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Project Documentation NITRIC ACID COMPLEX -DAHEJ PJ-210, DFPCL

IBIC-210-400-ENQ-0058

Enquiry Specification for Shop Fabricated Tanks

Rev

R1

Date of Rev

23/05/2017

Enquiry Specification for Shop fabricated Tanks

R1

23/05/2017

Issue for Enquiry

SAS

NAS

UAD

R0

19/05/2017

For Approval

SAS

NAS

UAD

Rev

Date

Purpose

Prepared by

Checked by

Approved by

REVISION CONTROL

Page 1

Project Documentation NITRIC ACID COMPLEX -DAHEJ PJ-210, DFPCL Enquiry Specification for Shop Fabricated Tanks

IBIC-210-400-ENQ-0058 Rev

R1

Date of Rev

23/05/2017

Table of Contents

1

Introduction

3

2

Site Condition

3

3

Equipment list

4

4

Equipment Detail

4

5

Scope of supply

4

6

Technical Details

5

7

Enclosures

5

I

Equipment General Drawing of equipment / Data Sheet

II

Standard Engineering Specification for Pressure vessels

III Standard Engineering Specification for Storage Tank III

Document Schedule

IV Price schedules V

Devition Form

VI Details for Addition and Deletion of Nozzles,fabrication work

Page 2

Project Documentation NITRIC ACID COMPLEX -DAHEJ PJ-210, DFPCL Enquiry Specification for Shop Fabricated Tanks

1.0

IBIC-210-400-ENQ-0058 Rev

R1

Date of Rev

23/05/2017

INTRODUCTION M/S Deepak Fertilizers and Petrochemicals Corporation Limited (DFPCL) is setting up Nitric Acid Complex having capacity 450 MTPD of Weak Nitric Acid (WNA) & 2 × 140 MTPD of Concentrated Nitric Acid (CNA) at Dahej, near Bharuch, Gujarat and M/S IBI Chematur (Engineering & Consultancy) Ltd.(is the Detailed Engineering Consultant for the same Project. General Information: Client / Owner: Consultant: Site: Plant: Supplier / Vendor:

2.0

Deepak Fertilizers and Petrochemicals Corporation Limited. (DFPCL) IBI Chematur (Engineering & Consultancy) Ltd.(IBIC) Dahej, Near Bharuch, Gujarat State. 450 MTPD of Weak Nitric Acid (WNA) & 2 × 140 MTPD of Concentrated Nitric Acid (CNA). -

SITE CONDITION

Sr.No

Parameters

1 a b c d 2 a b c 3 a b c 4 a b c 5 a b 6 a

Ambient Temp in° C Max DB Max WB Min DB Design dry bulb temperature RH Winter Summer Design Humidity Barometric Pressure Winter Summer Design pressure Rainfall Average rainfall per Year Max rainfall intensity June-Sept rainfall intensity Wind data Maximum velocity Wind direction Earth quake Zone

Units

Data for DFPCL-Dahej site

°C °C °C °C

48 29 5 35

% % %

45 85 75

psia psia psia

14.68 14.43 14.59

mm mm/hour mm

1000 65 920

m/s

47 as per IS-875 Rose diagram 3 as per IS-1893-1984 and Rookie Earth Quake School Report for Bharuch

Page 3

Project Documentation NITRIC ACID COMPLEX -DAHEJ PJ-210, DFPCL

IBIC-210-400-ENQ-0058

Enquiry Specification for Shop Fabricated Tanks 3.0

R1

Date of Rev

23/05/2017

EQUIPMENT LIST:

Sr.No .

Tag No.

Description

1

16T-1620

ABSORBER FEED WATER TANK

2

16V-1675

WEAK ACID TANK

3

16V-9704

4

61V-103

5

61V-104

PLANT AIR BUFFER VESSELS

6

91T-6952

SULPHURIC ACID STORAGE TANK

7

4.0

Rev

91T-6962

CONDENSATE COLLECTION TANK INSTRUMENT AIR BUFFER VESSELS

CAUSTIC STORAGE TANK

Drawing No./ Data Sheet IBIC-210-400-EGD016T-1620 IBIC-210-400-EGD016V-1675 IBIC-210-400-EGD016V-9704 IBIC-210-400-EGD061V-0103 IBIC-210-400-EGD061V-0104 IBIC-210-400-EGD091T-6952 IBIC-210-400-EGD091T-6962

Rev.

Quantity

0

1

0

1

0

1

0

1

0

1

2

1

0

1

EQUIPMENT DETAILS:

Sr.No.

Tag No.

Description

Size

1

16T-1620

ABSORBER FEED WATER TANK

2

16V-1675

WEAK ACID TANK

3

16V-9704

4

61V-103

5

61V-104

PLANT AIR BUFFER VESSELS

6

91T-6952

SULPHURIC ACID STORAGE TANK

7

91T-6962

CAUSTIC STORAGE TANK

1524 I.D x 3048 MM TL. TO TL. 3658 I.D x 10973 MM TL. TO TL. 1982 I.D x 3840 MM TL. TO TL. 1900 I.D x 5300 MM TL. TO TL. 1500 I.D x 4600 MM TL. TO TL. 2300 I.D x 3000 MM HEIGHT 3000 I.D x 3000 MM HEIGHT

CONDENSATE COLLECTION TANK INSTRUMENT AIR BUFFER VESSELS

MOC

Quantity

SS 304L

1

SS 304L

1

CS

1

CS

1

CS

1

CS

1

CS-RL

1

Page 4

Project Documentation NITRIC ACID COMPLEX -DAHEJ PJ-210, DFPCL Enquiry Specification for Shop Fabricated Tanks 5.0

IBIC-210-400-ENQ-0058 Rev

R1

Date of Rev

23/05/2017

SCOPE OF SUPPLY 5.1 The scope of work mainly consists The following 

Supply of all material



Design



Fabrication



Inspection & Testing



Painting for CS tank



Pickling & passivation for SS tanks



Tank Calibration for 91T-6952, 91T-6962 & 16V-1675



Packing & Forwarding

5.2 The Fabricator shall guarantee that the mechanical design, materials and workmanship of all

items are in accordance with this specification and all applicable codes 5.3 Scope of the fabricator shall include design, manufacturing, Testing, Packing & Forwarding as

per the attached drawings & specifications. 5.4 Supply all material required for completion of work in vendor’s scope. This shall cover Design Engineering, Fabrication, stage wise inspection and testing. The scope of vendor’s covers all services and activities required to be carried out for the Shop fabrication of Stainless Steel tanks, carbon steel tank & carbon steel tank with rubber lining. The services and activities to be carried out by the contractor shall include, but not limited to following 

Design calculation as per relevant code specified in drawing



Preparation of fabrication drawings , duly approved by IBIC/DFPCL



Fabrication of Structural work like monkey ladder ,hand railing, pipe support, platform cleats ,insulation ring/cleats



Stage wise inspection As approved QAP.



Testing As per API 650/ ASME Sec VIII Div I



Rubber lining by hot vulcanized rubber & Testing for (91T-6962) as per IS 4682 (PART –I)



Rubbers lining approved vendors are MIL, Lathia, Lebracs, Sriram Rub.



Surface preparation(Pickling & Passivation For SS) as per ASTM A 380.



All carbon steel parts shall be sand blasted as per SA 2 1/2 & painted with Protecto mastic primer (dft 50 micron) with final coat as per Standard Specification for site fabricated Tank Annexure-9.



Supply of foundation bolts as per drawing Page 5

Project Documentation NITRIC ACID COMPLEX -DAHEJ PJ-210, DFPCL Enquiry Specification for Shop Fabricated Tanks

IBIC-210-400-ENQ-0058 Rev

R1

Date of Rev

23/05/2017

5.5 Vendor to submit the following document along with offer 

Sub vendor list



Execution Schedule



Last 3 Years job record



Ongoing project



Last 3year turn over

5.6 The following items shall be constructed as part of fabricator’s scope of supply whether the

same is specially indicated in the drawings & datasheet or not. a. b. c. d.

e. f. g. h. i. j. k. l.

Cleats of insulation 3 sets of spare gaskets for manholes. Hand holes & connection where blind flange is provided. Blind flanges & extra 10% nut bolts for all manholes, hand holes & spare nozzles. Suitable flanged joints or otherwise removable designs in respect of all internals to enable removal through manhole unless specifically noted otherwise in the datasheets / drawings. Stiffening of nozzles 40 NB & below by 3 gussets. Lifting lugs Test rings / flanges wherever required for testing of the unit. Davit arms or hinge cover for man ways. Name plates Earthing cleats Foundation bolts/ Foundation Template Structural items like ladders, platforms etc.

5.7 Design requirement:



16T-1620 ABSORBER FEED WATER TANK:

Design Parameter Design code Volume (Nom.) Fluid Density Design Pressure (Int. / Ext.) Design Temperature Hydrotest pressure

Good Engineering Practice 6M³ Absorber Feed Water 994 Kg/M³ Atmosphere 95°C Water fill Page 6

Project Documentation NITRIC ACID COMPLEX -DAHEJ PJ-210, DFPCL Enquiry Specification for Shop Fabricated Tanks Corrosion Allowance Joint Efficiency (Shell / Roof) Wind Load Seismic Zone Material of construction



IBIC-210-400-ENQ-0058 Rev

R1

Date of Rev

23/05/2017

Nil 0.85 max. 47 m/s Zone 3 acc. to IS 1893 SS304L

16V-1675 WEAK ACID TANK:

Design Parameter Design code Volume (Nom.) Fluid Density Design Pressure (Int. / Ext.) Design Temperature Hydrotest pressure Corrosion Allowance Joint Efficiency(Shell / Dished End) Wind Load Seismic Zone Material of construction 

API650 LATEST EDITION 115 M³ Weak Acid 1340 Kg/M³ 8” WC + LIQUID HEAD 149°C AS PER CODE Nil 0.85 max. 47 m/s Zone 3 acc. to IS 1893 SS304L

16V-9704 CONDENSATE COLLECTION TANK:

Design Parameter Design code Volume (Nom.) Fluid Density Design Pressure (Int. / Ext.) Design Temperature Hydrotest pressure Corrosion Allowance Joint Efficiency (Shell / Dished End) Wind Load Seismic Zone Material of construction Insulation

ASME Sec VIII Div I 12 M³ Condensate 960 Kg/M³ 0.8 Bar 121 °C 1.04 Bar Nil 0.85/ 1 max. 47 m/s Zone 3 acc. to IS 1893 SS304L Hot Insulation 60 mm

Page 7

Project Documentation NITRIC ACID COMPLEX -DAHEJ PJ-210, DFPCL Enquiry Specification for Shop Fabricated Tanks 

IBIC-210-400-ENQ-0058 Rev

R1

Date of Rev

23/05/2017

61V-103 INSTRUMENT AIR BUFFER VESSELS:

Design Parameter Design code Volume (Nom.) Fluid Density Design Pressure (Int. / Ext.) Design Temperature Hydrotest pressure Corrosion Allowance Joint Efficiency (Shell / Dished End) Wind Load Seismic Zone Material of construction 

ASME Sec VIII Div I 15 M³ Instrument Air 7.7 Kg/M³ 9.4 Bar 70 °C 12.22 Bar 3 mm 0.85/ 1 max. 47 m/s Zone 3 acc. to IS 1893 Carbon steel

61V-104 PLANT AIR BUFFER VESSELS:

Design Parameter Design code Volume (Nom.) Fluid Density Design Pressure (Int. / Ext.) Design Temperature Hydrotest pressure Corrosion Allowance Joint Efficiency (Shell / Dished End) Wind Load Seismic Zone Material of construction 

ASME Sec VIII Div I 8 M³ Plant Air 9.32 Kg/M³ 9.4 Bar 70 °C 12.22 Bar 3mm 0.85/1 max. 47 m/s Zone 3 acc. to IS 1893 Carbon steel

91T-6952 SULPHURIC ACID STORAGE TANK:

Design Parameter Design code Volume (Nom.) Fluid Density Design Pressure (Int. / Ext.) Design Temperature Hydrotest pressure

API650 LATEST EDITION 12M³ 98% H2SO4 1840 Kg/M³ @ 25 °C Atmosphere 70°C AS PER CODE Page 8

Project Documentation NITRIC ACID COMPLEX -DAHEJ PJ-210, DFPCL Enquiry Specification for Shop Fabricated Tanks Corrosion Allowance Joint Efficiency(Shell / Roof) Wind Load Seismic Zone Material of construction



IBIC-210-400-ENQ-0058 Rev

R1

Date of Rev

23/05/2017

3 mm for shell & bottom & 1mm for roof 0.85 max. 47 m/s Zone 3 acc. to IS 1893 Carbon steel

91T-6962 CAUSTIC STORAGE TANK:

Design Parameter Design code Volume (Nom.) Fluid Density Design Pressure (Int. / Ext.) Design Temperature Hydrotest pressure Corrosion Allowance Joint Efficiency(Shell / Dished End) Wind Load Seismic Zone Material of construction

API650 LATEST EDITION 20 M³ 44% CAUSTIC SOLN. 1458 Kg/M³ Atmosphere 75°C AS PER CODE Nil 0.85 max. 47 m/s Zone 3 acc. to IS 1893 CS/RL

The contractor shall carry out mechanical design of the tanks as per specified codes and standard & submit design calculation for IBIC/DFPCL approval

6.0

TECHNICAL DETAIL 6.1

Equipment shall be designed as per ASME Sec VIII Div I edition 2015/API 650/ unless otherwise indicated.

6.2

Equipment shall be fabricated as per attached Equipment general drawing.

6.3

Rubber lining thickness: 4.5 mm natural rubber, hardness 65-70 shore A for rubber lined Tank (91T-6992).

6.4

Rubber lining & inspection shall be done as per IS4682 (part -I) for (91T-6992) Tank.

6.5

Vendor to use hot vulcanization method for curing rubber lining for (91T-6962) Tank.

6.6

All flanges opening shall be blanked off with 12thk plywood or steel disc to secure with 4 Nos bolts minimum.

6.7

Carbon content in forging & plates shall not exceed 0.25%.

6.8

All R/F pad holes shall be plugged. Page 9

Project Documentation NITRIC ACID COMPLEX -DAHEJ PJ-210, DFPCL Enquiry Specification for Shop Fabricated Tanks 6.9

IBIC-210-400-ENQ-0058 Rev

R1

Date of Rev

23/05/2017

All carbon steel part shall be sand blasted 2 ½ & 3 coat of zinc phosphate primer.

6.10 Vendor to mark the nozzle No. & orientation detail on equipment. 6.11 Water for hydro testing shall not have chorine content exceeding 25 ppm for SS 7 50 PPM for

CS. 6.12 Calibration of tank is in vendor's scope. Prepare calibration chart by ullage method & get it

duly Certified by local weight & measures authorities for 91T- 6962, 91T- 6952 & 16V-1675 Tanks.

1.0

ENCLOSURES

I. II. III. IV. V. VI.

Equipment General Drawing of equipment / Data Sheet Standard Engineering Specification for Pressure vessels Standard Engineering Specification for Storage Tank Document Schedule Price schedules Devition Form

Page 10

DESIGN DATA

NOZZLE DATA LIST 500

WASHER PLATE TO BE WELDED AFTER POSITIONING OF EQUIPMENT

RAFTERS

REFER DETAIL-'A'

5THK ROOF PLATE

170 88

82

= 175 =

= 100 = HOLE

8

150

180

50

HOLE

10 10

250

12 Thk.

250

165

ANCHOR BOLT

= 150 =

50

270

300 HOLD

5THK. PAD

= 230 =

12 Thk.

500

ID

HOLE

EARTHING EC CONN.

3048 TOTAL HEIGHT

50

10 Thk.

= 100 =

10 Thk.

25

R25

DETAIL OF ANCHOR CHAIR (4 NOS.)

5 THK

0 20

100

25

1/4" NPT (1 NO.) TELL TALE HOLE

225

150

750

100

1000

R40

250

12 250

L01A 2" L01B 2" L02A 2" L02B 2" M01 24" N01 2" N02 2" 4" N03 N04 3" N05 3" N06 4" N07 2" N08 1" N09 2" T01 1 1/2" EC NP LL

80S 80S 80S 80S 80S 80S 40S 40S 40S 40S 80S 80S 80S 80S -

Type SO SO SO SO SO SO SO SO SO SO SO SO SO SO SO -

Flange Face RF RF RF RF RF RF RF RF RF RF RF RF RF RF RF -

Rating CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 -

Description Level Transmitter Level Transmitter Level Transmitter Level Transmitter Manway (Access) Waste water Inlet DEMN. Water Inlet Drain Vent Water Outlet Overflow Spare + BF Pump Recirculation Spare + BF Temparature Indicator Earthing Conn. Name Plate Lifting Lug

Remarks

API 650

5

DESIGN CODE CODE STAMP REQUIRED Volume (Nom.)

GOOD ENGINEERING PRACTICE

Fluid Density

ABSORBER FEED WATER

6.0

994

Design Pressure (Int. / Ext.)

Bar g ATMOSPHERIC

Design Temperature Operating Pressure Operating Temperature

Bar g

Hydrostatic Test Pressure Corrosion Allowance

95

35 Bar g

WATER FILL

mm 0

Joint Efficiency (Shell / Dished End)

0.85

Radiography (Shell / Dished End)

10% + ALL T JOINT mm NIL

Insulation Type / Thk. 2 Nos 1 No. 4 Nos

ATM

Impact Test

-

P.W.H.T

-

M.D.M.T Wind Load

-

Notes continue...:-

Seismic Zone

Zone 3 acc. to IS 1893

19. PIPING ROUTINE FOR OVERFLOW NOZZLE UP TO GROUND FLOOR WILL BE IN OTHER'S SCOPE. 20. VENDOR TO PROVIDE 200% GASKETS & 10% EXTRA BOLTING AS SPARES. 21. LIFTING LUGS, EARTHING LUGS & NAME PLATE TO BE PROVIDED BY FABRICATOR.

Fabrication Tolerances

Refer Standard Specification

Painting Surface Preparation Lethal Service

-

max. 47 m/s

Pickling & Passivation YES kg ~ 1280

Empty Weight Operating Weight Hydrotest Weight Location Inspection Seismic Moment Wind Moment

kg ~ 4270 kg ~ 7280 OUT DOOR IBIC / DFPCL kg-m

-

kg-m

-

MATERIAL SPECIFICATION

HO LE

150

SCH/THK

23. FOR NAME PLATE REFER STANDARD IBIC-400-STD-70 & IBIC-400-STD-74. 24. CALIBRATION OF TANK IS IN VENDOR'S SCOPE. PREPARE CALIBRATION CHART BY NORMAL METHOD & GET IT DULY CERTIFIED BY BY LOCAL WEIGHT & MEASURES AUTHORITIES.

100 6 THK.

5 R1 P. TY

FOR 4 NOS. ANCHOR CHAIRS

ND

16 THK.

SA 240 GR.304L SHELL SA 240 GR.304L ROOF SA 240 GR.304L BASE PLATE IS 2062 GR.B RAFTERS SS 304L CURB ANGLE SA312 TP304L NOZZLE PIPE NOZZLE FLANGE SA182 F304L GASKET REFER NOTE 6

ANCHOR CHAIR ANCHOR BOLTS SUPPORT CLEATS INTERNALS NAME PLATE R.F.PAD FITTINGS EARTHING LUG

IS 2062 GR.B SA 193 GR B7 SA240 GR304L SS 304L SS.304L SA240 GR304L SA403 WP304L S.S.304

Notes:01. ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE STATED. 02. ALL NOZZLES UP TO 1 1/2" NB SIZE PROVIDED WITH 3 NOS. OF STIFFENERS.

DETAIL OF LIFTING LUGS (4 NOS.)

& OD OF R.F. PAD SHALL BE AS PER API 650.

ELEVATION 150

10 Thk. = 30 =

09. ALL T/T HOLES TO BE PLUGGED WITH METALLIC CAP.

15 80

DETAIL OF EARTHING CONN.

5 THK

12. VENDOR TO PROVIDE FABRICATION NOZZLE LOAD IN DRAWING. 13. VENDOR TO USE BACKING STRIP PLATE FOR BOTTOM PLATE WELD JOINT

TYP.

LL

LL

ROOF PLATE

05. MANHOLE FLANGE DIMENSIONS SHALL BE AS PER API 650. 06. GASKET - TYPE S.S. SPIRAL WOUND FLEXIBLE GRAPHITE FILLED S.S. INNER RING & S.S. OUTER RING, AS PER ASME B16.20 07. ALL NON PRESSURE PARTS MIN. 5 MM THK. UNLESS OTHERWISE SPECIFIED.

BY STRESS CALCULATION.

VALID FOR ALL NOZZLES IF NOT OTHERWISE INDICATE

17. ATTACHMENT WELDS OF ANY PERMANENT ATTACHMENT TO SHELL/ROOF SHALL BE DP TESTED. 18. PICKLING & PASSIVATION TO BE CARRIED OUT AS PER ASTM A380 FOR SS.

25

R1 R0

FPW LL LL

23.05.2017 03.05.2017

Rev.

Date

Issued for Enquiry Issued for Approval

VYT VYT

Description

SAS SAS

NAS NAS

Rev. By Chkd. By Appd. By

CLIENT:

5

Nitric Acid Complex at Dahej, Gujarat. CONSULTANT

Issued :

Approved

NAS

Dept. No.

400

Checked

SAS

Scale

1:20

VYT

Date

03/05/2017

Detailed Engineering (SUB CONTRACTOR)

NOZZLE ORIENTATION LADDER, PLATFORM ORIENTATION (HOLD) DETAIL 'A'

Project No

:

Created

Client

:

Dwg.No.

Project

:

Site

:

Title

:

Doc. Type

:

Sheet No.:

1 of 1

Rev

R1 A1

I P

H

1630 HOLD A

C

B 1150 HOLD

MH2

ID

HANDRAIL WASHER PLATE TO BE WELDED AFTER POSITIONING OF EQUIPMENT

1150 HOLD

175

515

650 HOLD

ROOF 5THK

REF. DETAIL 'B'

5 THK. PAD

55

150

45

125

350 HOLD G1B

20

8

150

50

200

20

US

ANCHOR BOLT

200

F1B

INS R365 IDE 8 RAD I

500

350 HOLD

75

100

8

75

EC

SHELL I.D.

R1

A B C D E F1A F1B G1A G1B H I J MH-1 MH-2 P EC NP LL

DESIGN DATA

NOZZLE DATA LIST Flange ND SCH/THK Description Type Face Rating 80S SO RF CL 150 2" 80S SO RF CL 150 2" 80S SO RF CL 150 2" 40S SO RF CL 150 3" 80S SO RF CL 150 Outlet 2" 40S SO RF CL 150 L.L. Gauge 3" 40S SO RF CL 150 L.L. Gauge 3" 40S SO RF CL 150 L.L. Gauge 3" 40S SO RF CL 150 L.L. Gauge 3" CL 150 Pressure Relief HOLD SO RF CL 150 Vac. Relief HOLD SO RF CL 150 Spare w/ B.F. 80S 2" API 650 Manway w / davit 20" API 650 20" WN RF CL 150 LT 40S 3" Earthing Conn. Name Plate Lifting Lug

DESIGN CODE CODE STAMP REQUIRED Volume (Nom.) Fluid Density Bar g Design Pressure (Int. / Ext.) Design Temperature Bar g Operating Pressure Operating Temperature

Remarks

Hydrostatic Test Pressure Corrosion Allowance As per API 650 As per API 650 2 Nos 1 No. 4 Nos

Notes continue...:20. VENDOR TO PROVIDE 200% GASKETS & 10% EXTRA BOLTING AS SPARES. 21. LIFTING LUGS, EARTHING LUGS & NAME PLATE TO BE PROVIDED BY FABRICATOR.

50

DETAIL OF ANCHOR CHAIR ON BASE PLATE (8 NOS.) DETAIL 'A'

MIDDLE ON LADDER. TOE GUARD - 100MM x 4 MM THICK MS PLATE. 24. FOR NAME PLATE REFER STANDARD IBIC-400-STD-70 & IBIC-400-STD-74. 25. CALIBRATION OF TANK IS IN VENDOR'S SCOPE. PREPARE CALIBRATION CHART BY ULLAGE METHOD & GET IT DULY CERTIFIED BY BY LOCAL WEIGHT & MEASURES AUTHORITIES. 26. GASKET - 1/8" VIRGIN NONPOROUS TEFLON TFE

5THK ROOF PLATE

50x50x6THK CURB ANGLE

5

25

1/4" NPT (1 NO.) TELL TALE HOLE

0 225

R4 150

1200

HO L

E

12

5 R1 P. TY

5

5THK

DETAIL OF LIFTING LUGS (4 NOS.)

