONSTRUCTION—a. TOP/BOTTOM/RIB PLATE— COMPATIBLE WITH PART IT IS WELDED TO (USE BOILER QUALITY FOR CARBON STEEL)

b. OTHERS IS 1239 OR EQUIV

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD CP KA

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG

Rev. Prepared Checked Date Purpose

No. by by

RKT

AKM Stds. Committee Stds. Bureau

Convenor Chairman Approved by

Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

Page 116 of 121

antnedirkEts/GINEERSligar EIRegle INDIA LIMITED

lawaleizowisagos0 (A Go* of India Undorteing)

EARTHING LUG STANDARD No.

7-15-0016 Rev. 4

Page 1 of 1(SHELL & TUBE EXCHANGERS)

10 THK. CARBON STEEL PLATE

\ 14 0 HOLE (FOR M12 BOLT)

NOTES: —ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.DO NOT WELD EARTHING LUGS TO PRESSURE PARTS. IF REQUIRED,TAKE PRIOR APPROVAL OF COMPANY.EARTHING LUG TO PROTRUDE OUT OF INSULATION, WHEREVER REQUIRED.ALL EXCHANGERS TO BE FITTED WITH 2 EARTHING LUGS.

5. LOCATION OF EARTHING LUGS :—FOR VERTICAL EXCHANGER WITH 2 LUG SUPPORTS :— ON BOTH LUG SUPPORTS AT VERTICAL WEB.FOR VERTICAL EXCHANGER WITH 3 LUG SUPPORTS :— ON ANY TWO AT VERTICAL WEB.FOR VERTICAL EXCHANGER WITH 4 LUG SUPPORTS :— ON ANY TWO DIAMETRICALLY OPPOSITE ATVERTICAL WEB.

(iii) FOR HORIZONTAL EXCHANGER ON TWO SADDLE SUPPORTS ONE ON CENTRAL WEB.

./48 VPR

Preparedby

4 30.09.2011 REVISED AND REISSUED AS STANDARD

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARDRev.

No. Date Purpose

RKT AKM / SC DMRKG AKM VC

Checked Stds. Committee Stds. BureauConvenor Chairman by Approved by

Format No. 8-00-0001-F4 Rev.0 Copyright EL - All rights reservedPage 117 of 121

YEAR BUILT

kcal /hr

OlgziTX ENGINEMS NDIA LIMITED (A Govt. of Indlo UnclortokIng)

NAME PLATE

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0017 Rev. 4

Page 1 of

6R

4 — 5.5 0 HOLES

NAME OF MANUFACTURER

ENGINEERS INDIA LIMITED DESIGNED BY

MANUFACTURED FOR

ITEM NO.

MANUFACTURER'S SERIAL NO.

CODES

=INSPECTED BY

DESIGN PRESSURE

DESIGN TEMPERATURE

TEST PRESSURE (HYD)

DATE OF TEST

OPERATING FLUID

CORROSSION ALLOWANCE

RADIOGRAPHY

HEAT TREATMENT

DUTY / SURFACE

1WEIGHT FULL OF WATER

TOTAL WEIGHT EMPTY

BUNDLE WEIGHT

SHELL TUBES

m2

'c kg/cm2 g

mm

kg/cm2 g

kg

kg

kg

15 20 52 78

1 5n

CFW

SIDE SHELL

3 THK. FOR SS (MIN.) 6 THK. FOR CS & LAS (MIN.)

MATERIAL : — NAME PLATE STAINLESS STEEL 18 : 8 NAME PLATE BRACKET :— SAME AS EXCHANGER SHELL

170 x 130 NNAME PLATE BRACKET

NOT S: —

1. ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.

2. ALL LETTERS AND LETTER BLOCKS SHALL BE ENGRAVED IN BLACK.

* 3. H = 75 OR 'INSULATION THK. + 10 WHICHEVER IS GREATER.

4. NAME PLATE SHALL BE RIVETED WITH 5 0 ALUMINIUM RIVETS AND SHALL BE TACK WELDED TO BRACKET ON ALL FOUR SIDES.

:(?5. BRACKET WITH NAME PLATE TO BE LOCATED AS MARKED ON DRAWING.

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD t•>6CIp KA RKT SC

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM

Rev. Prepared Checked Stds. Committee

No. Date Purpose by by Convenor

Format No. 8-00-0001-F4 Rev.O

VC Stds. Bureau

Chairman Approved by

Copyright EIL - All rights reserved Page 118 of 121

+0.0

REFER PARA 3.121 dc 3.122 OF TEMA

±3 ADDITION NO LONGITUDIANAL ELEMENT OF THE INSIDE SURFACE SHALL HAVE A BOW OF MORE THAN 1mm. PER METRE OF LENGTH UP TO MAX. OF 3mm.

Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved

1 _

Mo

±3

ENCNEERS UMITFD

11111.11.1•1111~10 (A Govt. of India Undertoking)

±16

TOLERANCES

(SHELL & TUBE EXCHANGERS)

±6

STANDARD No.

7-15-0019 Rev. 4

Page 1 of 3

±3

±3

fn0 + I

LIGAMENT BETWEEN HOLES WILL BE SAME AS LIGAMENT BETWEEN HOLES IN TUBE SHEET ( AS PER TEMA )

±6

±1.5 FOR EXPANDED I

+1

FOR WELDED

3

+0.8 —0.

to

-H

-...JMPINGEMENT PIATE

E—A

+0.8 —0.0

±0.8

±6(MAX.) (NOTE-4)

iqg +l

SECTION—AA

U—TUBE BUNDLE OVERALL LENGTH ±12

+0.8 —0.0

±3

BAFFLE

TAKE (-1 TOLERANCE WHEN TAKE (+) TOLERANCE WHEN CUT IS ON THE ( OF TUBES re=5_11U2EMEEILT±LE=

DETAIL—B TUBE SHEET / (TYPICAL) .Q1:16fflELSME13

Rev.

No. Date Purpose

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD 661D KA RKT

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM

Prepared Checked

by by

VC

Stds. Committee Stds. Bureau Convenor Chairman

Approved by

Page 119 of 121

TOLERANCES

(SHELL & TUBE EXCHANGERS)

STANDARD No.

7-15-0019 Rev. 4

Page 2 of 3

Rev. No. Date Purpose

Prepared Checked

by by

Stds. Committee Stds. Bureau Convenor Chairman

Approved by

RKT

AKM VC

±3 ±3

±3 ±3

00

—+ I

+2.0 —0.0

+8:8

rAri

±0.8 +0.0 +0.0

—0.8 r---1 -0 •8

le I

1n1 .c:D

ii-1 c0 + I co

d 0

-H -H

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD 4P6CP KA

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG

vt.

fI L

+3.0 —0.0

+0.8 —0.0

+0.0 —0.8

cc! 0 -H

L

+

+I-H

. —0+2

+0.8

3 MAX. I

I

TRUE VERTICAL C.

Format No. 8-00-0001-F4 Rev.0 Copyright EIL - AII rights reserved

ENGNEERS 11431A UMITED

somnewormowe (A Govt. ot Indlo UndortokIng)

Page 120 of 121

NENGNIA IRS ID UMITED

1:1111.1~1V111~0 (A Govl. of Indlo Undertoking)

TOLERANCES

(SHELL & TUBE EXCHANGER)

STANDARD No.

7-15-0019 Rev. 4

Page 3 of 3

1.0 FOR NOZZLE 4- dc UNDER

2.0 FOR NOZZLE 6" TO 10" INCL 2.5 FOR NOZZLE 12" TO 16" INCL 3.0 FOR NOZZLE 18" dc ABOVE

1.

11' ! ACTUAL NOZZLE Q

TRUE HORIZ Q

TRUE VERT q_

+1.0 —0.0

00

GENERAL NOTES: —

CUMULATIVE TOLERANCES ON CONSECUTIVE DIMENSIONS SHALL BE LIMITED BY OVERALL DIMENSION TOLERANCE.

2. SPECIFIC TOLERANCES DESIRED FOR ANY PART SHALL BE SHOWN ON THE DRAWING AND SHALL BE GIVEN PREFRENCE TO THOSE GIVEN IN THIS STANDARD.

3. TUBE HOLE TOLERANCES SHALL BE AS PER TEMA.

4. ONLY WHEN NUMBER OF BAFFLE PITCHES EXCEED EIGHT.

L3'

4 06.05.14 REAFFIRMED AND REISSUED AS STANDARD ;1--"G(6P KA RKT 'N3s/ Ofr

.-SC

3 27.01.09 REAFFIRMED AND REISSUED AS STANDARD VPR RKG AKM VC

Rev. Prepared Checked Stds. Committee Stds. Bureau

No. Date Purpose by by

Convenor Chairman Approved by

Fnrrnat Nn R-nn-nnni-F4 RAV n Cnnvrinht Fll - All rinhts rpsnrvnri Page 121 of 121