DETAIL 'B'

1340 8" W.C + Liquid Head 149 ATM

42 Bar g AS PER CODE mm NIL

Seismic Zone Fabrication Tolerances Painting Surface Preparation Lethal Service Empty Weight Operating Weight Hydrotest Weight Location Inspection Seismic Moment Wind Moment

Zone 3 acc. to IS 1893 Refer Standard Engineering Specification Pickling & Passivation kg ~ 8450 kg ~ 162550 kg ~ 124000 OUT DOOR IBIC / DFPCL kg-m kg-m -

SHELL ROOF / DISH END BASE PLATE RAFTERS CURB ANGLE NOZZLE PIPE NOZZLE FLANGE GASKET

SA240 GR304L SA240 GR304L SA240 GR304L SA240 GR304L SS 304L SA312 TP304L SA182 F304L SEE NOTE - 26

ANCHOR CHAIR ANCHOR BOLTS SUPPORT CLEATS INTERNALS NAME PLATE R.F.PAD FITTINGS EARTHING LUG

IS 2062 GR.B SA 193 GR B7 SA240 GR304L SS 304L SS.304L SA240 GR304L SA403 WP304L S.S.304

Notes:01. ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE STATED. 02. ALL NOZZLES UP TO 1 1/2" NB SIZE PROVIDED WITH 3 NOS. OF STIFFENERS.

16 THK. LL

& OD OF R.F. PAD SHALL BE AS PER API 650.

05. MANHOLE FLANGE DIMENSIONS SHALL BE AS PER API 650. 06. ALL NON PRESSURE PARTS MIN. 5 MM THK. UNLESS OTHERWISE SPECIFIED.

150

N

08. ALL T/T HOLES TO BE PLUGGED WITH METALLIC CAP.

EC

PLATE WITH 100% RADIOGRAPHY.

8 NOS - RAFTERS ISMC 75 LL

11. VENDOR TO PROVIDE FABRICATION NOZZLE LOAD IN DRAWING. 12. VENDOR TO USE BACKING STRIP PLATE FOR BOTTOM PLATE WELD JOINT

LL

R1630 HOLD

BY STRESS CALCULATION.

16. ATTACHMENT WELDS OF ANY PERMANENT ATTACHMENT TO SHELL/ROOF SHALL BE DP TESTED. 17. PICKLING & PASSIVATION TO BE CARRIED OUT AS PER ASTM A380 FOR SS.

VALID FOR ALL NOZZLES IF NOT OTHERWISE INDICATED

250

PROTECTO MASTIC PRIMER (DFT 50 MICRON)

R1 HO 150 LD LADDER-2

1 120

REFER DETAIL 'A'

D

VYT VYT

Description

NAS NAS

SAS SAS

Rev. By Chkd. By Appd. By

230 15

MID LANDING PLATFORM

LL

LL

EC LADDER-1

G1A G1B

ELEVATION

Date

Issued for Enquiry Issued for Approval

CLIENT:

NOZZLE ORIENTATION LADDER, PLATFORM ORIENTATION (HOLD)

80

TYP.

175

E

23.05.2017 18.05.2017

Rev.

500 HOLD

J

= 30 =

NP

R1 R0

150

10 Thk.

200

G1A F1A

750

10973 TOTAL HEIGHT

100

5

WEAK ACID

MATERIAL SPECIFICATION

5 THK.

RAFTERS

115

0.85 Joint Efficiency (Shell / Dished End) 10% + ALL 'T' JOINT Radiography (Shell / Dished End) mm Insulation Type / Thk. Impact Test P.W.H.T M.D.M.T max. 47 m/s Wind Load

100

5 THK

API 650 (LATEST EDITION) -

DETAIL OF EARTHING CONN.

Nitric Acid Complex at Dahej, Gujarat.

D

CONSULTANT

500 (HOLD) NOZZLE DETAIL FOR N05

Issued :

Approved

NAS

Dept. No.

400

Checked

SAS

Scale

1:20

VYT

Date

25/04/2017

Detailed Engineering (SUB CONTRACTOR)

Project No

:

Created

Client

:

Dwg.No.

Project

:

Site

:

Title

:

Doc. Type

:

Sheet No.:

1 of 1

Rev

R1 A1

200

90

125

12

12 THK

12 THK

12

EC

100

N02 N13 N09 N14

350 HOLD

LT

6Thk.

24 THK.

250 HOLD

250 HOLD

N06 N07 N08

350 HOLD

L01A L02A

W.L.

200 230 250 HOLD HOLD HOLD

2:1 ELLIPTICAL DISH END NOM. 8THK. MIN. 6THK. TYP. 3 NOS. INSULATION SUPPORT RING 2" x 2" x 3/8" ANGLE WELDED TO SHELL

50 S.F. (TYP.)

655

T.L.

FOR M 20 BOLTS.

N10

ND

SCH/THK

N01 N02 N03 N04 N05 N06 N07 N08 N09 N10 N11 N12 N13 N14 M01 L01A/B L02A/B EC NP LT

4" 3" 3" 3" 4" 4" 1 1/2" 1 1/2" 4" 3" 3" 3" 2" 1 1/2" 24" 2" 2"

40 40 40 40 40 40 160 160 40 40 40 40 160 160 40 40 -

-

Type SO SO SO SO SO SO SO SO SO SO SO SO SO SO SO WN WN -

Flange Face RF RF RF RF RF RF RF RF RF RF RF RF RF RF RF RF RF -

Rating CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 -

Description Vent Cold Cond. Inlet Inlet from Steam Cond. Hot Cond. Inlet Cond. Outlet Overflow Pump Min. Flow Inlet Inlet Spare Spare Pressure Indicator Temparature Indicator

Remarks

W/ B.F.

W/ B.F. W/ B.F.

W/ B.F. level gauge Level Transmitter Earthing Conn. Name Plate Lifting Trunion

2 Nos 1 No. 2 Nos

EACH SIDES TOTAL 94 NOS. SEE SPARGER SUPPORT DETAIL

M01 NP

750

610

N04

50

VALID FOR ALL NOZZLES IF NOT OTHERWISE INDICATED

DETAIL OF LIFTING TRUNION (QTY. 2 NOS.)

250

L01B

W.L.

T.L. 6NOS - 3" SKIRT VENT

REFER DETAIL 'B' VORTEX BREAKER

4" STD. WT.PIPE

38

U-BOLT FOR 3" PIPE W/NUTS

PIPE CAP

SPARGER PIPE

8" SCH. 40S PIPE SLEEVE x 3"(76MM) LONG

CL. OF 20" x 8" ACCESS OPENING

Design Temperature Operating Pressure Operating Temperature Hydrostatic Test Pressure Corrosion Allowance

960 Bar g

0.8 121

Bar a

1.0 98

Bar g

-

mm 3.0

Joint Efficiency (Shell / Dished End)

0.85/1

10% + ALL 'T' JOINT Radiography (Shell / Dished End) mm Hot Insulation / 60 Insulation Type / Thk.

Impact Test

-

P.W.H.T

-

M.D.M.T

-

Wind Load

max. 47 m/s

Seismic Zone

Zone 3 acc. to IS 1893

Fabrication Tolerances

Refer Standard Engineering Specification

Painting Surface Preparation Lethal Service

Refer Note 12 -

Empty Weight Operating Weight

kg ~ 2700

Hydrotest Weight Location Inspection Seismic Moment Wind Moment

kg ~ 16550

kg ~ 14220 OUT DOOR IBIC / DFPCL kg-m

776

kg-m

4304

22. FINISH CS : REMOVE ALL FUSED & LOOSE WELD SPATTER, SLAG, SCALE FOREIGN MATERIAL. SANDBLAST ALL OUTSIDE CARBON STEEL SURFACES TO SPEC-SP10 "NEAR WHITE FINISH" SHELL AND UPPER PORTION OF SKIRT - PRIME W/ ONE (1) COAT OF INTERNATIONAL PROTECTIVE COATINGS INTER ZINC 22. 2.0 MLS D.F.T.

SHELL

SA 516 GR.70

BOLTS & NUTS

HEADS

SA 516 GR.70

SUPPORT

SA 516 GR.70

BASE PLATE

SA 516 GR.70

INTERNALS

SS 304

COIL / JACKET

N.A

REINFORCING PAD

SA 516 GR.70

BODY FLANGE

NAME PLATE

SS 304

GASKET

N.A N.A

FITTINGS

SA 234 WPB

BOLTS & NUTS

-

INSULATION CLEATS -

NOZZLE PIPE

SA 516 GR.70/ SA 106 Gr.B

EARTHING LUG

NOZZLE FLANGE

SA 105

FOUNDATION BOLTS SA 193 B7

GASKET

SEE NOTE 22

LAP RING

SS 304 -

Notes

25 TYP.

6

6THK

52

ELEVATION

185

1425 (HOLD)

03.

8"

730

Condensate

01. ALL DIMENSIONS ARE IN M.M. UNLESS OTHERWISE STATED. 02.

6 THK

N05

TYP.

52

REFER DETAIL 'A'

25 6

185

M01 N13

CL. OF 20" ACCESS OPENING

SPARGER SUPPORT DETAIL (TYPICAL)

FOR M-20 BOLTS

N09

04. ALL T/T HOLES TO BE PLUGGED AFTER HYDROTEST. 05. ALL BOLT HOLES OF FLANGES SHALL BE STRADDLE WITH PRINCIPLE C/L OF VESSEL. 06. ALL NOZZLE FLANGES SHALL BE ASME B16.5 AND GASKET SEATING SURFACE SHALL BE SERRATED TYPE UNLESS OTHERWISE SPECIFIED. 07. LIFTING LUGS, EARTHING LUGS & NAME PLATE TO BE PROVIDED BY FABRICATOR. 08. WELD WHICH IS ACCESSIBLE FROM OTHER SIDE SHOULD BE BACK CHIP UP TO SOUNDMETAL AND REWELD OR OTHER WISE TIG WELDED. 09. EQUIPMENT TO BE HYDROTESTED IN HORIZONTAL POSITION. 10. CLEATS FOR INSULATION SHALL BE PROVIDE BY EQUIPMENT SUPPLIER. 11. ALL INSIDE WELDS SHALL BE FLUSH WITH SHELL I.D. 12. PRIMER PAINT SHALL BE PROVIDE ON ALL C.S PARTS. 13. PAD PLATE PROVIDED 3" NB & ABOVE NOZZLES. 14. FOR NAME PLATE DETAILS REF. DRG. NO:-IBI-400-STD-70 / 71.

16. VENDOR TO PROVIDE LADDER AND HANDRAIL WITH TOE PLATE.

N02 N10

N06

N

12

Fluid

ASME Sec. VIII DIV.1 Latest Edition, Code stamp required

MATERIAL SPECIFICATION 10THK.

1200 305 HOLD

N03

LT 1630 HOLD

803 23 SPACES @ 35

D

803 23 SPACES @ 35

150

PA

6THK RF PAD

1219 (HOLD)

L02B

200

RF

400 HOLD

N12 200 NB SCH 40 PIPE

DESIGN CODE CODE STAMP REQUIRED Volume (Nom.) Density Design Pressure (Int. / Ext.)

500 HOLD

6 THK

3840 T.L. TO T.L.

ID

DETAIL OF ANCHOR CHAIR ON BASE PLATE DETAIL 'A'

N11

TOE GUARD - 100MM x 4 MM THICK MS PLATE. 17. VENDOR TO PROVIDE FOUNDATION BOLTS AND TEMPLATE 18. VENDOR TO REINFORCE ALL NOZZLES TO COMPLY WITH CODE. 19. VENDOR TO BE FURNISHED & INSTALLED MATERIAL UNLESS OTHERWISE SPECIFIED. 20. VENDOR TO PROVIDE DESIGN AND PROVIDE LIFTING TRUNION, 21. SUPPLY OF LADDER AND HANDRAIL IS IN VENDOR'S SCOPE.

10 THK.

LT

6

LT

N01

N04 N11

N05 N08

R1 R0

= 30 =

2250 (HOLD)

DESIGN DATA

NOZZLE DATA LIST

HANDRAIL

N01

N12

23.05.2017 12.05.2017

Rev.

Date

Issued for Enquiry Issued for Approval

VYT VYT

Description

SAS SAS

NAS NAS

Rev. By Chkd. By Appd. By

CLIENT:

Nitric Acid Complex at Dahej, Gujarat.

6 35 50

L01A L01B

CL. OF 8" ACCESS OPENING 8" SCH.40S PIPE x 76 DEEP

L02A L02B N03 N07 N14

NOZZLE ORIENTATION PLAN (HOLD)

15

DETAIL 'B' SKIRT SHELL TO DISH JOINT

DETAIL OF EARTHING CONN. (QTY. 2 NOS.)

CONSULTANT

Issued :

Approved

NAS

Dept. No.

400

Checked

SAS

Scale

1:18

VYT

Date

12/05/2017

Detailed Engineering (SUB CONTRACTOR)

Project No

:

Created

Client

:

Dwg.No.

Project

:

Site

:

Title

:

Doc. Type

:

Sheet No.:

1 of 1

Rev

R1 A1

DESIGN DATA

NOZZLE DATA LIST 200 NB SCH 40 PIPE

D PA RF

200 10THK RF PAD

HAND RAIL

LT

10THK.

S03

50 S.F.

2:1 ELLIPTICAL DISH END NOM. THK. 14 MM MIN. THK. 12 MM TYP.

DETAIL OF LIFTING TRUNION (QTY. 2 NOS.)

ID

ND

SCH/THK

N01 N02 N03 N04 M01 P01 P02 S01 S02 S03 EC NP LL ACH

2" 2" 1 1/2" 2" 24" 2" 2" 2" 2" 2" -

160 160 160 160 10THK 160 160 160 160 160 --

Type WN WN WN WN WN WN WN WN WN WN -

Flange Face RF RF RF RF RF RF RF RF RF RF -

Rating CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 -

Description

Remarks

Pressure Safety valve With Davit arm Pressure Transmitter Pressure Gauge Spare Spare Spare Earthing Conn. Name Plate Lifting Lug Anchor Chair

DESIGN CODE CODE STAMP REQUIRED Volume (Nom.)

15

Fluid

INSTRUMENT AIR

-

Density

7.7

Design Pressure (Int. / Ext.) B.F. B.F. B.F. 2 Nos 1 No. 4 Nos 8 Nos

ASME Sec. VIII DIV.1

Design Temperature Operating Pressure Operating Temperature Hydrostatic Test Pressure Corrosion Allowance

Bar g Bar g

200

500

20

125

12

58

200

LT

10

12

20

24 THK.

100

EC

10

FOR M 20 F BOLTS.

LADDER

DETAIL 'A' SKIRT SHELL TO DISH JOINT

DETAIL OF ANCHOR CHAIR ON BASE PLATE

12 THK

0.85/1

Radiography (Shell / Dished End)

10Thk.

N02 S01

12.5

mm 3

10% + ALL 'T' JOINT mm -

Insulation Type / Thk.

W.L.

7.0 AMBIENT

Bar g

Joint Efficiency (Shell / Dished End)

T.L.

9.4 70

Impact Test

-

P.W.H.T

-

M.D.M.T Wind Load

-

Seismic Zone

Zone 3 acc. to IS 1893

Fabrication Tolerances

Refer Standard Engineering Specification

Painting Surface Preparation Lethal Service

Refer Note 12

max. 47 m/s

-

Empty Weight Operating Weight

kg ~ 5800

Hydrotest Weight Location Inspection Seismic Moment Wind Moment

kg ~ 22600

kg ~ 5900

OUT DOOR IBIC / DFPCL N-m

248162

N-m

889407

MATERIAL SPECIFICATION 5300 T.L. TO T.L.

N04

150

P01 P02

N S03

SHELL

SA 516 GR.70

BOLTS & NUTS

HEADS / ROOF

SA 516 GR.70

SUPPORT

SA 516 GR.70

BASE PLATE

SA 516 GR.70

INTERNALS

-

COIL / JACKET

N.A

REINFORCING PAD

SA 516 GR.70

BODY FLANGE

NAME PLATE

SS 304

GASKET

N.A N.A

FITTINGS

SA 234 WPB

BOLTS & NUTS

-

INSULATION CLEATS -

NOZZLE PIPE

SA 106 Gr.B

EARTHING LUG

NOZZLE FLANGE

SA 105

FOUNDATION BOLTS SA 193 B7

GASKET

ASBESTOS FREE

LAP RING

SS 304 -

NP

N02 N01

Notes 01. ALL DIMENSIONS ARE IN M.M. UNLESS OTHERWISE STATED. 02.

250

03.

S02 P01

04. ALL T/T HOLES TO BE PLUGGED AFTER HYDROTEST.

500

05. ALL BOLT HOLES OF FLANGES SHALL BE STRADDLE WITH PRINCIPLE C/L OF VESSEL. 06. ALL NOZZLE FLANGES SHALL BE ASME B16.5 AND GASKET SEATING SURFACE SHALL BE SERRATED TYPE UNLESS OTHERWISE SPECIFIED. 07. LIFTING LUGS, EARTHING LUGS & NAME PLATE TO BE PROVIDED BY FABRICATOR. 08. WELD WHICH IS ACCESSIBLE FROM OTHER SIDE SHOULD BE BACK CHIP UP TO SOUNDMETAL AND REWELD OR OTHER WISE TIG WELDED. 09. EQUIPMENT TO BE HYDROTESTED IN HORIZONTAL POSITION. 10. CLEATS FOR INSULATION SHALL BE PROVIDE BY EQUIPMENT SUPPLIER. 11. ALL INSIDE WELDS SHALL BE FLUSH WITH SHELL I.D. 12. PRIMER PAINT SHALL BE PROVIDE ON ALL C.S PARTS. 13. PAD PLATE PROVIDED 3" NB & ABOVE NOZZLES. 14. FOR NAME PLATE DETAILS REF. DRG. NO:-IBI-400-STD-70 / 71.

N03 BOTTOM N01 N04

NP M01

M01

50 S.F.

750

800

S02 S01

NOZZLE ORIENTATION (PIPING, LADDER AND PLATFORM SUPPORT CLEATS ORIENTATION) (HOLD)

W.L.

LT

T.L.

A0

350

ACH

V0 ACH

FOR M 20 BOLTS.

'B'

350

V0

1904 I.D.

1500

N03 10 THK

150

VALID FOR ALL NOZZLES IF NOT OTHERWISE INDICATE

16. VENDOR TO PROVIDE LADDER AND HANDRAIL WITH TOE PLATE. TOE GUARD - 100MM x 4 MM THICK MS PLATE. 17. VENDOR SHALL PROVIDE FOUNDATION BOLTS AND TEMPLATE (SA 36) WITHIN 3 MONTHS OF ORDER FOR FOUNDATION PREPARATION AT SITE 18. SUPPORT CLEATS FOR PLATFORMS AS REQUIRED SHALL BE SUPPLIED BY VENDOR. LADDER, HANDRAILS SHALL BE SUPPLIED BY VENDOR.

10 THK.

V0 EC ACH

= 30 =

350

EC

24 THK

A0

'A'

R1 R0

23.05.2017 03.05.2017

Rev.

ACH

Date

Issued for Enquiry Issued for Approval

VYT VYT

Description

SAS SAS

NAS NAS

Rev. By Chkd. By Appd. By

CLIENT:

ACH V0

35

Nitric Acid Complex at Dahej, Gujarat.

15

CONSULTANT

EC

50

Issued :

Approved

NAS

Dept. No.

400

Checked

SAS

Scale

1:18

VYT

Date

19/04/2017

Detailed Engineering (SUB CONTRACTOR)

ACH V0

ELEVATION

LT

ACH

ORIENTATION ANCHOR CHAIR DETAIL ON SKIRT SHELL (HOLD)

DETAIL OF EARTHING CONN. (QTY. 2 NOS.)

Project No

:

Created

Client

:

Dwg.No.

Project

:

Site

:

Title

:

Doc. Type

:

Sheet No.:

1 of 1

Rev

R1 A1

200 NB SCH 40 PIPE

50 S.F.

200

10THK RF PAD

LT

N02 S01

500

AD

W.L.

200

P RF

2:1 ELLIPTICAL DISH END NOM. THK. 12 MM MIN. THK. 10 MM TYP.

T.L.

DESIGN DATA

NOZZLE DATA LIST

HAND RAIL S03

LT

ID

ND

SCH/THK

N01 N02 N03 N04 M01 P01 P02 S01 S02 S03 EC NP LT ACH

2" 2" 1 1/2" 2" 24" 2" 2" 2" 2" 2" -

160 160 160 160 10THK 160 160 160 160 160 --

Type WN WN WN WN WN WN WN WN WN WN -

Flange Face RF RF RF RF RF RF RF RF RF RF -

Rating CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 -

Description

Remarks

Pressure Safety valve With Davit arm Pressure Transmitter Pressure Gauge Spare Spare Spare Earthing Conn. Name Plate Lifting Trunion Anchor Chair

B.F. B.F. B.F. 2 Nos 1 No. 2 Nos 8 Nos

10THK. 4600 T.L. TO T.L.

150

10Thk. 20 12

58

125

200

500

EC

20

100

20 THK. 800 50 S.F.

750

FOR M 20 F BOLTS.

W.L.

Hydrostatic Test Pressure Corrosion Allowance

Bar g

7.0 AMBIENT

Bar g

12.22

mm 3 0.85/1

Impact Test

-

P.W.H.T

-

M.D.M.T

-

Wind Load

max. 47 m/s

Seismic Zone

Zone 3 acc. to IS 1893

Fabrication Tolerances

Refer Standard Engineering Specification

Painting Surface Preparation Lethal Service

Refer Note 12 -

Empty Weight

kg ~ 3600

Operating Weight Hydrotest Weight Location Inspection Seismic Moment

kg ~ 3700

N-m

34547

Wind Moment

N-m

58938

kg ~ 12700 OUT DOOR IBIC / DFPCL

SHELL

SA 516 GR.70

BOLTS & NUTS

HEADS / ROOF

SA 516 GR.70

SUPPORT

SA 516 GR.70

BASE PLATE

SA 516 GR.70

INTERNALS

-

COIL / JACKET

N.A

REINFORCING PAD

SA 516 GR.70

BODY FLANGE

NAME PLATE

SS 304

GASKET

N.A N.A

FITTINGS

SA 234 WPB

BOLTS & NUTS

-

INSULATION CLEATS -

NOZZLE PIPE

SA 106 Gr.B

EARTHING LUG

NOZZLE FLANGE

SA 105

FOUNDATION BOLTS SA 193 B7

GASKET

ASBESTOS FREE

LAP RING

SS 304 -

350

01. ALL DIMENSIONS ARE IN M.M. UNLESS OTHERWISE STATED. 02.

VALID FOR ALL NOZZLES IF NOT OTHERWISE INDICATE

DETAIL OF ANCHOR CHAIR ON BASE PLATE

'B'

03. 04. ALL T/T HOLES TO BE PLUGGED AFTER HYDROTEST.

250

V0

05. ALL BOLT HOLES OF FLANGES SHALL BE STRADDLE WITH PRINCIPLE C/L OF VESSEL. 06. ALL NOZZLE FLANGES SHALL BE ASME B16.5 AND GASKET SEATING SURFACE SHALL BE SERRATED TYPE UNLESS OTHERWISE SPECIFIED. 07. LIFTING LUGS, EARTHING LUGS & NAME PLATE TO BE PROVIDED BY FABRICATOR. 08. WELD WHICH IS ACCESSIBLE FROM OTHER SIDE SHOULD BE BACK CHIP UP TO SOUNDMETAL AND REWELD OR OTHER WISE TIG WELDED. 09. EQUIPMENT TO BE HYDROTESTED IN HORIZONTAL POSITION. 10. CLEATS FOR INSULATION SHALL BE PROVIDE BY EQUIPMENT SUPPLIER. 11. ALL INSIDE WELDS SHALL BE FLUSH WITH SHELL I.D. 12. PRIMER PAINT SHALL BE PROVIDE ON ALL C.S PARTS. 13. PAD PLATE PROVIDED 3" NB & ABOVE NOZZLES. 14. FOR NAME PLATE DETAILS REF. DRG. NO:-IBI-400-STD-70 / 71.

1500

N03 10 THK

1500 I.D.

350

20 THK

A0

'A'

LT

A0

V0 16. VENDOR TO PROVIDE LADDER AND HANDRAIL WITH TOE PLATE.

ACH

ACH

ELEVATION

10 THK.

FOR M 20 BOLTS.

TOE GUARD - 100MM x 4 MM THICK MS PLATE. 17. VENDOR SHALL PROVIDE FOUNDATION BOLTS AND TEMPLATE (SA 36) WITHIN 3 MONTHS OF ORDER FOR FOUNDATION PREPARATION AT SITE 18. SUPPORT CLEATS FOR PLATFORMS AS REQUIRED SHALL BE SUPPLIED BY VENDOR. LADDER, HANDRAILS SHALL BE SUPPLIED BY VENDOR.

N04 V0 EC

N

= 30 =

10 ACH

P01 P02

R1 R0

S03

NP

N02 N01

9.4 70

Notes

T.L.

EC

Design Temperature Operating Pressure Operating Temperature

9.32 Bar g

MATERIAL SPECIFICATION

N01 N04

150

PLANT AIR

Density Design Pressure (Int. / Ext.)

12

S02 P01

NP M01

Fluid

-

10% + ALL 'T' JOINT Radiography (Shell / Dished End) mm Insulation Type / Thk.

10 THK

250

8

ASME Sec. VIII DIV.1

Joint Efficiency (Shell / Dished End)

DETAIL OF LIFTING TRUNION (QTY. 2 NOS.) 1500 I.D.

DESIGN CODE CODE STAMP REQUIRED Volume (Nom.)

ACH

23.05.2017 03.05.2017

Rev.

10

35

15

Date

Issued for Enquiry Issued for Approval

VYT VYT

Description

SAS SAS

NAS NAS

Rev. By Chkd. By Appd. By

CLIENT:

ACH V0 50

Nitric Acid Complex at Dahej, Gujarat.

EC CONSULTANT

N03 BOTTOM

ACH V0 LT

ACH

M01 S02 S01 NOZZLE ORIENTATION (PIPING, LADDER AND PLATFORM SUPPORT CLEATS ORIENTATION) (HOLD)

ORIENTATION (HOLD) ANCHOR CHAIR DETAIL ON SKIRT SHELL

DETAIL 'A' SKIRT SHELL TO DISH JOINT

DETAIL OF EARTHING CONN. (QTY. 2 NOS.)

Issued :

Approved

NAS

Dept. No.

400

Checked

SAS

Scale

1:18

VYT

Date

19/04/2017

Detailed Engineering (SUB CONTRACTOR)

Project No

:

Created

Client

:

Dwg.No.

Project

:

Site

:

Title

:

Doc. Type

:

Sheet No.:

1 of 1

Rev

R1 A1

WASHER PLATE TO BE WELDED AFTER POSITIONING OF EQUIPMENT

N03

N05 C01 N01

L02

REFER DETAIL-'A'

170

800

6THK. PAD

88

= 230 = 82

= 175 =

= 100 =

ANCHOR BOLT

= 150 = 20 Thk.

50

1000

HOLE

8

HAND RAIL

325

HOLE

150

350

R25

50

EARTHING EC CONN.

10 Thk.

= 100 =

25

250 HOLD

REFER DETAIL-'D'

10 10

20 Thk.

HOLE 300

6 THK

6 THK ROOF PLATE

50

65 x 65 x 6THK. CURB ANGLE

N08 N09

DESIGN DATA

NOZZLE DATA LIST

N10 C02 N07

10 Thk.

ID

ND

SCH/THK

C01 C02 L01 L02 M01 N01 N02 N03 N04 N05 N06 N07 N08 N09 N10 T01 EC NP LL

3" 3" 3" 4" 24" 2" 3" 2" 2" 3" 3" 2" 3" 3" 2" 1 1/2" -

80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 -

Type WN WN WN WN WN WN WN WN WN WN WN WN WN WN WN -

Flange Face RF RF RF RF RF RF RF RF RF RF RF RF RF RF RF -

Rating CL 150 CL 150 CL 150 CL 150 API 650 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 -

Description

Spare Manhole w / Cover H2SO4 Inlet H2SO4 Outlet Vent Drain Spare Pump Recirculation Overflow Nozzle Spare Spare Temperature Transmitter Earthing Conn. Name Plate Lifting Lug

Remarks

With B.F. As per API 650

With B.F. With B.F. Dip Pipe With B.F. With B.F. 2 Nos 1 No. 4 Nos

DETAIL OF ANCHOR CHAIR (8 NOS.)

3000

6 THK

100 6 THK.

00

2

100

T01 25

1/4" NPT (1 NO.) TELL TALE HOLE

NP M01

150

240

N02

225

150

L01

HO

LE

R2

12

N04

1

5 R1 P. TY

5

120

WEAR PLATE

12

Fluid

98% H2SO4

API 650 (LATEST EDITION) -

Density Design Pressure (Int. / Ext.)

Bar g 0.06

Design Temperature Operating Pressure Operating Temperature

Bar g

ATM

Bar g

FULL OF WATER

Hydrostatic Test Pressure Corrosion Allowance

70

mm 3 FOR SHELL & BOTTOM / 1 FOR ROOF

Joint Efficiency (Shell / Dished End)

0.85

Radiography (Shell / Dished End)

10% + ALL T JOINT mm NIL

Insulation Type / Thk. Impact Test

-

P.W.H.T

-

M.D.M.T

-

Wind Load

max. 47 m/s

Seismic Zone

Zone 3 acc. to IS 1893

Fabrication Tolerances

Refer Standard Engineering Specification

Painting Surface Preparation Lethal Service

Refer note 24 YES

Empty Weight Operating Weight

kg ~ 2950

Hydrotest Weight Location Inspection Seismic Moment

kg ~ 15410

N-m

6826

Wind Moment

N-m

17722

kg ~ 25150

OUT DOOR IBIC / DFPCL

MATERIAL SPECIFICATION

R40 500

100

700

R2

N06

DESIGN CODE CODE STAMP REQUIRED Volume (Nom.)

16 THK.

DETAIL OF LIFTING LUGS (4 NOS.)

SHELL

IS:2062 GRB

BOLTS & NUTS

SA193 GRB7/SA194 GR2H

ROOF / DISH END

IS:2062 GRB

SUPPORT

IS 2062 GR.B

BASE PLATE

IS:2062 GRB

INTERNALS

IS 2062 GR.B

COIL / JACKET

-

REINFORCING PAD

IS 2062 GR.B

BODY FLANGE

NAME PLATE

SS.304

GASKET

-

FITTINGS

SA213 GR WPB

BOLTS & NUTS

-

INSULATION CLEATS IS 2062 GR.B

NOZZLE PIPE

SA106 GRB

EARTHING LUG

NOZZLE FLANGE

SA350 GR.LF2 CL.1

FOUNDATION BOLTS

GASKET

R.F. PTFE

Rod / Bar

S.S.304 -

250

ELEVATION

= 30 =

10 Thk.

C01

15

M01 N01

N06

TYP.

N

80

L01 EC

VALID FOR ALL NOZZLES IF NOT OTHERWISE INDICATE

DETAIL OF EARTHING CONN.

T01 LE

2 NOS.

T01

LADDER WITH CAGE

00 0

20

N03

0

LE N10

N03

LE

TOE GUARD - 100MM x 4 MM THICK MS PLATE. 500

N09 NP N08 CLAMP

N05

NOZZLE DETAIL FOR TO1

MESH STAINLESS STEEL APERTURE 2mm. WIRE 0.8mm.

L02 N02

EC

6 THK. ROOF PLATE

03.05.2017 06.04.2017 28.03.2017

Rev.

Date

Issued for Enquiry Revised as per comments Issued for Approval Description

CONSULTANT

6

C02

6 6

N04 ISA 65x65x6THK CURB ANGLE

Rev. By Chkd. By Appd. By

6 THK.

DETAIL-`D'

Issued :

Approved

NAS

Dept. No.

400

Checked

SAS

Scale

1:20

VYT

Date

28/03/2017

Detailed Engineering (SUB CONTRACTOR)

500 (HOLD)

6

DETAIL-'A'

NAS NAS NAS

Nitric Acid Complex at Dahej, Gujarat.

160

6

NOZZLE ORIENTATION PIPING, LADDER & PLATFORM SUPPORT CLEAT ORIENTATION (HOLD)

SAS SAS SAS

15

R2

N07 LE

FABRICATOR'S SCOPE

VYT VYT VYT

CLIENT:

SILICA GEL POT (BY VENDOR)

N04

R2 R1 R0

150

DETAIL-'B' LE

LE

R2 UP TO GROUND FLOOR WILL BE IN OTHER'S SCOPE. 26. SILICA GEL POT IS IN VENDOR'S SCOPE. 27. CALIBRATION OF TANK IS IN VENDOR'S SCOPE. PREPARE CALIBRATION CHART BY ULLAGE METHOD & GET IT DULY CERTIFIED BY BY LOCAL WEIGHT & MEASURES AUTHORITIES. MIDDLE ON LADDER.

75

R1

R80 0

FABRICATOR'S SCOPE

PROTECTO MASTIC PRIMER (DFT 50 MICRON)

R2

NOZZLE DETAIL FOR NO4

Project No

:

Created

Client

:

Dwg.No.

Project

:

Site

:

Title

:

Doc. Type

:

Sheet No.:

1 of 1

Rev

R2 A1

NOZZLE DATA LIST

WASHER PLATE TO BE WELDED AFTER POSITIONING OF EQUIPMENT S03 N06

S02 N07

N01

S01

6 THK. PAD

N04

350

55

175 150 125

45

R1

75

950

ANCHOR BOLT

REFER DETAIL-'B' HAND RAIL

200

20 50

150

6 THK + 4.5THK RUBBER LINING ROOF PLATE

20

8

200

EQUI-SPACE RAFTERS ISMC 75

8

EC N08

50

ND

SCH/THK

L01 M01 N01 N02 N03 N04 N05 N06 N07 N08 N09 S01 S02 S03 T01 EC NP LL ACH

3" 24" 2" 2" 2" 2" 3" 2" 2" 3" 2" 3" 2" 4" 2" -

80 80 80 80 80 80 80 80 80 80 80 80 80 80 -

Type WN WN WN WN WN WN WN WN WN WN WN WN WN WN -

Flange Face FF FF FF FF FF FF FF FF FF FF FF FF FF FF -

Rating CL 150 API 650 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 CL 150 -

Description Manhole cover / Davit Inlet Outlet Drain Vent Goose neck Overflow Pump Recirculation Spare Spare Spare Spare Spare Spare nozzle for dip pipe Temperature Transmitter Earthing Conn. Name Plate Lifting Lug Anchor Chair

DESIGN DATA Remarks As per API 650

With Bird Screen

With B.F. With B.F. With B.F. With B.F. With B.F. With B.F. 2 Nos 1 No. 4 Nos

75

2 NOS.

4.5THK. RUBBER LINING

T01

20

0

3000

REFER DETAIL-'B1'

T01

1000

DETAIL-'B'

L01

1

N03

120

175

N02

MESH STAINLESS STEEL APERTURE 2mm. WIRE 0.8mm.

NOZZLE DETAIL FOR TO1

DETAIL-'B1'

160

200

N09

Bar g

ATM AMB

Bar g

Hydrostatic Test Pressure Corrosion Allowance

FULL OF WATER

mm NIL

Joint Efficiency (Shell / Dished End)

0.85

Radiography (Shell / Dished End)

10% + ALL T JOINT mm NIL

Insulation Type / Thk. Impact Test

-

P.W.H.T

-

M.D.M.T

-

Wind Load

max. 47 m/s

Seismic Zone

Zone 3 acc. to IS 1893

Fabrication Tolerances

Refer Standard Engineering Specification

Painting Surface Preparation Lethal Service

Refer note 23 -

Empty Weight

kg ~ 3590 (WITHOUT RUBBER LINING)

Operating Weight Hydrotest Weight Location Inspection Seismic Moment Wind Moment

kg ~ 32710 (WITHOUT RUBBER LINING) kg ~ 24790 (WITHOUT RUBBER LINING) OUT DOOR IBIC / DFPCL kg-m

-

kg-m

-

SHELL

ANCHOR CHAIR

IS 2062 GR.B

ROOF

ANCHOR BOLTS

SA 193 GR.B7

BOTTOM PLATE

SUPPORT CLEATS

IS 2062 GR.B IS2062 GR.B

INTERNALS

14. RUBBER LINING & INSPECTION SHALL BE DONE AS PER IS4682 (PART -I).

CURB ANGLE

IS2062 GR.B

REINFORCING PAD

IS2062 GR.B

RAFTERS

IS2062 GR.B

NAME PLATE

S.S 304

NOZZLE PIPE

FITTINGS

SA 234 WPB

NOZZLE FLANGE

INSULATION CLEATS N.A.

SOFT RUBBER

GASKET

12 ACH EC

ATM 75

INT. BOLTS & NUTS

SS304

EARTHING LUG

EXT. BOLTS & NUTS SA193 GR.B7,SA194 GR.2H

160

6

N

Design Temperature Operating Pressure Operating Temperature

1458 Bar g

N.A.

150

ISA 50x50x6 CURB ANGLE

ELEVATION

44% CAUSTIC SOLUTION (NaOH)

COIL

16. VENDOR TO USE HOT VULCANIZATION METHOD FOR CURING RUBBER LINING. 6

Fluid

-

13. RUBBER LINING THICKNESS :4.5 MM NATURAL RUBBER, HARDNESS 65-70 SHORE A

6 THK. ROOF PLATE

150

20

API 650 (LATEST EDITION)

MATERIAL SPECIFICATION

CLAMP

1000

750

100

M01 NP

DESIGN CODE CODE STAMP REQUIRED Volume (Nom.) Density Design Pressure (Int. / Ext.)

DETAIL OF ANCHOR CHAIR ACH (8 NOS.)

6 THK. AFTER RUBBER LINING

100

75

N05

150

250

350

250

REFER DETAIL-'A'

ID

N03

N01 ACH

L01

6 THK.

N08

500 HOLD NOZZLE DETAIL FOR N03

DETAIL-`A'

LE N03

T01 L01 LE

LADDER

150

PROTECTO MASTIC PRIMER (DFT 50 MICRON)

27. VENDOR TO PROVIDE LADDER AND HANDRAIL WITH TOE PLATE. TOE GUARD - 100MM x 4 MM THICK MS PLATE.

ACH

R1300

ACH

N04

50

15

30. CALIBRATION OF TANK IS IN VENDOR'S SCOPE. PREPARE CALIBRATION CHART BY ULLAGE METHOD & GET IT DULY CERTIFIED BY BY LOCAL WEIGHT & MEASURES AUTHORITIES.

4.5 THK. RUBBER LINED

TYP.

R9

= 30 =

10 Thk.

80 N06 S02

S01 M01

DETAIL OF EARTHING CONN.

NP

ACH

ACH N02

VALID FOR ALL NOZZLES IF NOT OTHERWISE INDICATE

100 6 THK.

100

1/4" NPT (1 NO.) TELL TALE HOLE

R1 R0

25

N05

Date

Issued for Enquiry Issued for Approval Description

ACH EC N09

NOZZLE ORIENTATION (PIPING, LADDER AND PLATFORM SUPPORT CLEATS ORIENTATION)

12 5

SAS SAS

NAS NAS

Rev. By Chkd. By Appd. By

Nitric Acid Complex at Dahej, Gujarat. CONSULTANT

ACH

VYT VYT

CLIENT:

225

S03 LE

N07

Rev.

0 R4

150

LE

23.05.2017 03.05.2017

HO LE

Issued :

Approved

NAS

Dept. No.

400

Checked

SAS

Scale

1:20

VYT

Date

25/04/2017

Detailed Engineering (SUB CONTRACTOR)

5 R1 P. TY DETAIL OF LIFTING LUGS (4 NOS.)

16 THK.

LE

Project No

:

Created

Client

:

Dwg.No.

Project

:

Site

:

Title

:

Doc. Type

:

Sheet No.:

1 of 1

Rev

R1 A1

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels

Rev

R0

Date of Rev

19/05/2017

Standard Specification for Pressure vessels

R0

16/01/2017

For Reference

SAS

NAS

ANS

Rev

Date

Purpose

Prepared by

Checked by

Approved by

REVISION CONTROL Page 1

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

Table of Contents 1

Introduction

3

2

Design basis & materials

3

3

Contractor's scope of work

4

4

Fabriction & erection

4

5

Inspection testing & repairs

7

6

Painting

7

7

Marking & Packing

8

8

Documentation

8

9

Reference standards

8

10

Guarantee

8

11

Annexure:-1 General instructions

9

12

Annexure:-2 Engineering standard for inspection of pressure vessel

12

13

Annexure:-3 Inspection programme for pressure vessel

23

14

Annexure:-3A Inspection test chart

25

15

Annexure:-4 Dimensional Tolerances for Pressure vessels

27

16

Annexure:-5 General notes for IBR vessels

32

17

Annexure:-6 Quality assurance plan for fabrication

35

18

Annexure:-7 Electrodes to be used in welding

40

19

Annexure:-8 Pickling & passivation for stainless steel

43

20

Annexure:-9 Dimensional tolerances for ASME flanges

47

21

Annexure:-10 Surface preparation & painting

50

Page 2

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels 1.0

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

INTRODUCTION This Specification together with the data sheets / drawings covers the general requirements for materials, design, fabrication, inspection, testing and erection of unfired pressure vessels. The requirements laid down herein are supplementary to the design/ fabrication code as specified.

2.0

DESIGN BASIS & MATERIAL 2.1

Design, fabrication, inspection and testing of the vessels are as per ASME SEC VIII Div.1. (Latest edition unless otherwise specified)/Good engineering practice.

2.2

The design information and overall dimensions etc. specified in the specification sheet drawing are only in respect of major details like shell and dish end thickness, skirts, flanges etc. Wherever such dimensions / thickness is not specified for minor parts such as nozzle reinforcement etc., the same shall be designed and supplied by the Fabricator as to meet all applicable provisions of the design code. Fabricator shall satisfy himself with the design and on placing the order shall submit the complete design calculations for IBIC's approval prior to fabrication.

2.3

Wherever Fabricator proposes to use materials either with a change in specification or in thickness, it shall be his responsibility to furnish all calculations as may be required to establish that the proposed change is in agreement with the overall provisions of design code.

2.4

In case of any class of work, which is not covered by the governing codes, the work should be carried out as per the standard engineering practice submitted to and approved by Purchaser.

2.5

All dimensions shown in the data sheets / drawings are in ‘mm’ unless otherwise specified. Thickness indicated for shell and formed heads are minimum specified after forming.

2.6

The minimum corrosion allowance for carbon steel shall be 3 mm unless otherwise specified in the data sheet. The corrosion allowance for nozzles and manholes shall be at least equal to that specified in vessel shell.

2.7

For austenitic steel the corrosion allowance shall be zero unless otherwise specified in the data sheet. The corrosion allowance for nozzles and manholes shall be at least equal to that specified in vessel shell.

2.8

All the materials shall be as per equipment data sheets and conform to ASME Sec II and inspected to corresponding ASTM specifications or IS specifications of equal grade. Check testing shall be performed for all the materials as per code.

2.9

Max. Carbon content of all weld able carbon steel shall be 0.25%.

Page 3

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels 3.0

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

CONTRACOTR’S SCOPE OF WORK & SUPPLY 3.1

Scope of the fabricator shall include design wherever necessary, preparation of detailed fabrication drawings furnish design calculations and taking approval for the same, supply of materials as per the specifications or as agreed upon, fabrication, testing, cleaning, transportation, getting any Statutory approval of the vessel, if required and all activities required for the completion of the work.

3.2

All the work other than specifically mentioned above required in order completing the jobs as per specifications in the data sheet, the Fabricator shall carry out Inspection Standard.

3.3

The following items shall be constructed as part of Fabricator's scope of supply whether the same is specifically indicated in the drawings / data sheets or not. a) Cleats for insulation. b) 3 sets of spare gaskets for all flanged joints c) Blind flanges for all manholes/hand holes and spare nozzles and extra 10% bolts and nuts for all flange joints. d) Suitable flanged joints or otherwise removable designs in respect of all internals to enable removal through manhole unless specifically noted otherwise in the data sheets / drawings e) Stiffening of nozzles 40 NB and below by 3 gussets. f) Lifting lugs g) Test rings / flanges wherever required for testing of the unit. h) Davit arms for man ways i) Name plate in SS material as per Purchaser’s Standard. j) Earthing clips. k) Foundation bolts/ Foundation Template

4.0

FABRICATION & ERECTION 4.1

The fabrication procedure shall confirm to all applicable requirements of specified code and established Engineering Practices for manufacture of vessels.

4.2

As far as practicable, the shell sections shall be made out of a single plate with one longitudinal weld seam only. The longitudinal seams of adjacent courses shall be staggered by a minimum of five times the greater thickness of plate section and, as far as possible seams shall be positioned clear of supports so as to be readily visible for examination. The weld seams shall be indicated on the fabrication / as built drawing.

4.3

Nozzles shall be located, as far as possible, clear of the weld joints by a minimum of 50 mm, where this is not possible, Fabricator shall obtain the necessary approval from Purchaser and shall provide adequate reinforcement.

4.4

All carbon and low alloy steel plates shall be cut to size by flame cutting and machined. Alternatively cold shearing of plates is acceptable up to 25 mm thick, provided the sheared edges are cut back by machining, chipping or grinding for a depth of 3 mm. In case of plates higher than 20 mm thk DP of cut edges shall be carried out.

4.5

Austenitic Stainless Steel plates may be cut by either cold shear or Plasma arc, but in all cases the edges should be ground by 3 mm. Page 4

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

4.6

All nozzle / manhole projections shall be 150 mm minimum, unless otherwise specified in the data sheet & drawings.

4.7 not

Rolling of plates shall be along longitudinal direction only. Re-rolling, after welding, which normally allowed may be resorted to only with prior approval and should be carried out directed by Purchaser.

4.8

Welders qualified as per requirements of ASME Section IX may perform welding manually or with semi-automatic or automatic machines according to qualified and approved procedures.

is as

4.9

Welding shall be done by any of the shielded arc welding process, either by TIG welding or by MIG welding process. Single pass submerged arc welding of butt joints is prohibited. Root run shall be done only by TIG welding for S.S. 4.10

Edges to be welded shall be free of foreign materials, moisture, oil, grease, paint, etc. to a distance of 25 mm minimum.

4.11 All the butt welds shall be full penetration welds, chipped back to sound metal and refrom other side.

welded

4.12 As far as practicable jigs, fixtures and other suitable methods shall be used to avoid due to welding.

distortion

4.13

Temporary attachment welds on vessels shall be removed. The surface under such welds and under backing rings, which have been removed, shall be properly conditioned to eliminate surface stress raisers. Such surface shall be examined by MT / DPT for stainless steel, and for carbon steel with a design temperature below 0º C. 4.14 Internal baffles, trays support beams or other internals spanning a chord or diametric of the vessel shall be provided with a means for allowing differential expansion between the part and vessel shell. 4.15 Internal non-pressure piping for carbon steel vessels shall be fabricated either from or ERW pipes extra heavy as indicated in the drawings.

seamless

4.16 Unless stated otherwise on vessel drawing, baffles or weir plates shall not be welded directly to the shell (or head) of vessels, but shall be bolted to support attachment, which are welded to the shell. 4.17

Whenever a dished end is made of more than two plates it must have a crown plate. Whenever a nozzle or manhole is positioned at the centre of the dished end, the crown plate should be larger than the nozzle / manhole reinforcing pad. 4.18

Manholes shall be a minimum of 600 mm nominal diameter unless otherwise specified.

4.19 Manhole cover shall be provided with a davit or hinge as per standard code unless stated in the drawing.

otherwise

4.20

Inside edge of manholes shall be smooth and rounded off with a radius of 3 mm.

4.21

Vessels shall be heat treated when specified on the drawing. In no case shall the heat treatment performed be less than that specified by the code. Page 5

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels

5.0

Rev

R0

Date of Rev

19/05/2017

4.22

While heat-treating the materials, the fire and flame shall not contact the metal directly and heating on all the metal part shall be uniform.

the

4.23

For vessels handling hydrogen sulphide, amines, caustics or other fluids, which cause hydrogen penetration, the annular space between welds on slip on flanges shall be vented to the atmosphere by using a 6 mm dia hole.

4.24

For hot working, the most suitable working temperature for each material shall be maintained strictly. Metalworking shall be made by cold working as far as practicable unless otherwise specified. Hot working shall be made at a temperature within the range of 850 ºC – 950 ºC and the heat treatments as specified in UHA-105 for austenitic steels & UCS-56 for carbon steels as per ASME Section VIII Div.1 shall be made after hot working.

4.25

All flange faces shall be suitably protected against, during heat treatment.

4.26

All vessels, which are stress relieved, shall have all attachments including insulations, support rings, welded prior to stress relieving.

4.27

If ring flanges are fabricated by butt-welding plate segments, the joints shall be fully heat treated and tested ultrasonically. All shell flanges shall have their gasket faces machined after welding and heat treatment.

4.28

The maximum allowable gap between nozzles and manhole reinforcing pads and the of the vessel shell or heads shall be 3 mm.

4.29

All nut sealing faces on flanges shall be either spot faced or machined.

4.30

All bolt holes shall straddle to the principal centre lines of the equipment for nozzles.

4.31

All flange facing when specified, as R.F. shall be serrated 0.5 mm deep and 0.8 mm wide over gasket sealing surface.

4.32

All reinforcement pads / body flanges shall have two ¼” dia telltale holes 180o apart.

4.33

All internal weld seams for lined vessels shall be ground flush. Others shall be dressed and finished smooth.

4.34

Stainless Steel surface shall be acid pickled and passivated in accordance with IBIC

4.35

All the internals shall be supplied and installed by the Fabricator unless otherwise stated on the vessel drawing.

curvature

Standard.

INSPECTION, TESTING & REPAIRS 5.1

Purchaser or Third party shall carry out stage-wise inspection as mentioned in the equipment data sheet. Inspection shall be carried out as per IBIC Standard and the applicable code.

5.2

Approval of work by the inspection agency or the release of vessels for shipment shall in no way release or relieve the manufacturer of any responsibility for carrying out all the work as per the data sheet / specifications.

5.3

The extent of radiography shall be as specified on the data sheets. In no case shall the Page 6

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

radiographic examination be less than that specified by the code.

6.0

5.4

Testing of the vessels shall be done as per the code requirements / IBIC Standard.

5.5

All nozzle-reinforcing plates shall be tested at 1 kg/Cm2 (g) with soap solution pneumatically.

5.6

If any structure or part of a structure were found not to comply with any of the provisions of this standard, it shall be liable to rejection. No structure or part of structure once rejected shall be accepted for re-test except in cases where it is considered that the defect is rectifiable.

5.7

Defects that may appear during fabrication shall be made good with the prior approval of IBIC.

5.8

Purchaser’s Inspector shall have the right to pass upon the qualification of erection personnel engaged by the erector and shall ask for replacement if desirable.

5.9

Material damaged by defective workmanship or otherwise defective shall be rejected. The Inspector in such cases shall ask the erector to furnish new material or correct defective workmanship and/or replace workmen engaged in the work.

5.10

All leaks detected during testing shall be repaired to the satisfaction of Purchaser’s Inspector and on completion the entire tank shall be right and free from leaks.

5.11

Lined vessels shall be inspected before lining is applied and again after installation of lining.

5.12

Dimensional tolerance shall be strictly as per Purchaser’s Standard and applicable codes.

PAINTING 6.1

7.0

Carbon steel vessels shall be thoroughly cleaned and shall be applied with two coats of protective primer as per IS 2074 after inspection and testing and greased on exposed machined parts to prevent rust, corrosion or damage due to bad weather.

MARKING & PACKING 7.1

All parts not assembled integral with the main body of the equipment shall be marked order number and equipment number for their identification.

with the

7.2

Vessels shall be identified by a nameplate as per IBIC Standard and shall be of stainless steel (300 series) or cast corrosion resistant material. The nameplate shall be attached near to the manhole or a place where it is readily visible.

7.3

All internals shall be suitably supported from inside to prevent damage during transit.

7.4

All openings shall be blanked with wooden covers fastened with wires and welds end to be closed with wooden plugs before dispatch.

Page 7

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels 8.0

Rev

R0

Date of Rev

19/05/2017

DOCUMENTATION 8.1

9.0

IBIC -400-SS-0002

Fabricator shall forward the necessary documents as specified in the Annexure-1 Sheet attached herewith.

REFERENCE STANDARDS Sr. No 1

2

Reference Doc. No

Description

ANNEXURE-2

ENGINEERING STANDARD FOR INSPECTION & TEST OF PRESSURE VESSELS

ANNEXURE-4

DIMENSIONAL TOLERANCES FOR PRESSURE VESSELS

10.0 GUARANTEE

10.1

The tank shall be guaranteed in accordance with the conditions given in the Conditions of Contract.

General

10.2

Any part of the tank found defective during the tests after installation or during operation, and not having been submitted to faulty operation or incorrect service conditions, shall be promptly replaced and re-assembled by the Contractor at his own cost.

Page 8

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

ANNEXURE-1

GENERAL INSTRUCTIONS

Page 9

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

1.0

Unpriced Bids and Technical parameters should be sent to M/s. IBIC office strictly on due date given in enquiry.

2.0

Acceptance of L.D / Penalty clause wherever applicable should be incorporated as per enquiry specifications in the Bid.

3.0

The Vendor should quote with respect to the specifications given. Any deviations with respect to the Materials of Construction and process required will be discussed at the time of technical discussion. This will ensure that there is no delay in sending the technical / commercial BIDs.

4.0

The Vendor can however mention their scope of supply wherever deviations along with the BIDs.

5.0

Raw material procurement status to be immediately furnished to IBIC / CLIENT office at the time of receipt of LOI / Purchase Order within one / two weeks.

6.0

Design calculations and drawings should be sent to IBIC / CLIENT office for approval within two weeks of receipt of LOI / Purchase Order.

7.0

Supply of required drawings and documents is the responsibility of the vendor. In the event of vendor's failure to meet this requirement of submission of drawing and documents, the supply shall be considered as incomplete and the purchase order is liable to be cancelled.

8.0

All drawings and documents shall show equipment number, order number, vendor's own title / reference number / drawing number and revision number on the lower side of right hand corner in each drawing. The first drawing shall have revision number as ‘R0' and subsequently, First revision shall be mark as ‘R1’.

9.0

Fold all prints to A4 size and roll the transparencies. All documents shall be supplied in folders / files.

10.0

Vendor shall make drawings to maximum size A1 only. Vendor shall avoid preparing drawing an A0 size due to handling problem.

11.0

Drawing or data returned, to be resubmitted within one week. Revised drawings and data must be marked on the drawing.

12.0

The drawings which are returned to the vendor “Without Comments”, Vendor shall prepare and submit three sets of final Assembly / detailed drawings to M/s. IBIC.

13.0

Within one week of shipment of each item vendor shall submit all drawings connected to it marked as “CERTIFIED AS BUILT DRAWING”.

14.0

All transparencies must be capable of producing legible prints.

15.0

Duly filled Material Chart must be sent to IBIC / CLIENT office after drawing approval within seven days. A format of MATERIAL chart will be sent along with the enquiry.

Page 10

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

16.0

Quality Assurance plan, Bar Chart of welding procedure specification wherever applicable to be sent to IBIC / CLIENT office within two weeks of receipt of LOI / Purchase Order. All document drawings approval will be given on a specified date intimated by M/s IBIC / CLIENT.

17.0

Procurement action of castings, forgings should be done by the Vendor wherever applicable immediately after receipt of LOI / Purchase Order. Unpriced Purchase Order copies of all Bought Out items should be sent by Vendor to IBIC / CLIENT’s office immediately on placing the order.

18.0

For items like Gasket, Nuts & Bolts, Seal, Special Welding Rods, Gases and other required items Vendor shall ensure that adequate stock is available. In case of delay, adequate action is to be initiated by the vendor. The same is to be intimated to IBIC / CLIENT’s office.

19.0

Prior approval of all Sub-vendors is to be obtained from IBIC / CLIENT at the time of Technical Discussion, also sub-vendor’s list with contact person details (name, telephone etc) to be furnished to IBIC during discussion.

20.0

Detailed progress report of the equipment order to be given to IBIC / CLIENT indicating the actual status of the job to be submitted every fortnight.

21.0

Status pertaining to the job ordered should be available with at least two persons in the vendors shop and contact person’s name and telephone no., to be given at the time of Technical Discussion / Receipt of LOI / Purchase Order.

22.0

Inspection call to be given in advance of a fortnight, after ensuring them the job is complete in all respect.

23.0

Inspection will be carried out as per approved Quality Assurance plan. All internal check testing Report, Radiographic, and other related certificates should be made available to IBIC / CLIENT pertaining to the job by the Vendor.

24.0

Material test certificates should be furnished & given to IBIC / CLIENT representative at the time or inspection. Check testing of main items to be carried out apart from mill test certificate.

25.0

Raw Material inspection at sub-vendor's workshop is solely the responsibility of the Vendor. IBIC / CLIENT representative reserves the right to inspect the material at sub- vendor’s workshop.

26.0

All Final Revised drawings incorporating all before final inspection.

27.0

All inspection

28.0

Material Release Order once released by M/s. IBIC, the items furnishing in M.R.O. should be dispatched immediately to Client’s works without any delay.

29.0

A copy of dispatch Detail should be sent to M/s. IBIC office by fax immediately after dispatch.

30.0

The vendor has to submit acknowledgement receipt for all documents to the CLIENT, in order to receive certificate from IBIC.

comments made by IBIC should be received at IBIC

call should be sent by E-mail / Fax.

Page 11

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels 31.0

All documents are to be submitted in English Language.

32.0

All dimensions, height and measurements shall be in Metric Unit.

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

Page 12

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels

Rev

R0

Date of Rev

19/05/2017

ANNEXURE-2

ENGINEERING STANDARD FOR INSPECTION & TEST OF PRESSURE VESSELS

Page 13

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels 1.0

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

GENERAL 1.1

SCOPE This standard gives the guidelines to shop inspection and testing of pressure vessels, shell and tube type heat exchangers etc. (generally referred as vessels henceforth) fabricated accordance with Purchaser's design, drawings and standards carried out by fabricator.

1.2

SPECIFIC JOB REQUIREMENTS Specific job requirements, if any shall be provided separately and shall over rule any contradictions.

1.3

CODES & STANDARDS The codes and standards shall be referred as needed, supplemented by this standard.

1.4

1.5

SPECIFICATIONS & DRAWINGS 1.4.1

The inspection and testing shall be in accordance with the IBIC Specification and drawings and fabricator's drawings or procedures as approved by Purchaser.

1.4.2

If there is any conflict, the same shall be brought to IBIC’s attention.

TEST PROCEDURES All the tests shall be performed according to the written and approved procedures only.

1.6

1.7

WITNESSING 1.6.1

Witnessing of inspection by Purchaser's Inspector is a must.

1.6.2

Witness shall be either Purchaser’s Inspector or their designated representative & CCOE authority.

1.6.3

At any time during fabrication is underway, Purchaser's Inspector shall have free access to any of the fabricator's shop concerned with the fabrication of the vessels.

1.6.4

Fabricator shall provide necessary facilities to satisfy the Purchaser's Inspector that the vessels are being furnished in accordance with the specifications.

1.6.5

The fabricator and the Purchasers shall reach into an agreement about the methods of inspection and items to be witnessed.

FABRICATOR'S RESPONSIBILITY 1.7.1

All inspections and tests specified shall be carried out by the fabricator and shall keep all the records of all the tests and inspections and the same shall be submitted to the Purchaser for approval.

1.7.2

Witnessing by Purchaser's Inspector shall in no way relieve fabricator from his Page 14

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels

Rev

R0

Date of Rev

19/05/2017

responsibility to meet specification. 2.0

INSPECTION AND TEST RECORDS 2.1

2.2

3.0

Fabricator shall submit to Purchaser the following records for each vessel. a)

Material mill test certificate

b)

Material laboratory test certificate

c)

Fabrication drawings / procedures.

d)

Test procedures.

e)

Pre Heat Treatment reports.

f)

Welding procedure qualification (WPS).

g)

Procedure Qualification record. (PQR)

h)

Welders or Welding Operators qualification.

i)

Dimensional Inspection.

j)

Non-destructive Testing (MT / LPT /LT / RT / UT/Helium Testing etc.).

k)

Post Weld Heat Treatment.

l)

Hydrostatic & Pneumatic Tests.

m)

Acceptance or Release Notes.

n)

Stage wise and final Inspection Reports.

o)

Other inspections and tests as specified.

p)

As built drawings and other document as per annexure.

The fabricator shall use the inspection formats provided by the Purchaser, if not, the fabricator shall get their formats approved by the Purchaser

INSPECTION AND TEST ITEMS 3.1

The inspection and test of vessel shall be done as specified in the design data sheets, code and standards. Refer to Inspection programme and Inspection Chart also.

3.2

Inspection and test items specified in the codes and standards shall govern where applicable.

Page 15

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels 4.0

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

INSPECTION AND TEST 4.1

Material Test 4.1.1

Fabricator shall submit the mill test certificates and Laboratory test certificates of Laboratories recognized by Lloyds or Bureau Veritas for the following: (Refer SA-370 of ASME Sec. II). a)

Shell, head, nozzle.

b)

Tube sheet, channel cover, flange.

c)

Tube, Alloy Steel Tray.

d)

Alloy steel bolts and nuts.

4.1.1

Fabricator shall conduct non-destructive tests wherever necessary as given in the data sheets and as per codes and standards, and certificates for the same shall be produced for Purchaser’s approval. A qualified person (Level II Minimum) shall do the testing and certification only. Mark the materials accordingly.

4.1.2

Impact tests shall be done for materials for low temperature service. Refer sections 19 to 28 of SA 370 of ASME Sec. II Part A.

4.1.3

Repairs if any shall only be done with the concurrence of the Purchaser’s Inspector.

4.1.4

Welding Procedure qualification and welder or welding operator’s qualification shall be done according to ASME Sec. IX.

4.1.5

Production weld test shall be done for all vessels in accordance with the standards and codes .

4.1.6

Welded joint category shall be according to the code as in UW-3 of ASME Section VIII Div. 1.

4.1.7

The following items shall be checked before starting off with production welding.

4.1.8

Welding groove dimensions, fit up, etc.

4.1.9

Plate edge alignment tolerance shall be generally taken, as t/4 for low thicknesses up to 20 mm and for thickness above 20 mm shall be t/8. But the maximum permissible tolerance for circumferential joint shall be 3 mm and for longitudinal joint shall be 5 mm.

4.1.10

Welding procedure, welding rod (specification and make), baking temperature and time of electrode if any, preheat temperature, welding machines, other welding consumables etc.

4.1.11

Root run shall be cleaned and inspected by liquid penetrant method.

4.1.12

Any cracks or slag inclusions shall not be found in the welding passes.

4.1.13

Defects that are to be looked out in visual inspection in the finished weldment and their acceptability. Page 16

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels

SR.No. a)

Defects Cracks

Rev

R0

Date of Rev

19/05/2017

Acceptability Not acceptable, to be repaired.

b)

Overlap

c)

Under-cut

d)

Root under-cut

e)

Bead width Non-uniformity

Not to exceed 5 mm

f)

Bead height Non-uniformity

Not to exceed 1.5 mm

g)

Not more than 1.5 mm. Not more than the allowance in thickness. The change in thickness should not be abrupt. Grind to make uniform.

Insufficient toe length of fillet weld

Same as above

Add welding.

h)

Crater

To be removed

I)

Bead dripping and Spatter

To be removed

j)

Deformation due to welding and eccentricity to weld seam

k)

Fittings and welded spots for temporary assembly

l)

Thickness of reinforcement

Shall be negligible.

To be removed. Not to exceed the values given in UW35 of ASME Sec. VIII Div.1.

4.1.14 Other internal defects detectable by non-destructive testing methods other than visual: Sr. No. a) b) c)

Defects Lack of root penetration Lack of root fusion Cracks

Acceptability Not acceptable Not acceptable Not acceptable

d)

Slag inclusion

According to the codes

e)

Lack of side-wall fusion

According to the codes

f)

Porosity

According to the codes

g)

Lack of inter bead fusion

According to the codes Page 17

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels 4.7

4.8

4.9

4.10

Rev

R0

Date of Rev

19/05/2017

Visual Inspection 4.7.1

Deformation of vessel shall be checked

4.7.2

Machined surfaces shall be checked.

4.7.3

The vessel and its parts to be assembled at the job site shall be temporarily assembled and checked, where necessary, at the fabricator's shop.

4.7.4

Nozzles and other fittings of vessels shall be checked for direction and orientation.

4.7.5

Vessels shall be checked for internal cleanliness

Dimensional inspection 4.8.1

Dimensions of the vessel and its parts shall be checked to meet IBIC data sheets, drawings and specifications.

4.8.2

Dimensional tolerances for columns and vessels shall be as per tolerance for pressure vessel specifications IBIC/ME 005 attached.

4.8.3

Actual wall thickness of pressure retaining parts shall be checked.

4.8.4

The inside diameter shall be measured at four or more positions for each section at a distance of about 100 mm from each side of circumferential welded seam.

4.8.5

The camber of the shell shall be measured.

Radiographic Testing 4.9.1

Radiographic examination shall be done when specified in the design data sheets according to UW51 and UW 52 of ASME Sec. VIII Div.1.

4.9.2

Radiographs shall have minimum sensitivity of 2.2T.

4.9.3

When spot radiography is specified, at least one spot for each welded seam and every cross-longitudinal to circumferential weldment shall be examined.

4.9.4

Acceptance Standard shall be according to code - Refer UW51 (b) and UW52 (d) of ASME Sec. VIII Div.1.

Ultrasonic Testing 4.10.1 Ultrasonic Testing shall be done according to UW53 of ASME Sec. VIII div.1, when specified in the design data sheets. 4.10.2 Generally all the critical joints shall be ultrasonically tested in addition to radiography especially for vessels for lethal use. 4.10.3 Acceptance shall be according to Appendix 12 of ASME Sec. VIII Div I, if not specified otherwise. Page 18

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels 4.11

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

Magnetic Particle & Liquid Penetration Testing 4.11.1 Both magnetic particle and liquid penetration testing shall be done according to the codes and design data sheets. 4.11.2 Root of all butt welds shall be checked using liquid penetration method. 4.11.3 All finished welds shall be checked with magnetic particle testing / liquid penetrant testing. 4.11.4 All bent and formed elements of the vessel shall be inspected using either magnetic particle or liquid penetration testing. 4.11.5 Solvent washable fluorescent dye shall be used in checking elements of vessels designed for high pressure.

4.12

Hydrostatic & Pneumatic Tests 4.12.1 Hydrostatic test shall be done according to UG-99 of ASME Sec. VIII Div. 1 when specified in the design data sheets. 4.12.2 Pneumatic test shall be done according to UG-100 of ASME Sec. VIII Div.1 when specified in the design data sheets.

4.13

Leak Testing 4.13.1 Leak Testing shall be performed according to Article 10 of ASME Sec. V, when specified in the design data sheets. 4.13.2 When leak test using Freon-12 gas and halogen detectors are specified, shall be performed according to IBIC engineering standard for leak testing using Freon- 12.

4.14

Other Tests 4.14.1 Other tests like Ferrite Test, Micro Test, Macro Test, IGC Test, etc shall be done as and when the same is specified in the data sheets or as per Codes and Standards.

5.0

PREHEATING & POST WELD HEAT TREATMENT 5.1

5.2

Pre Heat Treatment 5.1.1

Preheating shall be done wherever and whenever specified - Refer Table T1.

5.1.2

Preheat temperature shall be checked before commencing the welding using temperature pencils or chalks.

Post Weld Heat Treatment 5.2.1

Post weld heat treatment shall be done as per the design data sheets. Ref. Table T2.

5.2.2

Fabricator shall submit the time-temperature chart of post weld heat treatment.

5.2.3

As far as possible, welding on the vessels shall be avoided after heat treatment. Page 19

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels 6.0

Rev

R0

Date of Rev

19/05/2017

PASSIVATION / PICKLING Passivation / Pickling shall be done as per Standards, if required, as per data sheets.

7.0

8.0

9.0

10.0

RECORDS 7.1

Fabricator shall maintain test certificates, inspection reports, test reports, post weld heat treatment report etc.

7.2

Fabricator shall submit all the records concerning the vessel for the purchaser's approval.

MARKING 8.1

Nameplates shall be provided for all the vessels.

8.2

Nameplate format shall be provided by the Purchaser.

8.3

One copy of nameplate rubbing shall be submitted to Purchaser.

PAINTING 9.1

Painting and Stenciling shall be done in accordance with the specification and drawings.

9.2

DFT shall be checked and shall conform to specification.

DESPATCH 10.1

The Fabricator shall get the final Inspection Report and Release Note from the concerned Inspector before dispatch.

10.2

Make sure that the internal and external surfaces of vessel are free from loose scale or any other foreign material.

10.3

All exposed machined surfaces shall be coated with removable rust preventive and be protected against mechanical damage.

10.4

Nozzles shall be protected with bolted wooden covers and all threaded connections are to be suitably plugged.

10.5

All parts not assembled integral with main body of the vessel shall be marked with equipment no. and match marked to ensure proper fit-up.

Page 20

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels

Rev

R0

Date of Rev

19/05/2017

TABLE T1 PREHEAT REQUIREMENTS Pre-heating is needed if the values of the variables listed are more than the values given.

Temp. in

Sr. No.

P.No./ Group No.

1

1/1,2,3

2

1/1,2,3

3

3/1,2,3

4

3/1,2,3

5

4/1,2

6

4/1,2

7

5A&5B/1

8

5A&5B/1

9

6/1,2,3

10

7/1,2

None

11

8/1,2

None

12

9A/1

121

13

9B/1

149

14

10A/1 &10C/3

15

10B/2 &10F/6

16

10D/4 &10I/1

(Inter-pass temp. maintained between 177°C and 232°C)

17

11A/1

Preheating neither required nor prohibited

Thickness of joint mm

Content Specified

25

0.3% carbon

Tensile strength ksi

79

(All other materials in P.No.1 which are not covered in Sl.No.1) 16

70

(All other materials in P.No.3 which are not covered in Sl.No.3) 13

60

(All other materials in P.No.4 which are not covered in Sl.No.5) 13

6% Chromium

°C.

60

(All other materials in P.No.5 which are not covered in Sl.No.7)

10 79 10 121 10 204 149 204

(For P.No.10C Group No.3 materials Preheat is neither required nor prohibited

79 121 149

Page 21

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

18

11A/2,3

Same as P.No.5

19

11A/4

121

20

11B/1-5

Same as P.No. 3

21

11B/6-7

Same as P.No. 5

TABLE T2 POST WELD HEAT TREATMENT Sr. No.

P.No. / Group. No

Hold Temp 0C.

HOLDING TIME Up to 50 mm 1hr/ 25mm

1

2

1/ 1, 2, 3

1/4

650

NA

15 min minimum

None

1hr/ 25mm 3

3/1, 2, 3

595 15 min minimum

50-125mm

Over 125mm

2 Hrs + 15 min

2 Hrs + 15 min

for each additional 25 mm over

for each additional 25 mm over

50 mm

50 mm

None

None

2 Hrs + 15 min

2 Hrs + 15 min

for each additional 25 mm over

for each additional 25 mm over

50 mm

50 mm 5 Hrs + 15 min

1hr/ 25mm 4

4/1, 2

650

1 Hr/ 25 mm 15 min minimum

for each additional 25 mm over 125 mm 5 Hrs + 15 min

5

5A/1, 5B/1 & 5C/1

1hr/ 25mm 675

1 Hr/ 25 mm 15 min minimum

for each additional 25 mm over 125 mm

Page 22

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

5 Hrs + 15 min 1hr/ 25mm 6

5B/2

705

1 Hr/ 25 mm 15 min minimum

for each additional 25 mm over 125 mm

7

9A/1, 9B/1

595

1hr.min. + 15min/25 mm for thk. over 25mm

8

10A/1

595

1hr.min. + 15min/25 mm for thk. over 25mm

9

10B/1

650

1hr.min. + 15min/25 mm for thk. over 25mm

10

10C/1 & 10F/1

540

1hr.min. + 15min/25 mm for thk. over 25mm

Page 23

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

ANNEXURE-3

INSPECTION PROGRAMME FOR PRESSURE VESSELS

Page 24

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels

1.0

Material identification of shell and dish end.

2.0

Material identification of pipe and flange.

3.0

Material identification of balance items.

4.0

Check of cutting and edge preparation.

5.0

Qualification of welding procedure and welders or welding operators.

6.0

Checking of long seam set up, profile and root matching.

7.0

Rev

R0

Date of Rev

19/05/2017

Long seam welding, back chip and NDT (DPT).

8.0

Back chip and welding, profile check and radiography of long seam.

9.0

Alignment checkup, circumferential seam joint set up of shell.

10.0

Welding circumferential seam of shell-to-shell, back chip and DP test, RT etc.

11.0

Final welding, grinding and NDT (RT / UT).

12.0

Nozzle orientation marking and checkup and cutting.

13.0

Nozzle set up and checking.

14.0

Inspection of dished end (Radiography / Heat treatment as per specification).

15.0

Body flange set up or dished end set up checking.

16.0

Welding of above mentioned, back chip and NDT (DPT / RT).

17.0

Inspection of welding of lugs, earthing boss, cleats, lifting hooks, name plate bracket and touch up.

18.0

Dimensional check prior to heat treatment / hydro test.

19.0

Certification of heat treatment.

20.0

Hydro test / Pneumatic test and cleaning.

21.0

Wire brush / Sand blasting, Painting and checking.

22.0

Check-up of packing before dispatch.

Page 25

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

ANNEXURE-3A

INSPECTION & TEST CHART FOR PRESSURE VESSELS

Page 26

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels

Rev

R0

Date of Rev

19/05/2017

√

√

√

√

√

√

TRAY/INTERN ALS/ MATL. LUGS, CLEATS, LIFTING HOOKS STIFFENERS & NAME PLATE etc. PROFILE AND SET UP WELDING FASTENERS GASKETS HEAT TREATMENT FINAL INSPECTION

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√ √ √

√

√ √

√ √ √

√

√

REMARKS

√

LEAK TEST

√

PNEUMATIC TEST

√

HYDROSTATIC TEST

√

RADIOGRAPHIC TEST

√

MAGNETIC PARTICLE TEST

√

LIQUID PENETRATION TEST

√

ULTRASONIC TEST

√

WELDING QUALIFICATION

* IGC TEST *

√

INSPECTION OF FINISH

CHEMICAL ANALYSIS

√

MACRO TEST

HARDNESS TEST

√

MICRO TEST

PHYSICAL PROPERTIES TEST

√

ENQ. NO:

FERRITE TEST

VISUAL INSPECTION

SHELL DISH END MATERIAL. R. F PLATE + PAD PLATE MATL. NOZZLE PIPE + FLANGE MATL.

DESCRIPTION:

IMPACT TEST

DIMENSIONAL CHECK

PROJECT:

PART / MATERIAL / STAGE √

√

√

√

√

√ √ √ √ √ √ √ AS PER STANDARD CODE √

√

√

√

√

Page 27

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

ANNEXURE-4

DIMENSIONAL TOLERANCES FOR PRESSURE VESSELS

Page 28

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels

1.0

Rev

R0

Date of Rev

19/05/2017

Shell tolerances Nom. Vessel Diameter in mm 600 & Below

Tolerance in mm ± 2.5

Over 600 to 1200

±4

Over 1200 to 2100

±6

Over 2100 to 2700

±7

Over 2700

±8

2.0

Distance between top and bottom tangent line ± 1.5mm/m height, max. ± 12 mm.

3.0

Linearity of Cylindrical surface ± 3 mm / 6m, max. of 20 mm.

4.0

Height from base line to face of top nozzle, ± 5 mm max.

5.0

Face of nozzle from centre line of vessel, ± 3 mm.

6.0

Alignment of flange face of nozzle shall be as given in table (Refer detail “A” in attached drawing).

7.0

Rotation of flange holes with reference to nozzle axis 1.5 mm max (Refer detail “A” in the attached drawing).

8.0

Face of manhole from centre line of vessel ± 6 mm.

9.0

Alignment for flange face of manhole shall be ± 9 mm in both vertical & transverse planes.

10.0

Location of shell nozzle from reference line ± 3 mm.

11.0

Location of manholes from bottom reference line ± 12 mm.

12.0

Bottom of skirt base ring to the bottom tangent line of vessel + 0, -6 mm.

13.0

Orientation of anchor bolts with respect to principle axis ± 6 mm.

14.0

Tolerance in orientation of nozzles and external clips ± 3 mm.

15.0

Distances of bolt holes from axis: up to 2000 dia. ± 3mm and for over 2000 dia ± 6 mm.

Page 29

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels 16.0

Rev

R0

Date of Rev

19/05/2017

Maximum deviation of skirt base Nom. Vessel Diameter mm 1200 & Below Over 1200 to 2000 Over 2000

Tolerance mm ±3 ±5 ±7

17.0

Distance between level control nozzles, ± 1.5 mm

18.0

Distance between support bracket and reference line + 6, -0 mm.

19.0

Location of tray support ring from reference line, ± 6 mm.

20.0

Tolerance between adjacent tray plates, ± 3 mm.

21.0

Location of external clips and attachments from reference line ± 6 mm.

22.0

Distance between adjacent clips for platform brackets, ± 3 mm.

23.0 For nozzles located in heads distance from flange face of nozzle to reference plane shall be 6 mm. 24.0 Bolt hole circle tolerance shall be Vessel Dia. in mm 2100 and Under Above 2100

within ±

Tolerance in mm ±3 ±6

25.0

Height of weir above tray measured to the bottom of notches in notched weir within ± 1.5 mm.

26.0

Down comer vertical clearance at bottom within ± 3 mm

27.0

Maximum lateral translation of nozzle or any other attachment max. ± 3 mm.

28.0

Down comer horizontal clearance measured from bottom edge of the down cover to seal pan or inlet weir within ± 3 mm.

29.0

Tray levelness Tray Dia. (mm) Below 900

30.0

Max. Diff. Between high and low points (mm) 3

900 – 1500

4.5

Over 1500

6

Weir levelness: 1.5 mm. Page 30

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels 31.0

Rev

R0

Date of Rev

19/05/2017

Tray support shall be perpendicular to any shell generatrix within 1º. 27

THIS DIMENSION TO BE FINALLY ADJUSTED TO SUIT TOTAL HEIGHT

T.T.L. 1

23

22 10

3

10

6

31 29

30

9 21 5 4

26 2

5

17

20

28

6

25

7 12 4

14

8 19

9

BASE LINE

24

22

10 2 17

18

11

TOLERANCE FOR HORIZONTAL VESSEL REF.L. 23

2 MAX

12

13

S . MAX

16

DETAIL -'A'

BASELINE 15

NOMINAL NOZZLE

S.MAX

50-100 INCLUSIVE 150-300 INCLUSIVE OVER 300

1.5 2.5 5

1 MM/M OF HIEGHT WITH 20 MM MAX 13

=

=

PLUMB LINE 6

14

14

NOTES: FOR EQUIPMENT CONSTRUCTED IN FLANGED SECTIONS THE VERTICAL TOLERANCES SHALL BE VERIFIED FOR EACH SECTION

Page 31

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

ANNEXURE-5

GENERAL NOTES FOR IBR VESSELS

Page 32

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels 1.0

Rev

R0

Date of Rev

19/05/2017

GENERAL 1.1

Material Design, Construction and Inspection shall be in accordance with Chapter XV of IBR.

1.2

Fabricator shall obtain approval of design calculations and fabrication drawings from IBR authority.

1.3

This Vessels shall be designed as Class 1 vessels with efficiency of fusion welded shell, E=0.9.

1.4

Non-destructive testing shall be as per IBR Reg. 265 and 561. Certificates of manufacture & test in required forms signed by the maker and IBR inspector shall be obtained for all materials prior to fabrication.

1.5

All the plates used in fabrication shall be fully killed type and shall be the requirements in Chapter II of IBR.

1.6

Carbon content shall not be more than the limit specified in Reg. 234(a) of IBR.

1.7

Welder qualification testing shall be according to Chapter XIII of IBR.

1.8

After completion of welding but before Hydro test, heat treatment shall be carried out as per Reg. 267 of IBR.

1.9

General requirements of construction shall be met in accordance with Reg. 266 of IBR.

1.10

All dimensional tolerance for tubes and plates shall be as per regulations in IBR.

1.11

Method of making weld joints, mechanical fittings etc. shall be as per Chap. V & XII of IBR.

1.12

Boiler Mountings shall meet the requirements of Chap. VI of IBR.

1.13

All nozzles shall meet the requirements of Reg. 279.

1.14

Inspection of the vessel shall be carried out by IBR / Purchaser. Fabricator on required forms as per IBR code shall obtain stage wise and final inspection/ Approval from IBR authority.

1.15

Tube sheet shall be from forged material, and the same shall be ultrasonically tested.

1.16

Girth / body flange material shall be tested ultrasonically and by 100% radiography.

1.17

All flanges and tube sheets shall be LP tested after machining. Also all root run and fillet welds shall be LP tested.

1.18

All flange facing shall be of smooth finish, where gaskets are of SS wound type and glass filled PTFE.

1.19

All the tubes shall be tested by Eddy Current Testing method as per ASTM/ASME Specifications.

1.20

All tubes shall be hydro tested after bending and bend portion shall be tested using PT.

1.21

Hydro testing shall be carried out by the fabricator as per Reg.601 of IBR. Page 33

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels

Rev

R0

Date of Rev

19/05/2017

ANNEXURE-6

QUALITY ASSURENCE PLAN FOR FABRICATION

Page 34

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels 1.0

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

SCOPE To provide guidelines towards achieving better quality in fabrication of Vessels, Heat Exchangers or Storage tanks.

2.0

3.0

GENERAL 2.1

The fabricator should make sure that they have understood the design and requirements properly and if there is any doubt, the same shall be cleared beforehand. Equipment data sheet shall be referred along with this QA plan.

2.2

No deviation from drawings / standards shall be permitted without written approval by the Purchaser.

2.3

Fabricator can in general refer to ASME Sec. VIII Div.1, ASME Sec V, ASME Sec II, ASME TEMA, IS 803 and API 650 as applicable for the fabrication, inspection and testing.

Sec

IX,

MATERIAL 3.1

All the materials of construction should be strictly in accordance with the purchaser’s drawings and specifications. Alternative materials shall be used only on written approval by the purchaser.

3.2

The Fabricator should provide proper evidence to prove that the materials used in fabrication are according to approved drawings and specifications and are acceptable. Ref: UG-4 TO UG-15 & UG-93. (ASME Sec VIII Div I)

4.0

3.2.1

Fabricator should submit Mill test certificate for the materials in their scope and supply for both physical and chemical properties and also get the materials tested for the same by a reputed laboratory approved by Lloyds or Bureau Veritas and submit the certificate for the Purchaser’s approval.

3.2.2

All the materials if specified should be inspected and certified by a qualified inspector using non- destructive testing methods as per ASME Sec.V and Sec. II.

3.2.3

Repairs of defects in materials as per UG-78.

FABRICATION & INSPECTION General Ref: UW-26 to UW-42, UG-75 to UG-85, UG-90 to UG-103 and UW-11, UW-46 to UW-53. IS 803, API 650. 4.1

The Fabricator shall furnish fabrication procedure / fabrication drawings for Purchaser's approval.

4.2

All weld joints circumferential and longitudinal shall be marked on drawing. All longitudinal Page 35

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels

Rev

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joints shall be marked on orientation. 4.3 For fabrication tolerance, Fabricator can refer to TEMA F1, F2 & F3 for heat exchangers; for vessels, fabricator can refer to the tolerance specification sheets attached to data sheets and API 650 or IS 803 for storage tanks. 4.4

Fabricator shall use electrodes of reputed brand names only and get the same approved from Purchaser before beginning with any production welding.

4.5

4.6

4.5.1

It is advisable to make part drawings and get it approved if necessary.

4.5.2

Fabricator should prepare cutting diagrams for the materials for Purchaser’s approval.

4.5.3

Markings on the plates etc are to be checked and get it approved.

4.5.4

The part identification should be punched before cutting - Plate identification, Drg. No., Part No. refer to UG-77.

4.5.5

Cutting process should be referred to UG-76 and should also note that SS Plates should either be sheared off or cut off by plasma arc.

4.5.6

Fabricator should make the welded connections with reference to UW-15 to UW19 and UW-27.

4.5.7

All precautions shall be taken to avoid distortion (use jigs, fixtures etc.).

The fit up at various stages shall be made in tack-welded condition and get the same approved by the Purchaser’s Inspector. Ref: UG-94 to UG-97 & UW-31 to UW-33.

4.7

4.8

4.9

4.7.1

Fabricator shall use qualified and approved welding procedure and qualified welders or welding operators. Also Fabricator should get the welders qualified for tube-to-tube sheet joints separately. Refer: UW-27 to UW-29.

4.7.2

The weldment should be done with reference to UW- 35 to UW-39.

4.7.3

Non-destructive testing methods are to be employed for the inspection of weldment with reference to UG-103, UW-11, and UW-51 to UW-53 and in accordance with ASME Sec. V as indicated in data sheets.

4.7.4

Make repairs if any with Inspectors concurrence and get it retested. Ref UW-38.

Formed ends of vessels preferably be made in one piece. Larger heads which cannot be formed in one piece shall be fabricated as follows: 4.8.1

In two pieces, with welding seam included in the middle third and preferably on the central line.

4.8.2

In petal construction, with meridianal seams and central cap of diameter not larger than 0.75 times the vessel OD.

As far as practicable, the shell sections shall be made out of a single plate with one longitudinal weld seam only. The longitudinal seams of adjacent courses shall be Page 36

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

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19/05/2017

staggered and, as far as possible, seams shall be positioned clear of supports / nozzles, so as to be readily accessible for examination. Ref. UG-79. 4.10

Nozzles shall be located, as far as possible, clear of longitudinal weld joints. Where this cannot be avoided, Purchaser’s prior approval shall be obtained, since increase of reinforcement may be necessary.

4.11

All longitudinal and circumferential shell joints shall be full penetration double-welded butt joints. The reverse side shall be welded after chipping, grinding or gouging out the rest of first side to sound metal. Where sound back welding is not feasible, single welded joints with backing strips or rings shall be used. Alternatively, root run shall be done with TIG or MIG welding process to ensure proper penetration.

4.12 4.12.1 The Fabricator should get the stage wise and final inspection done to ensure the dimensional accuracy and quality of workmanship - Ref: UG-84 to UG-90. 4.12.2 The Fabricator should get the equipments tested using hydro test / pneumatic and leak tests as per data sheets. Refer UG-99 & UG-100 and Section V. 4.12.3 For storage tanks in addition to all the testing methods mentioned above, testing with reference to API Standard 650 - 5.3.3 to 5.3.7 and Article 10 of ASME section V shall be done.

5.0

POST WELD HEAT TREATMENT Post weld heat treatment of the weldments should be done as per UW-40 and time temperature chart should be submitted for Purchaser’s approval.

6.0

7.0

MARKINGS AND REPORTS (General Ref: UW-60, TEMA G-3) 6.1

In all markings and reports use SI Units system only.

6.2

Formats for inspection reports should be same as that provided by the Purchaser or the Fabricator should get their own alternative format approved from the Purchaser.

PACKING & DESPATCH 7.1

7.2

Make sure that the internal and external surfaces of vessel are free from loose scale or any other foreign material. 7.1.1

All exposed machined surfaces shall be coated with removable rust preventive and be protected against mechanical damage.

7.1.2

Nozzles shall be protected with bolted wooden covers and all threaded connections are to be suitably plugged.

All parts not assembled integral with main body of the vessel shall be marked with equipment number and match marked to ensure proper fit-up.

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400 Equipment Engineering Standard Specification for Pressure vessels

Rev

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ANNEXURE-7

ELECTRODES TO BE USED IN WELDING

Page 38

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels

CARBON STEEL TO CARBON STEEL

Rev

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19/05/2017

AWS SPECIFICATION

Structural IS 2062, A 36

E 6012 or E 6013

Pressure Vessel IS 2062, IS 2002 A 36, A 283, A 285

E 6012 or E 6013 or E 7018

Low temperature use

E 7018-1

Pressure Vessel A 285 Gr.C, A 515, A 516 A 204, A 203

E 7013 or E 7018

SA 357

E 9018

STAINLESS STEEL TO STAINLESS STEEL

AWS SPECIFICATION

AISI 304

E 308

AISI 304 L

E 308L

AISI 316

E 316-16

AISI 316 L

E 316L-16

AISI 318

E 318

AISI 321

E 321-15 or E 321-16

AISI 347

E 347-15 or E 347-16

STAINLESS STEEL TO CARBON STEEL

AWS SPECIFICATION

AISI 304 to C.S

E 309-16

AISI 316 to C.S

E 310 Mo

AISI 347 to C.S

E 310Cb

RECOMMENDED BRANDS: ADVANI-OERLIKON INDIA LTD, D&H JAMES GREAVES, THYSEEN, KOBE and ESAB or equivalent. Page 39

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

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WELDING WIRE AISI 304

AWS SPECIFICATION ER 308

AISI 304

ER 308

AISI 321

ER 347

AISI 347

ER 347

AISI 316

ER 316

AISI 316L

ER 316L

AISI 316 AND C.S.

ER 309-Mo.

Also C.S. to SS 304 & overlay

ER 309

Carbon steel filler metals

ER 70S-2 TO 6

Aluminium: AL 1060 H14

ER 1188

Titanium: SB 338 Gr.1, Gr.2, Gr.3, & Gr.7

ER Ti 1 to 4

Nickel: UNS N02200

ER Ni -1

Inconel: UNS N06600

ER Ni Cr Fe - 5 with discretion ERNiCr-3

Inconel 600 + C.S.: SB 166, SB 167 and SB 168

ER Ni Cr Fe - 6

Inconel 800 SB 409

ER Ni Cr - 6

Hastelloy: SB 575 UNS N10276 (HAST-C)

ER NiCr Mo -4

Hastelloy-C+Inconel 600:

ER NiCr Mo -4

N06455

ER NiCr Mo -7

RECOMMENDED BRANDS: ADVANI-OERLIKON INDIA LTD, D&H JAMES GREAVES, THYSEEN, KOBE and ESAB or equivalent

Page 40

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

ANNEXURE-8

PICKLING & PASSIVATION FOR STAINLESS STEEL

Page 41

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels 1.0

Rev

R0

Date of Rev

19/05/2017

GENERAL 1.1

This specification covers requirements for cleaning, pickling and passivating all stainless steel process equipment constructed of alloys containing more than 12% Cr.

1.2

In case of equipment / piping assemblies subjected to post weld heat treatment the whole surface shall be given the pickling treatment. Otherwise, only the weld joints and sealed surfaces are to be pickled. Passivation shall be the last operation before equipment / piping is put into service after testing.

1.3 The pickling and passivating solutions shall not be allowed to contact ferrous containing less than 12% Cr. or any non-ferrous surfaces. 2.0

surfaces

PROCEDURES 2.1

Cleaning 2.1.1 2.1.2

2.2

2.3

All welding flux and weld spatter shall be removed by grinding or blasting. All dirt, cinders, fly-ash or other extraneous matter shall be removed by brushing with a hard fiber brush or stainless steel wire brush. Carbon steel wire brush shall not be used. 2.1.3 All organic materials, paint, crayon marks, soaps, oils or grease shall be removed by washing with any commercial paint remover (those containing HCl or H2SO4 are not permitted) light solvent naphtha, di-chlorcethane or benzene. Soap solutions or similar detergents may also be used. Motor Petrol shall not be used. Pickling 2.2.1

The composition of the pickling solution shall be as follows 10 - 35 % concentrated nitric acid (technical Grade) with 65 – 90% water respectively. Temperature: 50 to 60 ºC for 10 % nitric acid and 20 ºC for 35 % nitric acid.

2.2.2

The material shall be exposed to the pickling solution only to an extent just necessary and sufficient to remove residual scale. The maximum period for which the pickling solution shall be allowed to remain on the surface is 30 minutes. During pickling, the removal of the oxides may be hastened by brushing with a hard fiber or S.S. wire brush together with clean sand. The pickling agent shall finally be washed off with plenty of water so as to leave no trace behind.

Passivating 2.3.1

The composition of the passivating bath shall be as follows: 0.5 % concentrated nitric acid 0.5 % sodium or potassium dichromate 99 % water with not more than 5-ppm chloride

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General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels 2.3.2

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Tanks, pipelines and other equipments shall be filled with the solution. Small parts shall be immersed in a tank containing this solution. The solution shall be held in the equipment for: a)

At least 24 hours at 25 ºC

b)

A minimum of one hour at the boiling point of this solution or

c)

The following minimum periods at the temperatures indicated. Temperature

2.4

IBIC -400-SS-0002

Duration

35 ºC

15 hours

50 ºC

8 hours

65 ºC

4 hours

80 ºC

2 ½ hours

Rinsing Finally the surface shall be thoroughly washed with a jet of water. Rubbing and brushing are prohibited during and after Passivation. Water used for rinsing shall contain no more than 1-ppm chloride.

3.0

INSPECTION 3.1

After treatment, the equipment shall be free of “water–break” (see note*) as observed during the rinsing operation.(* Failure of water to maintain a continuous film on a non-porous surface. Formation of drops or rivulets of water instead of a film when water is put on a surface indicating the presence of oil, grease or some contamination that water does not wet).

3.2

Free-Iron Test 3.2.1

The passivating solution used in clad or lined equipment shall be tested for iron at the midpoint of the treatment and the liquor shall show no increased rate of iron pick-up during the second half of the operation. An increasing rate indicates either a break in the cladding or an unusual iron contamination calling for repairs or replacement.

3.2.2

The free iron test shall be used on accessible parts of the equipment to avoid further contamination, unless the inspector has reasons to believe failure has occurred on some inaccessible surfaces.

3.2.3

The free-iron test solution shall be made as follows: 68 g. acceteacetainlide in a liter of acetone.

3.2.4

28 g. ammonium acetate in 250 cc of distilled water. Page 43

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels 3.2.5

IBIC -400-SS-0002 Rev

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19/05/2017

The solution shall be mixed within 24 hours on use and shall be applied by brush or spray on test area. Blood red color indicates presence of free iron and equipment must be rejected. Light pink color is acceptable.

Page 44

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

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ANNEXURE-9

DIMENSIONAL TOLERANCES FOR ASME FLANGES

Page 45

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

Outside Diameter

Inside Diameter

Outside Diameter of Hub Diameter of Contact Face Diameter of Counter bore

Drilling

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

THREADED, SLIP ON LAP JOINT AND BLIND When O. D. is 24" or less ± 1/16" (0.06 mm) When O. D. is above 24" ± 1/8" (0.125mm) Threaded To Standard Gauge Limits Slip-On and Lap-Joint When I.D. is 10" and less

+ 1/32", -0"

When I.D. is 12" and more + 1/16", -0" When dia is 12" and less + 3/32", – 1/16" When dia is 14" & above ± 1/8" 1/16" Raised face ± 1/32" 1/4" Raised face Tongue & ± 1/64" Groove Male, Female When dia is 10" and less ±1/32” When dia is 12" thru 24" ±1/16”, -0” Bolt Circle diameter ± 1/16" (1/2"- 24") Hole spacing ± 1/32" Eccentricity of bolt circle with respect to facing 2½” and less ± 1/32" Max 3” and more ±1/16" Max. Eccentricity of bolt circle with ± 1/32” Max. respect to bore Eccentricity of facing with ± 1/32” Max. respect to bore + 1/8", -0" 18" and smaller

Flange thickness 20" and above 10" and Smaller Length through hub 12" and above

+ 3/16", -0" ± 1/16" ± 1/8”

Page 46

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

Outside diameter Inside Diameter

Diameter of contact Face Diameter of Hub at base (X) Diameter Hub at point of Welding

Drilling

Flange Thickness Overall length Through Hub

IBIC -400-SS-0002 Rev

R0

Date of Rev

19/05/2017

WELDING NECK When O. D is 24" or Less ± 1/16"* When O. D. is above 24" ± 1/8"* 10" and Smaller ± 1/32" 12" thru 18" ± 1/16" 20" and above + 1/8", -1/16" 1/16" Raised face ± 1/32" ¼" Raised face Tongue & Groove ± 1/64" Male, Female When "X" is 24" or Smaller ± 1/16" * When "X" is 24" & above ± 1/8” * 5" and Smaller + 3/32", -1/32" 6" & Larger + 5/32", - 1/32" Bolt Circle diameter ± 1/16" (1/2"- 24") Bolt hole spacing ± 1/32" Eccentricity of bolt circle with respect to facing 2½” and smaller ± 1/32" Max. 3” and larger ±1/16" Max. Eccentricity of bolt circle with ±1/32” Max. * respect to bore Eccentricity of facing with respect ±1/32” Max. * to bore 18" and Smaller + 1/8", -0" Over 18" + 3/16", -0" 10" and Smaller ± 1/16" 12" and above ± 1/8"

Page 47

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

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Date of Rev

19/05/2017

ANNEXURE-10

SURFACE PREPERATION & PAINTING

Page 48

General Engineering Documentation Standard Specification

IBIC -400-SS-0002

400 Equipment Engineering Standard Specification for Pressure vessels 1.0

Rev

R0

Date of Rev

19/05/2017

SCOPE This specification describes the various aspects of painting of pressure vessels and related structure. This specification also covers and defines the material specification, surface preparation, application of paints, inspection and test. Note: Stainless Steel and other alloys, Plastic and Aluminium should not be painted.

2.0

SPECIFICATION OF PAINTS Uninsulated - Operating temperature: 0 - 60° C Primer paint type: Epoxy Polyamide - thickness (dry) min 3 mils Finish paint type: Poly Urethane - thickness (dry) min 3 mils Uninsulated - Operating temperature: 60 - 120° C Primer paint type: Zinc Silicate - thickness (dry) min 3 mils Finish paint type: Rich Silicone Finish - thickness (dry) min 3 mils Insulated - Operating temperature: 60° C and above Primer paint type: Zinc Silicate - thickness (dry) min 3 mils Finish paint type: None

3.0

SURFACE PREPARATION Surface pre-preparation before painting shall be confirm to SA 2 1/2

3.1

Dressing A careful dressing shall be carried out to eliminate all foreign materials, particularly glyceroids, hydrocarbon such as grease, oil naphtha and similar substances from the surface required to be painted. Dressing shall be carried out as follows: 3.1.1 Dry Sand Blasting Dry sand blasting shall be carried out by skilled personnel, approved by the Engineer-in- charge, on external plate surface unless otherwise specified. Before sand blasting all greasy substances shall be removed by means of adequate washing. The portion that appears to be still greasy after the sand blasting shall be cleaned with solvents and re-blasted. The sand blasting operation shall obtain surface of uniform grayish-white color. Sand blasted surface shall be rough enough to obtain the best condition for applying primer.

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General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

IBIC -400-SS-0002 Rev

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Date of Rev

19/05/2017

The surface examined under naked eye, should be free from corrosions, scales, oxide, paints, oil and other undesirable foreign matters. The compressed air used shall be free from moisture, oil and liquid vapors. Sand blasting shall be restricted to daytime only, however, night sand blasting may be permitted with the approval of the Engineer-in-charge. The sand blasting operation shall be suspended whenever the treated surface appears to be humid or the relative humidity of the environment exceeds 80%. The primer must be supplied on the sand blasted surface on the same day before sunset and in any case before any oxidation occurs. Any surface where primer has not beenapplied after sand blasting and consequently appears to the humid or oxidized will be blasted again. 3.1.2

Mechanical Cleaning Mechanical cleaning shall be carried out on external structure and all internal surfaces by means of equipment approved by the Engineer-in-charge. This operation shall be restricted to daytime only unless approved by the Engineer-in-charge. Painting shall be carried out on the same day the cleaning operation takes place. The surface not promptly painted will have to be brushed again if they appear to be humid or rusty. Greasy substances will have to be removed by solvent before the mechanical cleaning starts. Engineer-in-charge resolves the right to modify any procedures.

4.0

APPLICATION OF PAINT All material shall be applied in strict accordance to the manufacturer’s recommendations. No painting shall be carried out without the approval of Engineer-in-charge. The Engineer-in-charge reserves the right to ask for the suspension of works when the humidity increase to 85% or the ambient temperature is below 5° C and during rain, fog or dusty environment. A layer of coat can be applied only when the previous one is absolutely dry. Each coat of paint shall be preferably of different shade in order to facilitate the checking of painting. The protective coat will have to be firmly applied to the metallic surface. The overall thickness of the protective coats, after drying shall be checked by the Engineer-in- charge. In case the thickness is found insufficient, the contractor shall be obliged to give a further coat at his own cost. All paintings should be done by brushes. The width of the brushes should not exceed 1 cm.

5.0

6.0.

INSPECTION AND TESTS 5.1.

All consumables products such as paints, solvents, thinners etc. can be brought inside the work site only when they are supplied in sealed containers, as dispatched from the manufacturer. Specimen of such product shall be handed over to the Engineer-in-charge and will be kept separately to carry out a comparison if so desired by the Engineer-in- charge.

5.2.

If, in the opinion of the Engineer-in-charge any tests are to be conducted for the paints, the Contractor at his own cost will carry out the tests.

FINAL COAT COLORS

The final coat colors shall be as follows Page 50

General Engineering Documentation Standard Specification 400 Equipment Engineering Standard Specification for Pressure vessels

R0

Date of Rev

19/05/2017

Final colour

Munsel No

RAL No

Light gray

N.8.0

7047

Medium green

7.5G7/2

6021

Light green

2.5G8/2

6019

Light gray

N.8.0

7047

STRUCTURAL STEEL

Rev

Frame works

Medium green

7.5G7/2

6021

Platforms, stairs, floor plate, support

Medium green

7.5G7/2

6021

Handrail, ladders

Yellow

2.5Y8/16

1003

FURNACE

Item to be painted

IBIC -400-SS-0002

Exposed piping, header box, cast iron door, flue gas duct & stack

Silver

N7.0

7040

Bare surfaces Galvanized

Vertical Vessel, Drums and

Insulation finish

Exchangers

Mastic (hot Equipment)

EQUIPMENT

Mastic (cold equipment) Horizontal vessels,

Bare surfaces Galvanized Insulation finish

drums and heat

MACHINERY

exchangers

Mastic

Bare surfaces

Spheres and storage tank

Mastic Insulation finish

Cooler boxes

Outside surfaces

White

Pumps, compressors and Drivers

Bare surfaces Mastic Insulation finish

Light gray,

Galvanized metal jackets

NOTE. Thickness l mils = 25.4 m.

Page 51

General Engineering Documentation Standard Specification 400 Static equipment Engineering

IBIC-400-SS-0004 R0

Rev.

Standard Specification for Storage tanks

02/03/2017

Date of Rev.

STANDARD SPECIFICATION FOR STORAGE TANKS

R0

02/03/2017 For Reference

Rev.

Date

Purpose

CP

NS

AS

Prepared by

Checked by

Approved by

REVISION CONTROL File Location:

Page 1

General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

IBIC-400-SS-0004 R0

Rev. Date of Rev.

02/03/2017

Table of Contents 1

Introduction

4

2

Design basis & materials

4

3

Contractor's scope of work

4

4

Client's scope of supply

7

5

Fabrication/Welding/Testing & Inspection

7

6

Completion time

10

7

Measurement of work

10

8

Surface Preperation & Painting

11

9

Documentation

11

10

Guarantee

11

11

Reference standards

11

12

Measurement of setlement, Pressure & Leakage testing

11

13

Scope of inspection

13

14

Annexure-1 General instructions

15

14

Annexure-2 Engineering standard for inspection of storage tank

17

15

Annexure-3 Inspection programme

21

16

Annexure-3A Inspection test chart

23

17

Annexure-4 Tolerances of storage tank

24

18

Annexure-5 Quality assurance plan

26

19

Annexure-6 Electrodes to be used in welding

30

20

Annexure-7 Pickling & Passivation for stainless steel

32

21

Annexure-8 Dimensional tolerances for ASME flanges

36

22

Annexure-9 Details of addition & deletion of nozzles

39

23

Annexure-10 Deviation form

45

24

Annexure-11 Surface preparation & painting

47

File Location:

Page 2

General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks 1.0

IBIC-400-SS-0004 R0

Rev. Date of Rev.

02/03/2017

Introduction This Specification together with the data sheets / drawings covers the general requirements for materials, design, fabrication, inspection, testing and erection of Storage tanks. The requirements laid down herein are supplementary to the design/ fabrication code as specified.

2.0

Design basis & material 2.1 Design, fabrication, erection, inspection and testing of the site fabricated tanks shall be generally as per API 650 (Latest Edition). 2.2 Thicknesses indicated in the drawing are minimum. Thickness indicated shall not be the basis of offer. 2.3 Thickness shall be rechecked by vendor based on actual design calculation without any time/cost implication and submit the firm offer. 2.4 Material of construction will be as specified in EGD & equipment list.

3.0

Contractor’s scope of work

3.1 The scope of work mainly consists of Supply, Design, Engineering, fabrication,

erection, inspection, testing and painting of tanks as per API 650 and drawing furnished by IBIC. Fabrication / Erection of structural work like spiral stair case, hand railing, pipe supports etc.

3.2

3.3

The design, engineering, supply, fabrication, erection, inspection, testing and commissioning of CS/SS tanks as per following options. Option-I:

Plates will be supplied by CLIENT and all other material required for completion of work in vendor’s scope of supply. This shall cover Design, Engineering, Fabrication, Erection, stage wise inspections/tests to complete the job as per Enquiry documents and API 650 standards in all respect.

Option-II:

All material required for completion of work in vendor’s scope of supply. This shall cover Design, Engineering, Fabrication, Erection, stage wise inspection and testing.

The contractor shall submit the following drawings and documents for approval as per plate sizes procured by CLIENT within two weeks from date of LOI for both potions. a) b) c) d) e) f) g) h)

File Location:

General Arrangement drawing for tank Bottom layout drawing. Shell development drawing & nozzle details. Roof layout & roof nozzle details drawing. Nozzle Orientation plan Manufacturing schedule WQT shall be offer to IBIC PQR/WPS for tanks Page 3

General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks i)

3.4

IBIC-400-SS-0004 Rev. Date of Rev.

R0 02/03/2017

Quality Assurance plan for tanks & piping (QAP)

The following items shall be constructed as part of Fabricators scope of supply whether the same is specifically indicated in the drawings / data sheets or not; a. Cleats for platforms / ladders b. 3 sets of spare gaskets for all flanged joints. c. Blind flanges for all manholes / hand-holes and spare nozzles and extra 10% (Min. 2 Nos.) bolts and nuts for all flange joints. d. Stiffening of nozzles 50 NB and below by 3 gussets. e. Hinges or Davit arms for man ways. f. Name plate in SS material as per Purchaser’s Standard. g. Earthing Clips.

3.5

Fabrication and erection of carbon steel structural such as platforms, ladders, gratings, railing, supports, clamps, fasteners etc. as applicable.

3.6

Calibration of the tank shall be carried out through govt. agency as soon as the job is completed and documents in original shall be submitted to CLIENT.

3.7

Supply, Fabrication, erection, welding and testing of SS/CS LP steam piping and tracers under IBR as per EGD of IBIC. Vendor shall carry out approval of drawings under IBR authorities, if required. Contractor shall deploy IBR welders for IBR piping.(Applicable for IBR JOB)

3.8

The plate flanges/ RF pads etc. for nozzles and manhole shall be fabricated in one piece as required from the plate material. Any other special items require to be fabricated to complete the tank and its system shall be a part of contractor's scope.

3.9

Welder qualification test shall be arranged by the contractor for tank as well as piping at CLIENT site under IBIC’s Inspection.

3.10

For tank, contractor shall submit PQR and WPS for IBIC/CLIENT approval.

3.11 Testing shall be as per quality control plan (QAP) approved by IBIC/CLIENT. This includes IGC testing, radiography, DP Test, vacuum box test for the bottom joints of tank base plate, pneumatic leak test for reinforcement pads, hydro test for the tank. Air/vacuum test for the tank roof. Norms followed shall be as per API 650 & ANSI standards.

File Location:

3.11

All the SS weld joints of tank shall be pickled /passivated by solution/paste recommended by IBIC/CLIENT and it shall be arranged by contractor.

3.12

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3.13

Contractor shall make all arrangement for hydro test /water fill up test of the tanks/ piping system including fabrication and laying of temporary piping.

3.14

Handling of materials like plates, pipes, flanges, valves, fittings, fasteners, gaskets and all other miscellaneous items etc. as per the job requirement from CLIENT or Contractor’s stores to the contractors workshop or to the point of erection. All the excess material after the job is over shall be returned to the place indicated by the engineer in charge for material supplied by CLIENT.

3.15

The necessary equipments for loading, unloading, handling and erection of tanks/piping/Structure materials shall be arranged by contractor at his cost.

3.16

The procurement and supply of consumable materials, construction, erection and testing equipment required for the completion of work except the material specifically included in CLIENT’s scope of supply shall be the contractor’s responsibility. These items are as under but not limited to them; 1) 2) 3) 4) 5)

6)

7) 8) 9)

File Location:

IBIC-400-SS-0004

All consumables such as electrodes, filler wires, industrial gases for cutting and welding, grinding wheels, DP solution, pickling/ Passivation solution/paste, etc. Hydraulic jacking system for tank erection. Structural gratings for stairs and platforms. Steel scaffolding material and safety appliances require during execution of job. All tools, tackles, slings, chain pulley blocks, rolling machine, cutting machine, cutting sets, plasma cutting sets, welding generators, grinding machines, vacuum box, hydraulic pumps, pressure gages, dial gages, shims etc for fabrication, welding, erection, testing, leveling and alignment. Arrangement for radiography of tank/piping weld joints including required material, dark room and radioactive source, IGC testing arrangement for test coupons. Area preparation and scaffolding material. Area lighting and cabling required during execution of job. Preparing site office and store room at nearby available space cost.

3.17

Contractor shall strictly adhere to labor laws, ISO 14001 & OHSAS18001 norms and Safety Guidelines applicable for this job provided by CLIENT during execution. Safety appliances like safety belts, safety helmets, safety goggles, gloves, shoes, asbestos sheets etc. to the workers on job shall be provided by contractor. Execution shall be carried out on receipt of work permit issued by shift-in-charge of plant and shall be get renewed in each shift.

3.18

The contractor within their quoted rates and time schedule shall make any alteration, omission and/or modification as per the instructions of engineer in charge during site execution.

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3.19

Co-ordination with inspection department and keeping records of inspections reports shall be contractor’s responsibility.

3.20

Area cleaning and removal of debris after the job is over shall be the responsibility of the contractor.

3.21

Completing the entire job in all respect as per drawings, specifications and instructions of engineer in charge and keeping the system ready in all respect for further commissioning.

3.22

Contractor shall submit material reconciliation statement after the job is over.

3.23

The Contractor other than specifically mentioned above, though required in order to complete the jobs as per specifications in data sheet and Inspection Standards of IBIC shall carry out all the works.

Client’s scope of supply CLIENT shall supply the following materials/Services free of cost to the contractor. 4.1

5.0

The scope of work mainly consists of Supply, Design, Engineering, fabrication, erection, inspection, testing and painting of tanks as per API 650 and drawing furnished by IBIC. Fabrication / Erection of structural work like spiral stair case, hand railing, pipe supports etc.

4.2

Civil foundations for tanks and footing for pipe supports.

4.3

Electrical power at one point in the area of prefabrication /at erection will be arranged by client further distribution shall be done by contractor. a) HRC type fuses with isolation switch for individual welding machine. b) Earth leakage circuit breaker (ELCB) for each machine with extension board. c) For further distribution from single point, required standard quality cables in single piece within 200 meter.

Fabrication, Welding, Testing and Inspection.

File Location:

5.0

Fabrication involving welding shall not be sublet to others without the prior approval of the engineer-in-charge.

5.1

Nozzle necks 10” and above shall be fabricated from plates and shall be 100% radiographed.

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5.2

The cleats shall not be welded with shell plates for fixing temporary gratings (jails) for welders/fitters/workmen but scaffolding shall be made from bottom, as the tank material is special IGC tested for SS tanks. Hydraulic jack system shall be used for tank shell course/ roof construction so that unwanted welding cleats and huge scaffolding can be avoided.

5.3

All welders shall be qualified as per the specification. Contractor shall indicate brand names of electrodes and filler wires proposed for the entire job for the approval of IBIC. No welding shall be carried out without the approval of IBIC/CLIENT Engineer in charge at site.

5.4

Contractor shall carry out various tests as per QA plan approved by IBIC/CLIENT at his own cost including any other test required to complete the job in all respect as per the code / API650 requirements.

5.6

All the tests either on the field or at outside works/laboratories concerning the execution of the work and supply of materials shall be carried out by the contractor at his own cost.

5.7

The contractor shall provide for the purpose of inspection, all facilities such as access ladders, lighting, necessary instruments etc. at his own cost. Weld joints to be radio graphed shall be identified by inspection engineer and extent of radiography shall be as per tender terms & EGD.

5.8

5.9

Any work not conforming to the execution drawing, specifications or codes shall be rejected forthwith and contractor shall carry out rectifications at his own cost.

5.10

All results of inspection and tests will be recorded in the inspection reports, Performa of which will be approved by engineer-in-charge. These reports shall form part of the completion documents. Inspection, testing and acceptance of the work shall not relieve the contractor from any of his responsibilities under this contract.

5.11

File Location:

IBIC-400-SS-0004

5.12

The fabrication procedure shall conform to all applicable requirements of specified code and established engineering practices for manufacture of storage tanks.

5.13

Shell vertical joints in adjacent courses shall be staggered as per the code. The weld seam shall be indicated in the fabrication / as built drawings.

5.14

All the nozzle openings shall be a minimum of 50 mm away from the weld joints. All the nozzles and manhole projections shall be as per EGD.

5.15

Prior to welding, the edges of plates and adjoining surfaces for at least 25 mm on either side shall be dry and free from oil, grease or scale or other deposit that may be detrimental to weld quality.

5.16

Welding shall not be carried out when the surface of the any part to be welded is wet by any cause for e.g. during periods of rain and high winds unless the welder and work are properly shielded.

5.17

Tack welds shall be considered as having no strength and shall not be used for any purpose except for holding of weldments in proper alignment. Page 7

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5.18

All nozzle bolt holes shall straddle with principal centre line of Equipment.

5.19

All external and internal welds to be left ungrind but in decaled condition. (Respect to the requirement)

5.20

Temporary attachment welds on Tanks shall be removed. The surface under such welds and under backing rings, which have been removed, shall be properly conditioned to eliminate surface stress raisers. LPT shall be carried out for grinded area.

5.21

Roof shall not have depressions that will permit accumulation of water.

5.22

All the internals shall be supplied and installed by the Fabricator unless otherwise stated in the drawing / data sheets.

5.23

Suitable setting markers shall be provided on the tank shell before beginning of water fill up/ Hydro test.

5.24

If any structure or part of a structure were found not complying with any of the provisions of this standard, it shall be liable to rejection. No structure or part of structure once rejected shall be accepted for re-test except in cases where it is considered that the defect is rectifiable.

5.25

Defects that may appear during fabrication shall be repair with the prior approval of Purchaser.

5.26

Purchaser’s Inspector shall have the right to pass upon the qualification of erection personnel engaged by the erector and shall ask for replacement if desirable.

5.27

All erection lugs and cleats shall be removed before hydro-test for tanks fabricated at site.

5.28

All leaks detected during testing shall be repaired to the satisfaction of Purchaser’s Inspector and on completion the entire tank shall be right and free from leaks.

5.29

STORAGE: The plates shall normally be deposited and stored outside in such a way as to minimize contamination and corrosion. The prescribed storage symbols shall be observed. Bent plates shall be stored in a vertical position to avoid distortion. For plates stored in a horizontal position, provisions shall be made for adequate supports. Plates shall always be placed on timber under lays. When storing the plates, even temporarily, their unprotected bare or machined surfaces must not touch the ground. In the event of prolonged storage periods and/or extreme ambient conditions (high or low temperatures, corrosive atmosphere), adequate protective measures shall be taken.

5.30

CHECKING THE FOUNDATIONS: Prior to erection, the foundation shall be subjected to a dimensional check, and anchor bolt holes and cast–in–concrete anchor bolts or flat-bars anchors shall be examined for correct positioning. The site management shall be notified if any dimensional discrepancies are found. The foundation must have set (at least 3 days) and shall be free of impurities. Foundations must be “released” by the site management before commencing with the erection work. Page 8

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6.0 Completion time

7.0

6.1

Requirement as per the site area availability.

6.2

The contractor and engineer-in-charge will prepare a joint program of execution of the work. The program will take into account the time of completion mentioned in 6.1 above.

6.3

Daily construction targets will be drawn up by the engineer-in-charge with the contractor. The contractor shall scrupulously adhere to these targets and program and shall deploy adequate personnel, arrange construction equipments and aids

6.4

Daily work progress report shall be submitted by site In charge to the Engineer-incharge

6.5

Liquidated damages as per general conditions of contract shall be levied in case of delay in completion.

Measurement of work 7.1

The contractor shall take measurement in presence of the Engineer-in-charge or his representative.

7.2

Measurement of weights will be in metric tons corrected to the nearest kilogram and will be made based on the execution drawings. All other measurements will be as per the actual work executed at site.

7.3

Weld metal weight will not be taken into consideration for measurement.

7.4

Linear measurements will be in meters corrected up to the nearest centimeter. If physical measurement is not practicable; dimensions as given in the execution drawing may be adopted.

7.5

The following scrap allowances by weight are permissible for plates and pipe material. The percentage allowance shall be accounted on the basis of erected weights as per execution drawing as below: a) b)

Salvage 1.5% Unaccountable scrap 0.5%.

7.6 Wastage/consumption of plates/pipes beyond specified/agreed limits shall be at penalty rates, determined by the Engineer-in-charge. 7.7

File Location:

charged

The contractor shall submit the material reconciliation statement duly verified by the Engineer-in-charge for the free issue materials.

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Surface preparation & painting 8.1

9.0

IBIC-400-SS-0004

Surface preparation and painting shall be as per IBIC Standard. All external surfaces of the tanks shall be painted with Protecto Mastic Primer (DFT 50 micron) after inspection and testing, except gasket contact faces. Gasket contact faces and studs / bolts shall be protected with rust preventive compound.

Documentation Fabricator shall forward the necessary documents / drawings as specified in enquiry document

10.0 Guarantee

10.1

The tank shall be guaranteed in accordance with the conditions given in the Conditions of Contract.

General

10.2

Any part of the tank found defective during the tests after installation or during operation, and not having been submitted to faulty operation or incorrect service conditions, shall be promptly replaced and re-assembled by the Contractor at his own cost.

11.0 Reference standards & documents For reference standard drawing refer IBIC-400-STD-01 for standard drawing details.

12.0

Measurement of settlement, Pressure & Leakage testing 12.1 Prerequisites : All welding operations, the prescribed examinations of welded joints, the prescribed heat treatment operations as well as repair work, if any, must be completed. The anchor bolts must have been grouted. Fabrication tolerances must have been checked (refer to 12.3.2). Tanks shall be cleaned before testing. All welds shall be free of coating or insulation materials. During the time of pressure and leakage testing, no work shall be performed on the object being tested. Referring to tanks without bottom insulation, the vacuum test of bottom joints shall be performed after the pressure or leakage testing. For tanks with bottom insulation, the vacuum test shall be performed both before and after the pressure or leakage testing. The partial vacuum shall be at least 0.5 bar. If the vacuum test performed after the pressure test or leak test reveals any leaks, refilling of the tank (after repair of the leak) is not required. The filling level prescribed for testing with water need not be identical with the maximum filling level of the fluid to be stored. In no case shall the water fill penetrate across the top line of the shell.

12.2

File Location:

Measurement of settlement : Measurement of settlement shall be performed in conjunction with the leakage test. For the measurement of settlement, a minimum of 4 equally spaced points along the Page 10

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periphery of the foundation shall be marked before filling. The location of the reference point outside the foundation shall be agreed upon with site management. For extraordinary soil conditions, an expert shall be entrusted with the continual supervision of settlement. The following reading shall be taken while being filled: 1st reading: vessel empty, 2nd reading: at ¼ (+/- 500mm) level of fill, 3rd reading: at ½ (+/- 500mm) level of fill, 4th reading: at ¾ (+/- 500mm) level of fill, 5th reading: at prescribed level of fill, 6th reading: after emptying. If the readings indicate differences in foundation settlement of more than 15mm (referred to 10m) or uniform settlement of more than 10mm in 24 hours, filling operation shall be interrupted. It shall be resumed only after close examination by an expert and with due consideration to special regulations while the procedure is permanently being watched.

File Location:

12.3

Leakage testing: Atmospheric-pressure tanks intended for the storage of liquid shall be filled with water. Tanks of carbon steel shall normally be filled with portable water containing less than 100 ppm of chloride ions. Referring to tanks of stainless steel, the water shall normally contain less than 25 ppm of chloride ions. The quality of the water shall be evidenced by analyses. Check analyses shall be made if water is reused. Deviation from the specified chloride ions concentrations may be admitted, provided that the ordered prepares a technical specification with detailed data for the specific case.

12.4

Water filling procedure: Prior to filling, blind flanges shall be removed from all roof nozzles to ensure optimum venting & aeration during the time of filling and emptying. The filling rate shall not exceed 0.2m water level difference/hr. Depending on the possibilities of venting and/or on soil conditions, it may be necessary to reduce the rate to 0.1m/hr. Because measurement of settlement and leakage test are parallel operations, the holding time specified in 12.2 for the fractional filling levels shall be maintained. During the filling procedure, the shell contour line shall be checked for deviation from the vertical.

12.5

Extended leakage testing: Any tank that must not be filled with water to the maximum level and any vessels or tanks that is rated for a slight gauge pressure shall be subjected to an extended leakage test. Any safety elements (safety valves) may be tested in conjunction with this leakage test. Special precautions shall be taken for the extended leakage test. A personnel is not allowed to stay in the vicinity of the vessels or tank while the pressure is being raised. Leakage and vacuum tests shall not commence until temperature equalization between Page 11

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tanks wall and water fill has taken place. The water used for filling should have a temperature of at least 15 ºC. Attention shall be given to the influence of the outside temperature. Pressure and vacuum shall be measured with the aid of a U-tube manometer designed for a sufficient measuring range. The filling with water to the prescribed level shall be performed in accordance with 12.3.1. The nuts of the anchor bolts shall be checked and shall be retightened, if necessary. Air may then gradually be admitted to the free space above the water fill until the pressure has risen to 50% of the allowable working pressure. Shell and roof shall be examined for any distortion. After this examination, the pressure shall gradually be raised to 1.1 times the allowable working pressure and shall be held for approximately one hour. The pressure rise in the free space above the water fill may also be achieved by further gradual filling (approximately 0.1m/hr) if this method is permissible. If stipulated, all welds in the area above the water level shall be examined with the aid of forming liquids. Upon completion of the pressure tests, gradually venting the air and lowering the water level shall equalize the pressure. After removal of the blind flange from the safety valve, each safety valve shall be tested individually by restoring the pressure. If a vacuum test is also stipulated, the vacuum shall be produced by gradually lowering the water level to the prescribed marks or to the relief pressure setting of the safety valve. 13.0

Scope of inspection 13.1

13.2 13.3 13.4

13.5 13.6 13.7 13.8 13.9 13.10 13.11 13.12 13.13 13.14 13.15 13.16 13.17 13.18 13.19 File Location:

Approval of design calculations, Fabrication drawings and plate cutout drawings for shell, roof and bottom for compliance with relevant code requirements and General Engineering Practice. Witness of Material inspection and Identification. Witness of ultrasonic testing for plate material to be used for fabrication work. Verification of material test certificates of Chemical Analysis and Mechanical testing of material. In case if certificates are not clear or there is any doubt, check testing of the material from NABL approved laboratory without any extra cost. Verification of IGC test certificates for SS material & collection of sample pieces as per the requirement for Chemical, Physical and IGC testing in case of SS material. Verification of reports of supplementary test on material as applicable. Approval of Welding Procedures and witnessing of Procedure Qualification tests. Witness and approval of qualification tests for welders as per qualified WPS. Verification of welding consumables certificates and qualification for compliance to code requirements. Stage inspection during fabrication including checking of shell, roof, forging, alignment and fit up checks, to comply with the code requirements. . Witness NDT examinations as required. Witness Mechanical testing on coupons tensile, impact etc. as applicable. Verification of Calibration Records for M/c. and testing gauges. Witness of Air Soap Bubble Test for R.F. Pads. Carry out Visual and Dimensional Checks as per the requirements. Witness Hydrostatic testing tank in vertical position. Witness Vacuum leak test for roof and bottom of the tank. Checking of Nameplate and final stamping as per code requirements. Verification of pickling Passivation / painting inspection as applicable. Page 12

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13.20 Calibration of all the tanks shall be carried out by the vendor as per IS2009 and IS2008 (latest edition) for tanks fabricated at site. All the liaison work including arranging the visit and witnessing the strapping of work etc. with the competent authority, approving the calibration charts shall be the vendor’s responsibility.

File Location:

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GENERAL INSTRUCTIONS ANNEXURE-1 a) Unpriced Bids and Technical parameters should be sent to M/s. IBIC office strictly on due date given in enquiry. b) Acceptance of L.D./ Penalty clause wherever applicable should be incorporated as per enquiry specifications in the Bid. c) The Vendor should quote with respect to the specifications given. Any deviations with respect to the Materials of Construction and process required will be discussed at the time of technical discussion. This will ensure that there is no delay in sending the technical / commercial BIDs. The Vendor can however mention their scope of supply wherever deviations along with the BIDs. d) Raw material procurement status to be immediately furnished to IBIC / CLIENT office at the time of receipt of LOI / Purchase Order within one / two weeks. e) Design calculations and drawings should be sent to IBIC / CLIENT office for approval within two weeks of receipt of LOI / Purchase Order. f)

All drawings and documents shall show equipment number, order number, vendor's own title / reference number / drawing number and revision number on the lower side of right hand corner in each drawing. The first drawing shall have revision number as ‘R0' and subsequently, First revision shall be mark as ‘R1’.

g) Fold all prints to A4 size and roll the transparencies. All documents shall be supplied in folders / files. h) Vendor shall make drawings to maximum size A1 only. i)

Drawing or data returned, to be resubmitted within one week. Revised drawings and data must be marked on the drawing.

j)

The drawings which are returned to the vendor "Without Comments", Vendor shall prepare and submit three sets of final Assembly / detailed drawings to M/s. IBIC.

k) Within one week of completion of each tank, vendor shall submit all drawings connected to it marked as “CERTIFIED AS BUILT DRAWING”. l)

Quality Assurance plan, Bar Chart of welding procedure specification wherever applicable to be sent to IBIC / CLIENT office within two weeks of receipt of LOI / Purchase Order. All document drawings approval will be given on a specified date intimated by M/s IBIC / CLIENT.

m) Procurement action of forgings should be done by the Vendor wherever applicable immediately after receipt of LOI / Purchase Order. Unpriced Purchase Order copies of all Bought Out items should be sent by Vendor to IBIC / CLIENT’s office immediately on placing the order. n) For items like Gasket, Nuts & Bolts, Seal, Special Welding Rods, Gases and other required items Vendor shall ensure that adequate stock is available. In case of delay, adequate action is to be initiated by the vendor. The same is to be intimated to IBIC / CLIENT’s office. File Location:

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o) Prior approval of all Sub-vendors is to be obtained from IBIC / CLIENT at the time of Technical Discussion, also sub-vendor’s list with contact person details (name, telephone etc) to be furnished to IBIC during discussion. p) Detailed progress report of the equipment order to be given to IBIC / CLIENT indicating the actual status of the job to be submitted every fortnight. q) Material test certificates should be furnished & given to IBIC / CLIENT representative at the time or inspection. Check testing of main items to be carried out apart from mill test certificate. r) Raw Material inspection at sub-vendor's workshop is solely the responsibility of the Vendor. IBIC / CLIENT representative reserves the right to inspect the material at sub- vendor’s workshop. s) All Final Revised drawings incorporating all comments made by IBIC should be received at IBIC before final inspection. t) The vendor has to submit acknowledgement receipt for all documents to the CLIENT, in order to receive certificate from IBIC. u) All documents are to be submitted in English Language. v) Document and drawing submission as per document schedule.

File Location:

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ENGINEERING STANDARD FOR INSPECTION OF STORAGE TANKS ANNEXURE-2

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Scope To provide guide lines to be followed for the inspection of Storage Tanks.

2.0

3.0

4.0

File Location:

General 2.1

This standard shall be consulted in conjunction with the job specification, data sheets and drawings.

2.2

The standard generally refers to API 650 / IS 803 (Latest Edition) and the points reiterated below should be followed.

2.3

If the fabricator feels that any item of this standard is impractical the same shall be brought to Purchaser's attention prior to fabrication of tank, and get approved the alternative procedure suggested, if any.

2.4

At any time during fabrication is underway, Purchaser's Inspector should have free access to any of the fabricator's shop concerned with fabrication of tanks. Fabricator shall provide necessary facilities to satisfy the Purchaser's Inspector that the fabrication is being done in accordance with the specifications. Also para 8.8 of IS 803 shall be applicable.

2.5

Witnessing of inspection by Purchaser's Inspector is a must. Witness shall be by either Purchaser's Inspector or their designated representative.

2.6

Materials that are ready for the inspection shall be given in writing two weeks in prior.

Material inspection 3.1

Fabricator shall submit Mill Test Certificates for materials in their scope and supply.

3.2

The fabricator shall also submit Test Certificates of materials for both physical and chemical properties, tested by a reputed Laboratory approved by Lloyds or Bureau Veritas.

3.3

All plate edges shall be inspected for any cracks and laminations.

3.4

All forgings shall be tested with MP / PT.

3.5

Materials shall be marked to identify the same with the Test Certificates and to facilitate erection.

Fabrication 4.0

The fabrication shall be done according to the standard and in accordance with the specifications and drawings.

4.1

For the requirements of fabrication, the Fabricator shall refer to Section 8 of IS 803 and Section 4 of API 650. Page 17

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5.0

6.0

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Fabrication shall only be done according to the fabrication drawings prepared by the Fabricator and approved by Purchaser.

Erection 5.1

All the Welding Procedures and Welders or welding operators shall be qualified as per Section 7 of API 650 and ASME Section IX Boiler and Pressure Vessel Code.

5.2

All welds shall be done in accordance with approved Welding Procedures (WPS) only.

5.3

Welding rods shall be of reputed brands of D&H, ADVANI, THYSEEN, and KOBE & ESAB etc only. Fabricator shall get the same approved before commencement of any production welding. Welding machines shall be either rectifier type or generators.

5.4

Before starting with the erection, the Fabricator shall obtain the consent of the concerned authority regarding the foundation.

5.5

The erection in all respect shall comply with Section 5 of API 650 or Section 9 & 10 of IS 803, whichever applicable.

5.6

Painting and stenciling shall be done according to the specification and drawings. Dry Film Thickness check shall be done.

Inspection & testing

6.1

Inspection of welds shall be done with reference to clause 5.3.2 and section 6 of API 650. Also, all ‘T’ joints shall be radiographed 100% and 10% of other weld joints shall be radiographed.

6.2

Bottom testing shall be done either conforming to clause 12.1 of IS 803 or Clause 5.3.4 of API 650.

6.3

Vacuum Testing as described in clause 5.3.3 of API 650 shall be employed. Refer clause 12.1.3 of IS 803 also.

6.4

Bottom plate to shell fillet joints shall be checked using NDT (PT / MT).

6.5

Reinforcement plate welds shall be inspected as per clause 5.3.5 of API 650.

6.6

Testing of shell and roof shall be done according to clause 5.3.6 & 5.3.7 of API 650 respectively or clause 12.2 & 12.3 of IS 803 respectively. Accurately calibrated pressure gauge shall be used and the calibration certificate of the gauge shall be produced whenever the Purchaser’s Inspector demands.

6.7

For dimensional tolerances refer to clauses 9.3.5, 9.3.6 and 9.4 of IS 803 or clause 5.5 of API 650. Page 18

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Repair of leaks 7.1

Repair of the leaks shall be done with the concurrence of the Inspector only.

7.2

Repairing by mechanical caulking shall not be done at all.

7.3

The repair of leaks shall be carried out as per clause 5.4 and clause 6.1.7 of API 650 only.

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INSPECTION PROGRAMME ANNEXURE-3

File Location:

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Following Inspection programme provides step by step instructions for general inspection procedure

1.0

Qualification of Welding procedure and welders or welding operators.

2.0

Material Identification.

3.0

Bottom, plate to plate set up check.

4.0

Marking, cutting and welding of nozzle opening and man way, checking.

5.0

Bottom plates checking (Leak Test etc).

6.0

Shell profile check up.

7.0

Inspection of bottom fillet weld. Liquid Penetrant Test / Vacuum box test etc.

8.0

Welding of circumferential and vertical joints. Dimensional check and RT as per specification.

9.0

Fit-up, welding and inspection of Curb angle. Magnetic Particle Test of the weldment.

10.0

Welding and checking of handles, staircase, vent etc if any.

11.0

Final dimensional and internal check prior to fit up of top roof.

12.0

Fabrication and inspection of top roof (Radiography and Visual).

13.0

Assembly of top roof over tank and alignment check.

14.0

Final touch up and inspection. Radiographic check if any repair.

15.0

Hydrostatic / Pneumatic test.

16.0

Wire brush / cleaning and painting (stencilling if any), checking.

17.0

For inspection & test chart for storage tanks refer “Annexure -3A”

File Location:

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INSPECTION TEST CHART ANNEXURE-3A

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√

√

√ √

√ √

REMARKS

√

LEAK TEST

√

PNEUMATIC TEST

√

HYDROSTATIC TEST

√

RADIOGRAPHIC TEST

√

MAGNETIC PARTICLE TEST

√

LIQUID PENETRATION TEST

√

ULTRASONIC TEST

√

WELDING QUALIFICATION

√

INSPECTION OF FINISH

√

MICRO TEST

√

FERRITE TEST

√

* IGC TEST

CHEMICAL ANALYSIS

√

IMPACT TEST

HARDNESS TEST

PART / MATERIAL / STAGE SHELL & BOTTOM MATERIAL ROOF MATERIAL CURB ANGLE MATERIAL GIRDER MATERIAL R.F PLATE + PAD PLATE MATL. NOZZLE PIPE+FLANGE MATL. INTERNALS. LUGS, CLEATS, LIFTING HOOKS STIFFNERS & NAME PLATE ETC. PROFILE AND SET UP WELDING FASTENERS GASKETS HEAT TREATMENT FINAL INSPECTION

PHYSICAL PROPERTIES TEST

ENQ. NO:

VISUAL INSPECTION

DESCRIPTION:

DIMENSIONAL CHECK

PROJECT:

AS PER STANDARD CODE √

√

√

√ Page 22

General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

IBIC-400-SS-0004 Rev. Date of Rev.

R0 02/03/2017

TOLERANCES FOR STORAGE TANKS ANNEXURE-4

File Location:

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General Engineering Documentation Standard Specification 400 Static equipment Engineering

IBIC-400-SS-0004 Rev.

Standard Specification for Storage tanks 1.0

Date of Rev.

R0 02/03/2017

SHELL TOLERANCES Nom. Tank Diameter (meter) 12 & Below

Radius Tolerance (mm) ± 13

Over 12 to 45

± 19

Over 45 to 75

± 25

Over 75

± 32

2.0

The maximum out-of-plumpness of the top of shell relative to the bottom of shell shall not exceed 1/200 of the total tank height. It applies to fixed roof columns also.

3.0

The out-of-plumpness in one shell course shall not exceed the permissible variations for flatness and waviness as specified in ASTM A 6M/A 6, ASTM A 20M/A 20 or ASTM A 480M/A 48, whichever is applicable.

4.0

Deviations (peaking) at vertical weld joint shall not exceed 13mm.

5.0

Deviations (banding) at horizontal weld joint shall not exceed 13mm. Spots measured in the vertical plane shall not exceed the appropriate plate flatness and waviness requirements (refer Flat Sr.No.3.0) For concrete ring wall foundation under the shell, the top of the ring wall shall be level within ± 3mm (1/8 in.) in any 9m of the circumference and within ±6 mm (¼ in.) in the total circumference measured from average elevation.

6.0

7.0

For foundation other than concrete ring, the foundation under the shell shall be level within ± 3mm (1/8 in.) in any 3m of the circumference and within ±13mm (1/2 in.) in the total circumference measured from average elevation.

8.0

When a concrete slab foundation is provided, the first 0.3m of the foundation, measured from the outside of the tank radially towards the center, shall comply with the concrete ring wall requirement. The remainder of the foundation shall be within ± 13mm (1/2 in.) of the design shape.

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

IBIC-400-SS-0004 Rev. Date of Rev.

R0 02/03/2017

QUALITY ASSURANCE PLAN FOR FABRICATION ANNEXURE-5

File Location:

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks 1.0

IBIC-400-SS-0004 R0

Rev. Date of Rev.

02/03/2017

Scope To provide guidelines towards achieving better quality in fabrication of Vessels, Heat Exchangers or Storage tanks.

2.0

3.0

General 2.1

The fabricator should make sure that they have understood the design and requirements properly and if there is any doubt, the same shall be cleared beforehand. Equipment data sheet shall be referred along with this QA plan.

2.2

No deviation from drawings / standards shall be permitted without written approval by the Purchaser.

2.3

Fabricator can in general refer to ASME Sec. VIII Div.1, ASME Sec V, ASME Sec II, ASME Sec IX, TEMA, IS 803 and API 650 as applicable for the fabrication, inspection and testing.

Material 3.1

All the materials of construction should be strictly in accordance with the purchaser’s drawings and specifications. Alternative materials shall be used only on written approval by the IBIC/Purchaser.

3.2

The Fabricator should provide proper evidence to prove that the materials used in fabrication are according to approved drawings and specifications and are acceptable. Ref: UG-4 TO UG-15 & UG-93. (ASME Sec VIII Div I)

4.0

3.2.1

Fabricator should submit Mill test certificate for the materials in their scope and supply for both physical and chemical properties and also get the materials tested for the same by a reputed laboratory approved by IBIC and submit the certificate for the Purchaser’s approval.

3.2.2

All the materials if specified should be inspected and certified by a qualified inspector using non- destructive testing methods as per ASME Sec.V and Sec. II.

3.2.3

Repairs of defects in materials as per UG-78.

Fabrication and Inspection General Ref: UW-26 to UW-42, UG-75 to UG-85, UG-90 to UG-103 and UW-11, UW-46 to UW-53.

File Location:

4.1

The Fabricator shall furnish fabrication procedure / fabrication drawings for Purchaser's approval.

4.2

All weld joints circumferential and longitudinal shall be marked on drawing. All longitudinal joints shall be marked on orientation.

4.3

For fabrication tolerance, Fabricator can refer to TEMA F1, F2 & F3 for heat exchangers; for vessels, fabricator can refer to the tolerance specification sheets Page 26

General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

IBIC-400-SS-0004 R0

Rev. Date of Rev.

02/03/2017

attached to data sheets and API 650 or IS 803 for storage tanks. 4.4

Fabricator shall use electrodes of reputed brand names only and get the same approved from IBIC/ Purchaser before beginning with any production welding.

4.5

Approval Document/ Drawings It is advisable to make part drawings and get it approved if necessary.

4.5.2

Fabricator should prepare cutting diagrams for the materials for IBIC/Purchaser’s approval.

4.5.3

Markings on the plates etc are to be checked and get it approved from IBIC

4.5.4

The part identification should be punched before cutting - Plate identification, Drg. No., Part No. Refer to UG-77.

4.5.5

Cutting process should be referred to UG-76 and should also note that SS Plates should either be sheared off or cut off by plasma arc.

4.5.6

Fabricator should make the welded connections with reference to UW-15 to UW19 and UW-27.

4.5.7

All precautions shall be taken to avoid distortion (use jigs, fixtures etc.).

4.6

The fit up at various stages shall be made in tack-welded condition and offer for IBIC/Purchaser’s Inspector. Ref: UG-94 to UG-97 & UW-31 to UW-33.

4.7

Welder Qualification

4.8

4.9

4.10 File Location:

4.5.1

4.7.1

Fabricator shall use qualified and approved welding procedure and qualified welders or welding operators. Also Fabricator should get the welders qualified for tube-to-tube sheet joints separately. Refer: UW-27 to UW-29.

4.7.2

The weldment should be done with reference to UW- 35 to UW-39.

4.7.3

Non-destructive testing methods are to be employed for the inspection of weldment with reference to UG-103, UW-11, and UW-51 to UW-53 and in accordance with ASME Sec. V as indicated in data sheets.

4.7.4

Make repairs if any with Inspectors concurrence and get it retested. Ref UW-38.

Formed ends of vessels preferably are made in one piece. Larger heads which cannot be formed in one piece shall be fabricated as follows: 4.8.1

In two pieces, with welding seam included in the middle third and preferably on the central line.

4.8.2

In petal construction, with meridianal seams and central cap of diameter not larger than 0.75 times the vessels OD.

As far as practicable, the shell sections shall be made out of a single plate with one longitudinal weld seam only. The longitudinal seams of adjacent courses shall be staggered and, as far as possible, seams shall be positioned clear of supports / nozzles, so as to be readily accessible for examination. Ref. UG-79. Nozzles shall be located, as far as possible, clear of longitudinal weld joints. Where this Page 27

General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

IBIC-400-SS-0004 R0

Rev. Date of Rev.

02/03/2017

cannot be avoided, Purchaser’s prior approval shall be obtained, since increase of reinforcement may be necessary. 4.11

All longitudinal and circumferential shell joints shall be full penetration double- welded butt joints. The reverse side shall be welded after chipping, grinding or gouging out the rest of first side to sound metal. Where sound back welding is not feasible, single welded joints with backing strips or rings shall be used. Alternatively, root run shall be done with TIG or MIG welding process to ensure proper penetration.

4.12

Stage Inspection mentioned as below 4.12.1 The Fabricator should get the stage wise and final inspection done to ensure the dimensional accuracy and quality of workmanship - Ref: UG-84 to UG-90. 4.12.2 The Fabricator should get the equipments tested using hydro test / pneumatic and leak tests as per data sheets. Refer UG-99 & UG-100 and Section V.

5.0

Markings & reports (General Ref: UW-60, TEMA G-3) 5.1

In all markings and reports use SI Units system only.

5.2 Formats for inspection reports should be same as that provided by the Purchaser or the Fabricator should get their own alternative format approved from the purchaser.

File Location:

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

IBIC-400-SS-0004 Rev. Date of Rev.

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ELECTRODES TO BE USED IN WELDING ANNEXURE-6

File Location:

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

CARBON STEEL TO CARBON STEEL

IBIC-400-SS-0004 Rev. Date of Rev.

R0 02/03/2017

AWS SPECIFICATION

Structural IS 2062, A 36

E 6012 or E 6013

Pressure Vessel IS 2062, IS 2002 A 36, A 283, A 285

E 6012 or E 6013 or E 7018

Low temperature use

E 7018

Pressure Vessel A 285 Gr.C, A 515, A 516 A 204, A 203

E 7013 or E 7018

SA 357

E 9018

STAINLESS STEEL TO STAINLESS STEEL AWS SPECIFICATION AISI 304

E 308

AISI 304 L

E 308L

AISI 316

E 316-16

AISI 316 L

E 316L-16

AISI 318

E 318

AISI 321

E 321-15 or E 321-16

AISI 347

E 347-15 or E 347-16

STAINLESS STEEL TO CARBON STEEL

AWS SPECIFICATION

AISI 304 to C.S

E 309-16

AISI 316 to C.S

E 310 Mo

AISI 347 to C.S

E 310Cb

RECOMMENDED BRANDS: ADVANI-OERLIKON INDIA LTD, D&H JAMES GREAVES, THYSEEN, KOBE and ESAB or equivalent. File Location:

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

IBIC-400-SS-0004 R0

Rev. Date of Rev.

02/03/2017

PICKLING & PASSIVATION FOR STAINLESS STEEL ANNEXURE-7

File Location:

Page 31

General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks 1.0

2.0

IBIC-400-SS-0004 R0

Rev. Date of Rev.

02/03/2017

General 1.1

This specification covers requirements for cleaning, pickling and passivating all stainless steel process equipment constructed of alloys containing more than 12% Cr.

1.2

In case of equipment / piping assemblies subjected to post weld heat treatment the whole surface shall be given the pickling treatment. Otherwise, only the weld joints and sealed surfaces are to be pickled. Passivation shall be the last operation before equipment / piping is put into service after testing.

1.3

The pickling and passivating solutions shall not be allowed to contact ferrous containing less than 12% Cr. or any non-ferrous surfaces.

surfaces

Procedures 2.1

2.2

Cleaning 2.1.1

All welding flux and weld spatter shall be removed by grinding or buffing.

2.1.2

All dirt, cinders, fly-ash or other extraneous matter shall be removed by brushing with a hard fiber brush or stainless steel wire brush. Carbon steel wire brush shall not be used to clean SS welding.

2.1.3

All organic materials, paint, crayon marks, soaps, oils or grease shall be removed by washing with any commercial paint remover (those containing HCl or H2SO4 are not permitted) light solvent naphtha, di-chlorcethane or benzene. Soap solutions or similar detergents may also be used. Motor Petrol shall not be used.

Pickling

2.2.1

The composition of the pickling solution shall be as follows 10 - 35 % concentrated nitric acid (technical Grade) with 65 – 90% water respectively.Temperature: 50 to 60 ºC for 10 % nitric acid and 20 ºC for 35 % nitric acid.

2.2.2 The material shall be exposed to the pickling solution only to an extent just necessary and sufficient to remove residual scale. The maximum period for which the pickling solution shall be allowed to remain on the surface is 30 minutes. During pickling, the removal of the oxides may be hastened by brushing with a hard fiber or S.S. wire brush together with clean sand. The pickling agent shall finally be washed off with plenty of water so as to leave no trace behind.

File Location:

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks 2.3

IBIC-400-SS-0004 R0

Rev. Date of Rev.

02/03/2017

Passivating

2.3.1

The composition of the passivating bath shall be as follows: 0.5 % concentrated nitric acid 0.5 % sodium or potassium dichromate 99 % water with not more than 5-ppm chloride

2.3.2

Tanks, pipelines and other equipments shall be filled with the solution. Small parts shall be immersed in a tank containing this solution. The solution shall be held in the equipment for: a)

At least 24 hours at 25 ºC

b)

A minimum of one hour at the boiling point of this solution or

c)

The following minimum periods at the temperatures indicated. Temperature

2.4

Duration

35 ºC

15 hours

50 ºC

8 hours

65 ºC

4 hours

80 ºC

2 ½ hours

Rinsing Finally the surface shall be thoroughly washed with a jet of water. Rubbing and brushing are prohibited during and after passivating. Water used for rinsing shall contain not more than 1-ppm chloride.

3.0

Inspection 3.1

After treatment, the equipment shall be free of “water–break” (see note *) as during the rinsing operation.

observed

(* Failure of water to maintain a continuous film on a non-porous surface. Formation of drops or rivulets of water instead of a film when water is put on a surface indicating the presence of oil, grease or some contamination that water does not wet).

3.2

Free-Iron Test 3.2.1 The passivating solution used in clad or lined equipment shall be tested for iron at the midpoint of the treatment and the liquor shall show no increased rate of iron pick-up during the second half of the operation. An increasing rate indicates either a break in the cladding or an unusual iron contamination calling for repairs or replacement.

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IBIC-400-SS-0004 Rev. Date of Rev.

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3.2.2

The free iron test shall be used on accessible parts of the equipment to avoid further contamination, unless the inspector has reasons to believe failure has occurred on some inaccessible surfaces.

3.2.3

The free-iron test solution shall be made as follows: 68 g. acceteacetainlide in a liter of acetone. 28 g. ammonium acetate in 250 cc of distilled water. The solution shall be mixed within 24 hours on use and shall be applied by brush or spray on test area. Blood red color indicates presence of free iron and equipment must be rejected. Light pink color is acceptable.

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

IBIC-400-SS-0004 R0

Rev. Date of Rev.

02/03/2017

DIMENSIONAL TOLERANCES FOR ASME FLANGES ANNEXURE-8

File Location:

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

Outside Diameter

Inside Diameter

Outside Diameter of Hub Diameter of Contact Face Diameter of Counter bore

Drilling

R0

Rev. Date of Rev.

02/03/2017

THREADED, SLIP ON LAP JOINT AND BLIND When O. D. is 24" or less ± 1/16" (0.06 mm) When O. D. is above 24" ± 1/8" (0.125mm) Threaded To Standard Gauge Limits Slip-On and Lap-Joint When I.D. is 10" and less

+ 1/32", -0"

When I.D. is 12" and more + 1/16", -0" When dia is 12" and less + 3/32", – 1/16" When dia is 14" & above ± 1/8" 1/16" Raised face ± 1/32" 1/4" Raised face Tongue & ± 1/64" Groove Male, Female When dia is 10" and less ±1/32” When dia is 12" thru 24" ±1/16”, -0” Bolt Circle diameter ± 1/16" (1/2"- 24") Hole spacing ± 1/32" Eccentricity of bolt circle with respect to facing 2½” and less ± 1/32" Max 3” and more ±1/16" Max. Eccentricity of bolt circle with ± 1/32” Max. respect to bore Eccentricity of facing with ± 1/32” Max. respect to bore + 1/8", -0" 18" and smaller

Flange thickness 20" and above 10" and Smaller Length through hub 12" and above

File Location:

IBIC-400-SS-0004

+ 3/16", -0" ± 1/16" ± 1/8”

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

Outside diameter Inside Diameter

Diameter of contact Face Diameter of Hub at base (X) Diameter Hub at point of Welding

Drilling

Flange Thickness Overall length Through Hub

File Location:

IBIC-400-SS-0004 Rev. Date of Rev.

R0 02/03/2017

WELDING NECK When O. D is 24" or Less ± 1/16"* When O. D. is above 24" ± 1/8"* 10" and Smaller ± 1/32" 12" thru 18" ± 1/16" 20" and above + 1/8", -1/16" 1/16" Raised face ± 1/32" ¼" Raised face Tongue & Groove ± 1/64" Male, Female When "X" is 24" or Smaller ± 1/16" * When "X" is 24" & above ± 1/8” * 5" and Smaller + 3/32", -1/32" 6" & Larger + 5/32", - 1/32" Bolt Circle diameter ± 1/16" (1/2"- 24") Bolt hole spacing ± 1/32" Eccentricity of bolt circle with respect to facing 2½” and smaller ± 1/32" Max. 3” and larger ±1/16" Max. Eccentricity of bolt circle with ±1/32” Max. * respect to bore Eccentricity of facing with respect ±1/32” Max. * to bore 18" and Smaller + 1/8", -0" Over 18" + 3/16", -0" 10" and Smaller ± 1/16" 12" and above ± 1/8"

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

IBIC-400-SS-0004 Rev. Date of Rev.

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DETAILS OF ADDITION AND DELETION OF NOZZLES ANNEXURE-9

.

File Location:

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

IBIC-400-SS-0004 R0

Rev.

02/03/2017

Date of Rev.

DETAILS OF ADDITION & DELETION OF NOZZLES ANNEXURE - 9 A) FOR C.S MATERIAL Class 150 (LG type) Sr. No.

Nozzle Size

W/O Blind Flange

With Blind Flange (LT type)

1 2 3 4 5 6 7 8

Up to 1" 1 1/2" 2" 3" 4” 6” 8" 10"

9 10 11 12 13 14 15

12" 14" 16" 18" 20" 24" 24” Manhole as per API 650

NOT NOT APPLICABLE APPLICABLE

Class 150 (WNRF type) W/O With Blind Blind Flange Flange

Class 300 (LG type) W/O Blind Flange

With Blind Flange

Class 300 (WNRF type) W/O With Blind Blind Flange Flange

(LT type)

NOT NOT APPLICABLE APPLICABLE

NOTE – 1. The Schedule of rates includes supply of nozzle neck, flanges, studs/bolts, nuts & gaskets.

File Location:

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

IBIC-400-SS-0004 R0

Rev.

02/03/2017

Date of Rev.

B) FOR SS-304 MATERIAL Class 150 (LG type) Sr. No.

Nozzle Size

W/O Blind Flange

With Blind Flange (LT type)

1 2 3 4 5 6 7 8

Up to 1" 1 1/2" 2" 3" 4” 6” 8" 10"

9 10 11 12 13 14 15

12" 14" 16" 18" 20" 24" 24” Manhole as per API 650

NOT NOT APPLICABLE APPLICABLE

Class 150 (WNRF type) W/O With Blind Blind Flange Flange

Class 300 (LG type) W/O Blind Flange

With Blind Flange

Class 300 (WNRF type) W/O With Blind Blind Flange Flange

(LT type)

NOT NOT APPLICABLE APPLICABLE

NOTE – 1. The Schedule of rates includes supply of nozzle neck, flanges, studs/bolts, nuts & gaskets.

File Location:

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

IBIC-400-SS-0004 R0

Rev.

02/03/2017

Date of Rev.

C) FOR SS-304L MATERIAL Class 150 (LG type) Sr. No.

Nozzle Size

W/O Blind Flange

With Blind Flange (LT type)

1 2 3 4 5 6 7 8

Up to 1" 1 1/2" 2" 3" 4” 6” 8" 10"

9 10 11 12 13 14 15

12" 14" 16" 18" 20" 24" 24” Manhole as per API 650

NOT NOT APPLICABLE APPLICABLE

Class 150 (WNRF type) W/O With Blind Blind Flange Flange

Class 300 (LG type) W/O Blind Flange

With Blind Flange

Class 300 (WNRF type) W/O With Blind Blind Flange Flange

(LT type)

NOT NOT APPLICABLE APPLICABLE

NOTE – 1. The Schedule of rates includes supply of nozzle neck, flanges, studs/bolts, nuts & gaskets.

File Location:

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

IBIC-400-SS-0004 R0

Rev.

02/03/2017

Date of Rev.

D) FOR SS-316L MATERIAL Class 150 (LG type) Sr. No.

Nozzle Size

W/O Blind Flange

With Blind Flange (LT type)

1 2 3 4 5 6 7 8

Up to 1" 1 1/2" 2" 3" 4” 6” 8" 10"

9 10 11 12 13 14 15

12" 14" 16" 18" 20" 24" 24” Manhole as per API 650

NOT NOT APPLICABLE APPLICABLE

Class 150 (WNRF type) W/O With Blind Blind Flange Flange

Class 300 (LG type) W/O Blind Flange

With Blind Flange

Class 300 (WNRF type) W/O With Blind Blind Flange Flange

(LT type)

NOT NOT APPLICABLE APPLICABLE

NOTE – 1. The Schedule of rates includes supply of nozzle neck, flanges, studs/bolts, nuts & gaskets.

File Location:

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E) SCHEDULE RATES IN Rs. FOR ADDITION/DELETION OF FABRICATION WORK Type of Material

Rate (Rs/kg)

For C.S along with grade 1) 2) 3) 4) For S.S along with grade 1) 2) 3) 4) For Exotic along with grade 1) 2) 3) 4)

Note: - This cost includes all the requirements. (i.e.-material, labor, fabrication, testing, inspection, painting etc.)

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

IBIC-400-SS-0004 Rev. Date of Rev.

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DEVIATION FORM ANNEXURE-10

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

IBIC-400-SS-0004 Rev. Date of Rev.

R0 02/03/2017

DEVIATION FORM ANNEXURE - 10 Sr. No.

Clause no.

Deviation

Declaration by Bidder: We have read the Enquiry document with related engineering requirements and specifications. We agree to fulfill the requirements indicated therein.

Deviations taken by bidder are indicated clause wise for each document in separate bunch of sheets titled as “DEVIATION ON POINTS FOR…………..SYSTEM/EQUIPMENT”. Other than the deviations indicated there, all other requirements are acceptable unconditionally.

Where the variation in parameter/specifications of any items/system is observed in different Appendix of Enquiry documents, most stringent requirement is considered by the bidder.

Bidder’s Name

Name of authorized signatory

Stamp of bidder’s Firm

For the Bidder

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IBIC-400-SS-0004 Rev. Date of Rev.

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SURFACE PREPERATION & PAINTING ANNEXURE-11

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General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks

1.0

IBIC-400-SS-0004 R0

Rev. Date of Rev.

02/03/2017

Scope This specification describes the various aspects of painting of pressure vessels and related structure. This specification also covers and defines the material specification, surface preparation, application of paints, inspection and test. Note: Stainless Steel and other alloys, Plastic and Aluminum should not be painted.

2.0

Specification of paints Uninsulated - Operating temperature: 0 - 60° C Primer paint type:

Epoxy Polyamide - thickness (dry) min 3 mils

Finish paint type:

Poly Urethane - thickness (dry) min 3 mils

Uninsulated - Operating temperature: 60 - 120° C Primer paint type:

Zinc Silicate - thickness (dry) min 3 mils

Finish paint type:

Rich Silicone Finish - thickness (dry) min 3 mils

Insulated - Operating temperature: 60° C and above Primer paint type:

Zinc Silicate - thickness (dry) min 3 mils

Finish paint type:

None

If the client is required the specific paint requirement then contractor should follow the same. 3.0

Surface preparation Surface pre-preparation before painting shall be confirm to SA 2 1/2 3.1

Dressing A careful dressing shall be carried out to eliminate all foreign materials, particularly glyceroids, hydrocarbon such as grease, oil naphtha and similar substances from the surface required to be painted. Dressing shall be carried out as follows: 3.1.1 Dry Sand Blasting Dry sand blasting shall be carried out by skilled personnel, approved by the Engineer-in- charge, on external plate surface unless otherwise specified. Before sand blasting all greasy substances shall be removed by means of adequate washing. The portion that appears to be still greasy after the sand blasting shall be cleaned with solvents and re-blasted. The sand blasting operation shall obtain surface of uniform grayish-white color. Sand blasted surface shall be rough enough to obtain the best condition for applying primer.

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IBIC-400-SS-0004 Rev. Date of Rev.

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The surface examined under naked eye, should be free from corrosions, scales, oxide, paints, oil and other undesirable foreign matters. The compressed air used shall be free from moisture, oil and liquid vapours. Sand blasting shall be restricted to daytime only, however, night sand blasting may be permitted with the approval of the Engineer-in-charge. The sand blasting operation shall be suspended whenever the treated surface appears to be humid or the relative humidity of the environment exceeds 80%. The primer must be supplied on the sand blasted surface on the same day before sunset and in any case before any oxidation occurs. Any surface where primer has not been applied after sand blasting and consequently appears to the humid or oxidized will be blasted again. 3.1.2

Mechanical Cleaning Mechanical cleaning shall be carried out on external structure and all internal surfaces by means of equipment approved by the Engineer-in-charge. This operation shall be restricted to daytime only unless approved by the Engineer-incharge. Painting shall be carried out on the same day the cleaning operation takes place. The surface not promptly painted will have to be brushed again if they appear to be humid or rusty. Greasy substances will have to be removed by solvent before the mechanical cleaning starts. Engineer-in-charge resolves the right to modify any procedures.

4.0

Application of paint All material shall be applied in strict accordance to the manufacturer’s recommendations. No painting shall be carried out without the approval of Engineer-in-charge. The Engineer-in-charge reserves the right to ask for the suspension of works when the humidity increase to 85% or the ambient temperature is below 5° C and during rain, fog or dusty environment. A layer of coat can be applied only when the previous one is absolutely dry. Each coat of paint shall be preferably of different shade in order to facilitate the checking of painting. The protective coat will have to be firmly applied to the metallic surface. The overall thickness of the protective coats, after drying shall be checked by the Engineer-in- charge. In case the thickness is found insufficient, the contractor shall be obliged to give a further coat at his own cost. All paintings should be done by brushes. The width of the brushes should not exceed 15 cm.

5.0

Inspection and tests 5.1. All consumables products such as paints, solvents, thinners etc. can be brought inside the work site only when they are supplied in sealed containers, as dispatched from the manufacturer. Specimen of such product shall be handed over to the Engineer-in- charge and will be kept separately to carry out a comparison if so desired by the Engineer-incharge. 5.2. If, in the opinion of the Engineer-in-charge any tests are to be conducted for the paints, the Contractor at his own cost will carry out the tests.

File Location:

Page 48

General Engineering Documentation Standard Specification 400 Static equipment Engineering Standard Specification for Storage tanks 6.0.

IBIC-400-SS-0004 Rev. Date of Rev.

R0 02/03/2017

Final coat & colors The final coat colors shall be as follows Final color

Munsel No

RAL No

Light gray

N.8.0

7047

Medium green

7.5G7/2

6021

Light green

2.5G8/2

6019

Light gray

N.8.0

7047

STRUCTURAL STEEL

Frame works

Medium green

7.5G7/2

6021

Platforms, stairs, floor plate, support

Medium green

7.5G7/2

6021

Handrail, ladders

Yellow

2.5Y8/16

1003

FURNACE

Item to be painted

Exposed piping, header box, cast iron door, flue gas duct & stack

Silver

Bare surfaces Galvanized

Vertical Vessel, Drums and Exchangers

Insulation finish

Mastic (hot Equipment)

EQUIPMENT

Mastic (cold equipment) Horizontal vessels, drums and heat

Bare surfaces Galvanized Insulation finish

exchangers

Mastic

Bare surfaces

Spheres and storage tank

Mastic Insulation finish

Cooler boxes

Outside surfaces

White

NOTE. Thickness l mils = 25.4 m.

File Location:

Page 49

Project Documentation NITRIC ACID COMPLEX -DAHEJ PJ-210, DFPCL

IBIC-210-400-DSS-0001

Document schedule for Shop fabricated Tanks

Rev

R0

Date of Rev

19/05/2017

CLASSIFICATION: Q - WITH BID. C - FOR REVIEW / COMMENTS AFTER LOI/PO. F - FINAL CERTIFIED AFTER FINAL APPROVAL P - PDF (IBIC+CLIENT) H - HARD PRINTS / COPIES. (IBIC+CLIENT) R - INDICATES CD/DVD IN PDF & EDITABLE FORMAT (IBIC+CLIENT) QUANTITY REQUIRED C

Q

F

Serial Drawing / Data /Documents

By

By

No. P

H

P

H

Weeks

R

H

Weeks

1

Bar Chart (M.S. Project Form)

1+1

3+4

1+1

2+2

2

1+2

1+4

2

2

QAP (Inspection & Testing Plan)

1+1

3+4

1+1

2+2

2

1+2

1+4

2

3

Procurement Evidence

1+1

-

-

-

-

-

-

-

4

Qualification Details

1+1

-

-

-

-

-

-

-

5

Design Calculations

-

-

1+1

2+2

2

1+2

1+4

2

6

Fabrication Drawing

-

-

1+1

2+2

2

1+2

1+4

2

7

WPS, PQR, Welder Qualification

-

-

1+1

2+2

2

1+2

1+4

2

8

NDT Procedure (LPT, MPT, UT, RT, LT)

-

-

1+1

2+2

2

1+2

1+4

2

9

Plate Cutting Diagram

-

-

1+1

2+2

2

1+2

1+4

2

Foundation plan-load plan with details of anchor bolts and their location, template etc.

-

-

-

-

-

-

-

-

10

11

Sub–Order Copies & Sub Vendor List

1+1

3+4

1+1

2+2

2

1+2

1+4

2

12

BOM For scope of supply

-

-

-

-

-

-

-

-

Page 1

Project Documentation NITRIC ACID COMPLEX -DAHEJ PJ-210, DFPCL

IBIC-210-400-DSS-0001

Document schedule for Shop fabricated Tanks

Rev

R0

Date of Rev

19/05/2017

-

-

-

-

-

-

-

-

13

Sketch for equipment transportation in case of O.D.C. (Including weights of gravity and slinging facility)

14

Stress analysis of equipment

-

-

-

-

-

-

-

-

15

PWHT report (if req.)

-

-

-

-

-

-

-

-

16

Material Test Certificate

1+1

2+2

2

1+2

1+4

2

17

Check testing reports and Lab analysis report

-

-

1+1

2+2

2

1+2

1+4

2

18

Test certificates for explosion proof items of equipment

-

-

-

-

-

-

-

-

19

Assembly & Installation Detail

-

-

-

-

-

-

-

-

20

RT Sketch & Annexure

-

-

1+1

2+2

2

1+2

1+4

2

21

Pressure/ vacuum test reports

-

-

1+1

2+2

2

1+2

1+4

2

22

Lining test reports

-

-

1+1

2+2

2

1+2

1+4

2

23

Packing list

-

-

-

-

-

-

-

-

24

Dimensional deviation drawings

-

-

-

-

-

1+2

1+4

2

25

Guarantee certificate

-

-

-

-

-

1+2

1+4

2

Equipment stamping detail

-

-

-

-

-

1+2

1+4

2

26 (Rub–Off) 27

Final Dimension report

-

-

-

-

-

1+2

1+4

2

28

Final Inspection report

-

-

-

-

-

1+2

1+4

2

29

IBR/ CCOE Certificate

-

-

-

-

-

-

-

-

Page 2

IBIC-210-400-ENQ-0058

Project Documentation NITRIC ACID COMPLEX-DAHEJ PJ-210, DFPCL

0

19-05-17

Rev.

Date

Issue for Enquiry Description

SAS

ANS

UAD

Prpd by

Bhkd by

Apprd by

Price Schedule for Shop fabricated Tanks Cost Of Spares (B) Unit Rate Excluding Spares (A)

Quantity

Unit of Measure

Currency

16T-1620 (ABSORBER FEED WATER TANK)

1

NO.

INR

N.A

II

16V-1675 (WEAK ACID TANK)

1

NO.

INR

N.A

III

16V-9704 (CONDENSATE COLLECTION TANK)

1

NO.

INR

N.A

IV

61V-103 (INSTRUMENT AIR BUFFER VESSELS)

1

NO.

INR

N.A

V

61V-104 (PLANT AIR BUFFER VESSELS)

1

NO.

INR

N.A

VI

91T-6952 (SULPHURIC ACID STORAGE TANK)

1

NO.

INR

N.A

VII

91T-6962 (CAUSTIC STORAGE TANK)

1

NO.

INR

N.A

Sr.No

Item Description

1

Scope of the fabricator shall include design, manufacturing, Testing, Packing & Forwarding as per the attached drawings & specifications. Vendor to consider mechanical guarantee of supply equipment and agreed in IBIC's enquiry, all technical and commercial discussions, clarrifications by IBIC/DFPCL till date

I

10% Spare Fasteners

300% Spare Gasket

Other Spares (Ref. Note 1)

Total Cost (A+B)

N.A

2

Third Party Inspection Charges, as per Enquiry specifications. (Incase TPI to be arranged by Vendor). Total Amount Packing and Forwarding Excise Duty Education Cess on Excise Duty Higher Education Cess on Excise Duty CST/VAT

N.A

N.A

N.A

INR

N.A

N.A

N.A

N.A

N.A

Transportation From Vendor’s Works upto DFPCL-Dahej site Grand Total with all taxes/duties Cenvat credit Amount/VAT credit Amount Net Value(Net of credit)

Note:

Project Documentation NITRIC ACID COMPLEX -DAHEJ PJ-210, DFPCL

IBIC-210-400-ENQ-0058

Deviation Form for Shop Fabricated Tanks

Rev

R0

Date of Rev

19/05/2017

DEVIATION FORM Sr. No.

Clause no.

Deviation

Declaration by Bidder: We have read the Enquiry document with related engineering requirements and specifications. We agree to fulfill the requirements indicated therein.

Deviations taken by bidder are indicated clause wise for each document in separate bunch of sheets titled as “DEVIATION ON POINTS FOR…………..SYSTEM/EQUIPMENT”. Other than the deviations indicated there, all other requirements are acceptable unconditionally.

Where the variation in parameter/specifications of any items/system is observed in different Appendix of Enquiry documents, most stringent requirement is considered by the bidder.

Bidder’s Name

Name of authorized signatory

Stamp of bidder’s Firm

For the Bidder

Page 1

Project Documentation NITRIC ACID COMPLEX -DAHEJ

IBIC-210-400-ADN-0002

PJ-210, DFPCL Addition/Deletion Of Nozzles/ Fabrication Works

Rev

R0

Date of Rev

19/05/2017

A) FOR C.S MATERIAL Class 150 (LG type) Sr. No.

Nozzle Size

W/O Blind Flange

With Blind Flange (LT type)

1 2 3 4 5 6 7 8

Up to 1" 1 1/2" 2" 3" 4” 6” 8" 10"

9 10 11 12 13 14 15

12" 14" 16" 18" 20" 24" 24” Manhole as per API 650

NOT NOT APPLICABLE APPLICABLE

Class 150 (WNRF type) W/O With Blind Blind Flange Flange

Class 300 (LG type) W/O Blind Flange

With Blind Flange

Class 300 (WNRF type) W/O With Blind Blind Flange Flange

(LT type)

NOT NOT APPLICABLE APPLICABLE

NOTE – 1. The Schedule of rates includes supply of nozzle neck, flanges, studs/bolts, nuts & gaskets.

Page 1

Project Documentation NITRIC ACID COMPLEX -DAHEJ

IBIC-210-400-ADN-0002

PJ-210, DFPCL Addition/Deletion Of Nozzles/ Fabrication Works

Rev

R0

Date of Rev

19/05/2017

B) FOR SS-304 MATERIAL Class 150 (LG type) Sr. No.

Nozzle Size

W/O Blind Flange

With Blind Flange (LT type)

1 2 3 4 5 6 7 8

Up to 1" 1 1/2" 2" 3" 4” 6” 8" 10"

9 10 11 12 13 14 15

12" 14" 16" 18" 20" 24" 24” Manhole as per API 650

NOT NOT APPLICABLE APPLICABLE

Class 150 (WNRF type) W/O With Blind Blind Flange Flange

Class 300 (LG type) W/O Blind Flange

With Blind Flange

Class 300 (WNRF type) W/O With Blind Blind Flange Flange

(LT type)

NOT NOT APPLICABLE APPLICABLE

NOTE – 1. The Schedule of rates includes supply of nozzle neck, flanges, studs/bolts, nuts & gaskets.

Page 2

Project Documentation NITRIC ACID COMPLEX -DAHEJ

IBIC-210-400-ADN-0002

PJ-210, DFPCL Addition/Deletion Of Nozzles/ Fabrication Works

Rev

R0

Date of Rev

19/05/2017

C) FOR SS-304L MATERIAL Class 150 (LG type) Sr. No.

Nozzle Size

W/O Blind Flange

With Blind Flange (LT type)

1 2 3 4 5 6 7 8

Up to 1" 1 1/2" 2" 3" 4” 6” 8" 10"

9 10 11 12 13 14 15

12" 14" 16" 18" 20" 24" 24” Manhole as per API 650

NOT NOT APPLICABLE APPLICABLE

Class 150 (WNRF type) W/O With Blind Blind Flange Flange

Class 300 (LG type) W/O Blind Flange

With Blind Flange

Class 300 (WNRF type) W/O With Blind Blind Flange Flange

(LT type)

NOT NOT APPLICABLE APPLICABLE

NOTE – 1. The Schedule of rates includes supply of nozzle neck, flanges, studs/bolts, nuts & gaskets.

Page 3

Project Documentation NITRIC ACID COMPLEX -DAHEJ

IBIC-210-400-ADN-0002

PJ-210, DFPCL Addition/Deletion Of Nozzles/ Fabrication Works

Rev

R0

Date of Rev

19/05/2017

D) FOR SS-316L MATERIAL Class 150 (LG type) Sr. No.

Nozzle Size

W/O Blind Flange

With Blind Flange (LT type)

1 2 3 4 5 6 7 8

Up to 1" 1 1/2" 2" 3" 4” 6” 8" 10"

9 10 11 12 13 14 15

12" 14" 16" 18" 20" 24" 24” Manhole as per API 650

NOT NOT APPLICABLE APPLICABLE

Class 150 (WNRF type) W/O With Blind Blind Flange Flange

Class 300 (LG type) W/O Blind Flange

With Blind Flange

Class 300 (WNRF type) W/O With Blind Blind Flange Flange

(LT type)

NOT NOT APPLICABLE APPLICABLE

NOTE – 1. The Schedule of rates includes supply of nozzle neck, flanges, studs/bolts, nuts & gaskets.

Page 4

Project Documentation NITRIC ACID COMPLEX -DAHEJ PJ-210, DFPCL Addition/Deletion Of Nozzles/ Fabrication Works

IBIC-210-400-ADN-0002 Rev

R0

Date of Rev

19/05/2017

E) SCHEDULE RATES IN Rs. FOR ADDITION/DELETION OF FABRICATION WORK Type of Material

Rate (Rs/kg)

For C.S along with grade 1) 2) 3) 4) For S.S along with grade 1) 2) 3) 4) For Exotic along with grade 1) 2) 3) 4)

Note: - This cost includes all the requirements. (I.e.-material, labor, fabrication, testing, inspection, painting etc.)

Page 5